Water & Wastewater Asia September/October 2019

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32 | INSIGHT Communicative trends in process automation By Peter Lindmueller, Industry Manager, Water & Waste Water, Endress+Hauser The current standard for signalling the measured values generated by the instrumentation (measurement line) is the analogue current interface. This method maps the measured value to a loop current. 0 or 4mA corresponds to the lowest, 20mA to the highest reading that you want to transmit. Current interfaces offer the advantage of high interference immunity, a starting motor does not bother them, for example, but they only allow the representation of measured values within very narrow limits. The user does not get any information on the status or other conditions of the measuring point. Sometimes the information is enhanced by having an alarm relay for the status, but the overall content is very limited. In the end, it’s difficult to talk about communication at all. Why are operators and users interested in the details of instrumentation statuses? Where are the propellants for communication, where does the desire to know more about the process come from? Essentially, there are two reasons behind this: • There are more and more remote installations (satellites) that need to run 24/7 but are staffed only at certain times or not at all. • Less staff with deep process and instrumentation skills is available. Due to both reasons, plant operators need to get deeper insight into the plant in the future and must be able to assess its functioning and the potential of defects from a distance. There are further trends that drive the need for deeper process knowledge: • Cost pressure: Plant operation and maintenance in the context of limited financial budgets. • Information needs: A city mayor might be asked in a budget round discussion if a facility is used to capacity, how effective and how efficient it is. Here, a qualified answer is expected which means that the above mentioned KPIs (Key Performance Indicator) must be ready at hand. • Planning needs: Deployment of expert emergency services is expensive. All assignments that can be moved from the non-plannable to the plannable zone allow a more favourable cost calculation. • Greater linkage between professional and private aspects: Although professional and private life do not merge into symbiosis, they are getting closer. Operators are, for example, able to do a remote evaluation of the system from their home while caring for their children. In other words: The digital twin of the system is available on their smartphone, tablet, or computer displaying the real conditions of the plant. It is not just about a measured value and a status, but about much more information on the measuring point. “How are you?” Describes an information that goes much deeper than the pure measured value and describes the state of the measuring point. This can range from “everything ok” to “cannot do any more”, it can contain references to the status of consumables (e.g. 20 per cent of the bottle’s detergent has been used up) and it can of course contain information about the measured value quality, e.g. my last calibration was 60 days ago and must be renewed in 30 days. Regular calibrations can be: • forced by authorities • necessary to optimise process flows Very often we can distinguish between process-optimising measurement (operational measurement) and product quality determination. While processoptimising measurement supports optimised usage and dosing of excipients for example, the second measurement describes the final product quality, or the quality of the raw materials used. Water & Wastewater Asia • September / October 2019
INSIGHT | 33 What are the technical requirements for getting advanced information on a measuring point? A variety of data must be provided from the measurement lines and these data must be transmitted to a central location for further display and evaluation. Digitisation (or IoT or Industry 4.0 or ...) is the buzzword here. On sensor level, information on the sensor status is needed. Memosens provides e.g. calibration data and trends, operating temperatures over ranges of measured values, stress situations of the sensor such as the number of CIP or SIP runs. This information must now be passed on digitally, which requires a fieldbus. If the system is rather slow and you have time and leisure, you can start with HART – a rather slow method. If the process is fast, an Ethernet-based variant is more likely to be used (e.g. EtherNet/IP, Modbus TCP, PROFIINET). Which fieldbus is used largely depends on the DCS system, and which language variant this system understands. When the diverse data are now available in the DCS or PCS (process control system), they must be interpreted to determine KPIs and derive measures from the data. What kind of measures could that be? Everything from information to necessary activities: make maintenance assignments predictable, get away from forced, unplanned maintenance at any time of the day or night (measurement lines seem to prefer to fail on weekends and then at night), get to a planned activity. Even a central planning of maintenance and service assignments can be implemented. Endress + Hauser’s Heartbeat Technology Back to the KPIs. Many can be standardised, some are specific and can only be used for the respective system. At this point, Heartbeat Technology comes into the game: Heartbeat Technology is able to indicate how long a sensor or measuring line can run without any further service, taking into account previous loads on the sensor, such as high temperatures. It makes planned maintenance a reality and brings down the costs directly. These are all good reasons to explore the digital revolution! WWA Liquiline multi-parameter transmitter – ready for seamless integration into the process control system Water & Wastewater Asia • September / October 2019
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Water & Wastewater Asia September/October 2019

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