7 Ye YingMin Diagnostics and Maintenance
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This document outlines the methods and experiences related to the diagnosis and maintenance of fieldbus systems, aiming to make these processes easier for users. It discusses various factors affecting fieldbus reliability, including common fault types, diagnostic techniques, and the importance of data analysis in identifying issues. Furthermore, it emphasizes the value of proper maintenance strategies and collaboration with industry professionals to optimize system performance and reduce operational risks.
7 Ye YingMin Diagnostics and Maintenance
- 1. 现场总线诊断与维护 Ff Diagnosis & Maintenance 叶迎民 Place Company 上海赛科主任工程师 Logo Here YeYingmin Leader Engineer Shanghai Secco
- 2. 前言Preface 我们如何让现场总线诊断和维护变得更加容易？ How can we make Ff diagnosis and maintenance easier？ 这个演示目的是从用户的体验和实践出发，探讨现场总线的诊断和维 护应用的范围，以及如何有效地开展现场总线诊断和维护工作。This presentation is from the point of view of the user experience and practice, to explore the application scope of fieldbus diagnosis and maintenance, and how to eFfectively carry out the fieldbus diagnosis and maintenance 现场总线诊断和维护涉及的因素广，关联性强，演示的出发点是与大 家共同探索如何将问题简单化，以适应更广泛的应用。Fieldbus diagnosis and maintenance factors involved in a wide range, strong relevance, the speech is the starting point to jointly explore in the face of various problems with you, how to simplify problems, in order to adapt to the more extensive application.
- 3. 内容Content Ff诊断和维护的范畴 Scope of Ff diagnosis and maintenance Ff诊断和维护的方法 Method of Ff diagnosis and maintenance − 典型方法和案例分享The typical methods and case sharing − 诊断数据记录与分析Recording and analyzing data diagnosis − 报警管理及状态监测Alarm management and monitoring Ff诊断和维护的价值 The value of Ff diagnosis and maintenance Ff诊断和维护的体会 Experience of Ff diagnosis and maintenance
- 4. Secco简介及其Ff应用 Introduction and Ff Application in Secco Ff Segment 2475 Center Control Room Ff Devices 11637 Outstation 17 Outstation Unit: ktpa 实践证明，Ff大规模应用的可靠性是可以保证的，并且 可以为用户带来价值。Practice has proved, the reliability of Ff large-scale application can be guaranteed, and can bring value to the user.
- 5. Ff故障类型/诊断范围 Ff Fault Type / Diagnosis Scope 故障源 诊断范围 故障表现Fault 诊断途径 Fault Source diagnosis scope performance Diagnostic methods 物理层缺陷（包括潜 现场总线网段（主干网、分 设备丢失/通信报 网段物理参数测量/物理层 在的缺陷）The 支电缆、接线箱、终端保护 警The device is 指标监测Segment physical physical layer defects 器、电源）Fieldbus lost / parameter measurement / (including latent segment (backbone, branch communication physical layer monitoring defect) cables, junction box, alarm index(ADM) terminal protector, power) 设备缺陷(元件、传感 现场总线设备（变送器、阀 测量/控制异常 设备报警管理及诊断软件 器、阀门)defective 门定位器、转换器、指示仪） Measurement / Equipment alarm equipment (electronic Fieldbus devices control abnormal management and components, sensors, (transmitter, valve positioner, diagnosis software valve) converter, indicator ) (AMS and SnapON) 软件组态缺陷（包括 现场总线软体（数据包、功 状态异常/失控he H1主机通信监测；BUS通 兼容性）Software 能块）Fieldbus software abnormal state / 信数据监测；FDS检查H1 configuration ( data packet, function out of control host/Bus communication defects( including block ) monitoring; monitoring; compatibility) functional design specification examination
- 6. Ff/HART故障表现及区别 DiFferences between Ff and HART 1. Ff仪表诊断报警的类型数量多于 HART，报警检测是基于宏周期的， HART一般是轮询的。Ff instrument Alarm / fault rate diagnostic alarm type more than the ( based on unit ) number of HART, and the Ff alarm detection is based on the macro cycle, HART alarm detection is generally polling. 2. 通信报警不同。DiFference communication s and alarms. 1. 现场总线具有相当程度的“容错性”，故障具有 “潜伏性”；Fieldbus has a considerable degree Alarm type contrast of " tolerance ", " potential "; ( based on equipment ) 2. 现场总线设备共用一个网段，故障源和故障发 生点有时分离，具有“交叉性”；Fieldbus devices share a segment, the fault source and fault point sometimes separate with the "cross "; 3. 现场总线通信可能受到干扰，间歇性的干扰使 得故障表现出一种“随机性”；Fieldbus communication may be subject to interference, intermittent interference makes the fault to show a " random ";
- 7. Ff故障原因分类 Classification of Ff Failure Causes 除了仪表的本体以外，常见的是接线、进水问题。except the instrument body, common wiring, water problems. 对故障原因的分类统计有利于预防性维护措施的制定。 Classification and statistics on the fault reason is conducive to the development of preventive maintenance measures 根据故障多发的情况，采取相应的改进措施。According to the multiple fault situations, take corresponding measures. Note: Proportion is for reference only
- 8. Ff故障影响及操作处理 Deal with Ff Failures
- 9. 现场总线网段诊断及故障源排除 Ff Segment Failure Diagnosis and Exclusion 在接线柜采集数据。一般情况下，数据集中采集可 以安排在停车机会之前进行。Not for the deployment of online diagnosis system of the factory, in the cabinets of data collection. In general, data collection can be arranged in the parking opportunity before. 对数据进行整理，选择需要排查的对象。连接待检 查网段，在现场接线箱处，采用排除法（依次断开 分支，观察指标是否恢复），进行故障源的定位。 To organize the data, select the object needs investigation. Connection to network, in the junction box, exclusive method ( disconnect the branch, observed whether recovery), location of fault source.
- 10. 现场总线诊断典型案例 Typical Cases of Fieldbus Diagnosis Water penetration Electrical interference
- 11. 现场总线诊断数据关联分析 Fieldbus Diagnostics Data Correlation Analysis 诊断数据分布特征-复合型 Physical layer parameters exceed distribution characteristics – composite ——一般情况下，幅值和不平衡超标比较突出。其 中，应主要关注不平衡因素。不平衡降低了网段的 抗干扰能力，应特别关注 In general, amplitude level and unbalance exceed the standard more prominent. Among them, should be the main concern imbalance factor. Unbalanced lower segment of the anti-interference ability, we should pay special attention to. “设备类型+物理层指标”合并分析 “ Type of equipment + physical layer index” combined analysis ——应注意到设备本体作为网段的一个组成部分， 在正常的情况下，对网段的性能也会造成的叠加的 影响。Attention should be paid to the body of the device as part of a segment, under normal circumstances, the impact on performance of the segment will also cause the stack.
- 12. 现场总线诊断数据分布分析 Fieldbus Diagnostics Data Distribute Analysis 噪音分布数据分析 Data analysis of Noise distribution 信号畸变分布数据分析 Distributed data analysis of signal distortion 不平衡分布数据分析 Data analysis of Unbalance distribution 信号幅值分布数据分析 Distributed data analysis of signal level amplitude
- 13. 现场总线网段诊断数据记录表 Fieldbus Segment Diagnostic Data Record 记录表应有辅助的信息。包括DCS端口、接线箱、 接线柜端子、设备厂家型号。由于网段配置是动态 的，可编制程序从INtools和AMS的数据库中自动扫 描生成。Records should be auxiliary information. Includes a DCS port, junction boxes, cabinets, equipment manufacturers type terminal. Because the network configuration is dynamic, can be programmed from INtools and AMS database automatic scanning. 企业根据自己的实践，制定合理的诊断参考指标。Enterprises according to their own practice, formulate reasonable diagnostic reference index. 注意在正常工作状态下的“背景”噪声/电平。Note that in the normal working state under the " background “ noise / level. 尽可能消除不平衡，提高网段抗干扰和免疫能力。To eliminate the unbalanced as far as possible, to improve the anti-interference ability and immune network.
- 14. DCS Ff诊断参数(DeltaV) DCS Ff Diagnostic Parameters (DeltaV)
- 15. 现场总线数据链路/报文诊断 NI-FBUSTM Fieldbus Data Link/Message Diagnosis BUS-Monitor案例-雷达指示仪电缆 BUS-Monitor case - radar indicator cable BUS-Monitor案例-Host H1卡故障 BUS-Monitor case -Host H1 card failure
- 16. 现场总线现场维护检查的内容 Fieldbus Site Maintenance Examination Items
- 17. AMS Ff报警管理-“报警周报” AMS Ff Alarm Management- Weekly Report 开发报警统计报表。对仪表报警进行监测和统 计；从报警区域、报警类型、事件种类、设备 型号、报警频率等不同维度观察仪表报警的分 布。发现和解决主要问题。The development of alarming statistics. The instrument alarm monitoring and statistics; From the alarm, alarm types, regional event categories, types of equipment, alarm frequency diFferent dimensions of observation instrument alarm distribution. To discover and solve problems.
- 18. AMS Ff设备管理-“网段树” AMS Ff device management-Segment Tree AMS数据库按网段的拓扑构建 树形结构，并与DCS的Port口 同步更新。 由于Ff通信故障 具有“关联性 和交叉性”，采用“网段树”进行 报警管理有利于故障分析、定 位。 Build AMS database tree structure according to the network topology, and synchronize with DCS Port. Since the Ff communication fault "relevant and cross", the " segment tree " alarm management is beneficial to the fault location analysis.
- 19. AMS Ff通信故障管理-“报警排行” AMS Ff Fault Management – Alarm Ranking 以DCS Port口（TRUNK/JB）为集合单 位，进行Ff通信报警的测量和排序。优 先检查报警排行在前的网段存在的问题。 DCS Port (TRUNK/JB ) as a collection of units, measuring and sorting Ff communication alarm. Priority check the problem in before the segment alarm ranking.
- 20. Ff仪表/阀门诊断信息统计 Ff Instrument / Valve Diagnostic Statistics
- 21. Ff设备诊断应用-阀门诊断 Ff Equipment Diagnosis Application– Valve Diagnosis Example：41FV12100A: 防 喘振阀门振荡，有失控现象， 存在安全隐患。气动附件存在 故障所致，放大器内漏。 Anti-surge valve oscillation, a runaway phenomenon, the existence of security risks. Pneumatic accessories fault caused by leakage of amplifier.
- 22. Ff诊断减少检修成本&时间 Ff Diagnosis Reduces Overhaul Cost & Time 在大修开展诊断和维护，阀门检修量减少 49%。降低近一半的检修成本和检修时间。 Development of diagnosis and maintenance in turnaround, valve repair to reduce the amount of 49%, reduce maintenance cost and maintenance time of half of the overall. 通过诊断对阀门检修进行验收，查出158台检 修不合格阀门，占13%。有效地防止了风险。 Through the diagnosis for the acceptance of the valve repair, found 158 unqualified valve, accounted 13%. To effectively prevent 通过开展阀门诊断和维护，大检修 the risk. 前后，阀门(定位器)报警数量减少 了65%。阀门偏差减少了66%。提 高了阀门运行可靠性。Through the diagnosis carried out valve and maintenance, before and after overhaul, valve (positioner) alarm number was reduced by 65%, valve deviation is reduced by 66%. To improve the availability.
- 23. 现场总线维护管理的方法 Method of Fieldbus Maintenance 制定和执行Ff设计选型、施工接线、维护组态的工程规范；Establish and implementation of Ff engineering specification design, selection, construction, wiring, maintain configuration; 定期进行网段/设备健康体检，结合“基线”数据，发现缺陷，消除故障 源；Regular segment&device health examination, combined with the "baseline" data, found defects, eliminate the fault source; 开展Ff设备的状态监测，发现并解决仪表本身的问题；To carry out condition monitoring equipment Ff, find and solve the problems of instrument itself;
- 24. 现场总线维护管理的体会 Experience of Fieldbus Maintenance 正确面对Ff故障。认识Ff的容错性。消除对Ff故障的恐惧心理和畏难情绪。采用 PID CIF控制策略。执行统一的FB FDS规范，取消故障后Shutdown的设置，减少 Ff故障对工艺控制的影响，避免Ff故障“衍生”的风险。A correct understanding of Ff fault. Fault tolerance to Ff. The elimination of Ff fault of fear and fear. Using the PID CIF control strategy. The implementation of a unified FB FDS specification, set the Shutdown to cancel the fault, reduce Ff fault influence on process control, to avoid the risk of Ff failure "derivative". 树立网段的意识。不要孤立地看待单一设备的问题，在任何时候都要把完整的网 段作为一个“Ff回路” 研究。Establish the consciousness of network. Don't think of a single device isolated problems, at any time to the integrity of the network as a " Ff loop " collective research. 认识Ff的优势，开展预防性诊断和维护工作，防止Ff运行条件和设备性能的劣 化。 Know the advantages of Ff, Carry out preventive diagnosis and maintenance work, preventing deterioration of Ff operating conditions and device performance. 联合Ff领域专业公司，获取产品和技术上的支持，结合企业的实践，开展研究， 将知识简约化，把Ff应用、诊断和维护管理要求，转化为企业标准、策略，程序 和流程，以及可以被非专家人员接受和执行的方法。associate with the Professional Company in Ff field, get the product and technical support, combined with the practice of enterprises, research, knowledge reduction, the application of Ff, diagnosis and maintenance management requirements, into the enterprise standards, policies, procedures and processes, as well as by non-specialists acceptance and implementation method.
- 25. Q&A