HART technology - How to introduce HART into an existing plant

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1 HART technology - How to introduce HART into an existing plant FCG-Japan (azbil) Hiroyuki Tsugane 2017/04/13 1

2 introducing HART to existing facilities Why HART? How to introduce HART into an existing plant? What are the benefits? 2 2

3 Why HART? It s a global standard and already popular in market Many of installed devices are already HART Can apply without any modification to existing facilities No gap to existing operation 3

4 It s a global standard and already popular in market Established in IEC International Standard as well as FOUNDATION fieldbus Start at 15 company Now More than 340 companies are already support HART protocol in world wide. Spread to world wide

5 It s a global standard and already popular in market Number of types of instruments Counted by Number of registered DD Including wireless HART devices 5

are in HART communication http://www.automation.

6 It s a global standard and already popular in market From ARC report 46% (32 million units) of all installed field devices are in HART communication 6

0100110111 Can apply without any modification to existing facilities Analog band

7 Can apply without any modification to existing facilities Analog band width 1~10Hz HART band width 1200~2200Hz HART Controller AIO 4-20mA Filter A/D 7

8 Can apply without any modification to existing facilities For configuration and calibration use You already use like this! Just hock up and play 8

9 Can apply without any modification to existing facilities For configuration and calibration use + Temporary monitoring Available at the same time HART support two HOSTs Just hock up and play Utilize your PC with HART modem Just hock up and play 9

+ permanent monitoring (utilize multi variable of

utilize easily to 4-20mA world Just hock up and

10 Can apply without any modification to existing facilities For configuration and calibration use + permanent monitoring (utilize multi variable of device) HART multi variable capability can utilize easily to 4-20mA world Just hock up and play 4-20mA as HART digital variable HART loop convertor 10

11 Can apply without any modification to existing facilities For configuration and calibration use + Monitoring and Asset Multi-conductor connection Multi-conductor terminal blocks Huck up permanently by Multi-conductor connection / terminal blocks 11

12 For configuration and calibration use + Monitoring and Asset + data in controller Can apply without any modification to existing facilities Change AIO board to AIO with HART 12

13 No gap to existing operation Nothing change before and after HART No DCS software/operation change No Maintenance Operation Change 13

14 How to introduce HART into an existing plant? How big scale is it to be introduced? Is there any case can not communicate with? Is HART signal affect 4-20mA signal? What should be careful about operation? 14

15 How big scale is it to be introduced? Single loop HART can be installed from any scale Activate specific functionality of particular device Monitoring PH conductor life, Valve readback of unstable process flow Selected loop Get readback from all positioner Monitoring all valve movement and get condition data for over hole of valve Every loop Apply every device at modernization improve maintenance efficiency and utilize full capability of devices Very flexible because HART communicate is one by one, not bus/network You can decide form one loop to whole loops by your own purpose and budget. 15

16 In rare cases you may face a noise problem (It can be confirmed easily) Noise on the loop Is there any case can not communicate with? Near HART band width noise affect HART communication Power cable, specially invertor motor cable sometimes affect HART communication. Check before loop noise level is good idea to get better result Don t worry, even it not communicate, your plant never affect. Because analog loop is still normal and healthy! Recommended loop noise check before introduction 16

17 Is there anything case can not communicate with? Noise affect digital communication Specially existing wiring sometimes not awarded for noise Analog 4-20mA usually works well under high noise environment Parallel wiring with power cable often makes high noise to analog signal line Line with high noise need to re-wiring to avoid high influence of power cable (Easy to know how much noise) Tray Instruments cables Power cables Fig.1 JB Fig.2 17

18 Is there any case can not communicate? Noise example ( affected by power cable) 1KHz Average 0 Fig. 1 18

19 Wiring by avoiding power cable Is there any case can not communicate? 1KHz Fig. 2 19

20 Is there any case can not communicate? Now it works 20

21 Check if auxiliary devices are ready for HART Auxiliary device that does not transmit HART signal Change it to HART transparent device Auxiliary device that absorb HART signal Is there any case can not communicate with? Affected by noise suppress condenser in auxiliary device 22

22 Is there any case can not communicate? What kind of auxiliary devices in a loop Arrester Distributor Isolator (I.S) Barrier For I.S Arrester Are those HART ready? 23

23 Is there any case can not communicate? Distributor / Isolator AIO with HART and Isolator for I.S. uses this point for connection Even with actual results of this usage Swap to HART through type Distributor / Isolator Some Distributor / Isolator blocks HART signal If you add HART signal at AI/AO, you need change it for HART through type 24

24 Is there any case can not communicate? Most external HART system use this point for connection And existing plant may introduce this style 1-5V Distributor barrier Arrester Make sure that these devices do not affect HART signal 25

25 Is HART signal affect 4-20mA signal? In rare cases you need attention Self diagnostic check affected by HART signal Measurement value fluctuation at high scan rate system Many systems have already considered the impact on HART signals, but problems may be manifest in some older systems 26

26 Case of AO card with self read back diagnostic Is HART signal affect 4-20mA signal? HART signal HART ready Read back Diagnostic D/A A/D Filter No HART consideration Read back Diagnostic D/A A/D HART signal HART filter solves this problem 27

27 Is HART signal affect 4-20mA signal? Please care about your desired analog signal band width Noise (1KHz) HART High cut at 10Hz Filter Analog (e.g. 12mA) 12.01,11.99,12.0,12.02 A/D High cut at 100Hz Filter A/D 12.01,11.99,12.50,11.72 High scan rate loop need to pay attention about this matter PLC sometime works this high speed It can be solved by reviewing the filter constant 28

28 What should be careful about operation? New technology requires education but thanks HART use it just as 4-20mA device, nothing change Utilize HART benefits, Education and Training Management cycle Working time to utilize new information 29

29 What are the benefits? Basic Benefits of HART Operation and support of configuration, calibration and source trouble hunting from remote place No need to climb high tower with heavy instrument for just checking Utilize multivariable capability which was wasting Reduce wiring cost and controller point cost Get more information without cost Utilize device diagnostic capability which was unused sometime it enable to prepare before actual fail Solve problem much speedy than before More accurate measurement/manipulating by digital communication These kind of benefits come with every HART loop 30

30 What are the benefits? Additional Benefits of HART Utilize quantitative state information from device diagnostics Shifting to condition base maintenance from time base maintenance Predictive maintenance based on fault symptoms Increase data for analyzing Plant efficiency, Optimization, Safety The data from device data contribute more than just controller data To get these benefit Education and Training Management cycle Working time to utilize new information are required 31

31 Introduction of digitizing field devices is the first step towards IIoT Let s start with HART for an existing plant There is nothing to lose but you can only get value. Also there is no significant risk for your plant operation. 32

32 ご清聴ありがとうございました Thank you Terima kasih atas perhatian anda 2017/01/20 一部修正 33 33

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