Pressure and Temperature Instrumentation Best Practices

Original publication - Intech Focus | Pressure and Temperature Instrumentation Best Practices 

When examining facilities and processes, users often see many opportunities for improved operation and efficiencies. They also might wonder how to better prepare their process for the next level of performance the future will inevitably require.

Fortunately, many locations are better prepared than they realize to seize opportunities for improvement and that the task of future proofing is already done. The information many locations need could be hiding in plain sight. Stranded instrumentation data sits waiting to be used, connections among systems need waking up, and data connectivity and analysis tools reside within reach or are simple to add.

Data is closer than you think

Data also can be found in devices that have been untouched for a while. Some field instruments are so reliable that they become “set and forget.” In some cases, that is the most economical solution, but realize that such an approach could leave value on the table. These forgotten devices may be the superstars of digital transformation efforts.

After reviewing the data the current devices provide, think about how that data can be best used. When eventually adding instrumentation, first consider how robust and reliable the devices are so they continue to give value for a long time. It is also imperative to measure their sophistication—the data they gather—so information continues to be harvested for future opportunities.

Tap into stranded data

Tapping into data collected by devices is important to the goal of process improvements. Standards such as HART communications and FDT technology can simplify the job.

Communication standards.

Communication protocols enable device interoperability, which means an array of devices from multiple suppliers can be used in a single facility often without the added expense of translating that data for each system using it. To help future-proof installations, look for devices that communicate using an open standard protocol (figure 2). It is acceptable to have more than one standard in a given facility because many tools support multiple protocols. However, using too many different standards will place a greater burden on instrument and maintenance technicians.

Methods or mechanics.

The mechanics required to tap into data range from straightforward to complex. Once the data is unlocked, the information can deliver benefits throughout the organization. Accessing stranded data is linked to one of three primary methods:

1.  Native:  When native communications are used, a simple license or software checkbox in the control system or data collector can begin the process of gathering information from field instruments.  Though some system vendors charge an additional software license fee, this is usually trivial next to the simplicity of accessing the data.

2.  Software:  Data sharing sometimes requires users to add a software plugin to the system. These may be provided by the automation supplier or developed by a third-party software company. Older systems may require a custom solution, while newer systems rely more on standard protocols.  FDT technology, for example, is an open standard for the integration of industrial automation networks and devices. Device suppliers provide a device type manager (DTM), which functions as a device driver to interpret information from the device.

3.  Hardware:  The third way to access data involves incorporating hardware such as gateways, multiplexers, or other edge devices. While the additional hardware and maintenance cost more, there are increased benefits to this approach. Dedicated hardware channels may provide faster communications than a native host system channel, which must prioritize control and safety data over asset performance and health.

Standard reduces data overload.

Once the gates have been opened, a wealth of information is made available. Sometimes the amount of existing data can be overwhelming. Look to NAMUR NE107 for assistance. NE107 is a way to structure data into categories based on severity and simplify how data is delivered (figure 3). NE107 helps users better understand an issue’s severity and helps users prepare appropriate responses.

An asset management system will be able to display alarms in the appropriate category, enabling technicians to recognize the severity of device alerts and take the necessary corrective actions.

Due to innovations, many pressure and temperature devices—some possibly already in place—sort the data into NE107 categories: check function, maintenance required, out of spec, and failure. When used correctly, this information can improve operations and maintenance by helping technicians prioritize troubleshooting and repair work.

Put data to work

Once the data and the connections are set, plans can be created to put everything to work. Consider the facility’s improvement goals and what data could move the team toward them. For example, digital diagnostics helps technicians troubleshoot existing issues. Predictive warnings provide early indications of impending failures so maintenance can be planned before excess loss is realized. This type of data can reduce maintenance costs while improving plant availability and safety.  As data is being put into action, additional instrumentation and maintenance insights can help teams move from preventive to predictive maintenance. This means that device alerts will automatically report when a device needs attention. Technicians will no longer need to be sent out on monthly routes just to check device health.

For example, to promote continued reliable process operation and accuracy, users of certain advanced temperature sensors can set threshold and frequency limits to trigger an alarm status.  This alarm can be used to estimate the remaining life of the sensor, allowing users to plan when maintenance would be most effective.

If using certain advanced multivariable sensors, users can put data to work in detecting line blockages. The fluctuations of differential and static pressure, and the
capsule and ambient temperature signals are continuously monitored. Statistical calculations and comparison to reference conditions can show impulse line blockage.

Raw data from these devices also is more valuable than ever. In the past, case studies and failure analysis would guide software teams to develop algorithms allowing smart pressure and temperature transmitters to detect a specific issue or failure mode. Now artificial intelligence and machine learning (AI/ML) can replace these specific algorithms and begin detecting a wider range of potential conditions that may affect the process.

Note that users can choose from a wide variety of tools, from basic to high-end, that can help gather and analyze data. Open, enterprise level asset management software for both automation and production assets can contribute to improving the quality of maintenance plans and optimizing maintenance costs throughout the plant lifecycle.

Imagine the changes, plan the route

As users discover the data and tools they already have—or make a few adjustments to obtain—they must think about the opportunities that await. As they plan their actions, they must look for robust instrumentation and tools that deliver performance today and continue to perform well into the future. Data is only accessible from a device that continues to operate reliably and communicates with the right protocols.

All images courtesy of Yokogawa Corporation of America.

 

Nicholas Meyer is the chemical industry marketing manager at Yokogawa Corporation of America with 20 years of process industry experience, including applications engineering, product line management, marketing, and product development. He holds a degree in Chemical Engineering from the University of Minnesota.