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SA Instrumentation & Control Buyers' Guide

Technews Industry Guide - IIoT 2018

Technews Industry Guide - Maintenance, Reliability & Asset Optimisation

 

Save time and effort through streamlined commissioning
Technews Industry Guide: Maintenance, Reliability & Asset Optimisation 2018, Maintenance, Test & Measurement, Calibration


Automation projects are under cost pressure now more than ever. Time available from the final investment decision until start up is getting shorter because companies need to start generating revenue as early as possible. Contractors and project leads typically follow KPIs based on time savings and cost reduction within a project, while comparing them to previous similar project experiences. Last minute changes in projects are common, e.g. adding new devices or changing configurations after the final order is placed, so it is important to be flexible and take an agile approach to managing these situations wherever possible.

Smart commissioning is an efficient time-saving approach to commissioning intelligent devices via a fieldbus. By using smart DCS/PLC functions such as Device Templates, Pre-Configuration, and Remote and Bulk Configuration, engineers can commission faster and safer when compared to conventional onsite processes. The result is drastically reduced commissioning time, risk and effort.

Expertise is the key to fast, smooth and solid plant start-up

Commissioning is on the critical path for start-up, and since delays can cost millions, customers are constantly searching for new ways to be more efficient during this phase.

Assuming an average time of 1,5 hours per device, with conventional (device display, handheld or a service tool) commissioning, at a price of R1000/h in a medium size project with 2000 devices, this task will take 3000 hours and cost R3 million. Taking the same project, but using Device Templates combined with a streamlined commissioning processes, this task can be done in less than 500 hours and cost only R500 000.

Typically, the time-saving results in a 50-80% cost saving, mainly related to labour costs in larger projects with more than 200 devices and a good portion of intelligent devices. In addition, most work can be completed more efficiently due to early planning, reducing the likelihood of any impact on the project’s critical path. Moreover, this approach also avoids the risk of working on construction sites, as most of the work is done offline in safe office and workshop environments. All configuration and integration tasks are discussed and tested before the final commissioning of the devices, hence compatibility risks are eliminated.

With conventional commissioning, device diagnostics, like NAMUR NE107 and Heartbeat Technology, are sometimes not considered and therefore not configured, which often leads to false alarms in the DCS or Asset Management Systems. This often forces the customer to ‘switch off’ this functionality in the host system, which makes it impossible to utilise Heartbeat Technology and to adopt a preventive maintenance concept using sensor data as a source of information. To enable best practices, the optimum configuration of each device is mandatory.

Figure 1: Smart Commissioning is planned and executed in two major stages.
Figure 1: Smart Commissioning is planned and executed in two major stages.

The ‘smart’ factor is in the commissioning process

The essence of smart commissioning is to get involved as early as possible in the project discussions and make the best decisions at an early stage related to:

• Planning and preparing commissioning tasks in the engineering office.

• Efficiently performing commissioning in the field.

Figure 1 gives an overview of the two main phases as well as their associated deliverables.

Conclusion

Smart commissioning enables a faster and safer commissioning process and drastically reduces commissioning time, risk and effort. This value-added service is an integral part of Endress+Hauser’s extended service offering as it works to provide project consulting and execution services.

For more information contact Preston Reddy, Endress+Hauser, +27 (0)11 262 8080, preston.reddy@za.endress.com, www.za.endress.com


Credit(s)
Supplied By: Endress+Hauser
Tel: +27 11 262 8000
Fax: +27 11 262 8062
Email: info@za.endress.com
www: www.za.endress.com
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Further reading:

  • Bernhard Klöss takes the wheel at Endress+Hauser South Africa
    January 2019, Endress+Hauser, News
    Following the move of Rob Mackenzie to Endress+Hauser’s Swiss-based head office, the company recently announced its choice of Bernhard Klöss as the new managing director of southern African operations. ...
  • A wavelength for all situations
    January 2019, Endress+Hauser, Level Measurement & Control
    113 GHz: the best fitting radar frequency for every level application.
  • 2-in-1 combo test instrument
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    Thermal imagers are invaluable to troubleshoot electrical equipment, panels and transformers, but electricians and maintenance technicians do not often have access to one when they need it. Comtest now ...
  • Optimised condition monitoring
    January 2019, ifm Electronic RSA, Maintenance, Test & Measurement, Calibration
    The VSE150 from ifm electronic is a 6-channel diagnostic system designed to evaluate four dynamic signals (e.g. rotational acceleration) and two analog inputs. The new VSE15x family provides different ...
  • Pressure calibrator with electric pump
    January 2019, WIKA Instruments, Maintenance, Test & Measurement, Calibration
    WIKA has expanded its range of portable calibrators to include an instrument with integrated electric pressure pump. The new model CPH7650 pressure calibrator – supplied in a robust case – is multi-functional ...
  • SKF digital tachometer provides accuracy and versatility
    January 2019, SKF South Africa, Maintenance, Test & Measurement, Calibration
    The SKF TKRT 10 is a fast and accurate tachometer utilising laser or contact to measure rotational and linear speeds. Equipped with a laser and a range of contact adaptors, it is a versatile instrument ...
  • RS unveils LED lighting portfolio
    January 2019, RS Components SA, Maintenance, Test & Measurement, Calibration
    RS Components has launched a comprehensive range of RS Pro LED lighting products for use in a range of energy-saving options, including torches and inspection lights, high-bay lighting, ceiling panels, ...
  • IR cameras with leading edge technology
    December 2018, Comtest, Maintenance, Test & Measurement, Calibration
    Fluke Ti450 and Ti480 Pro series cameras capture and display small temperature differences for faster diagnosis of problems.
  • Paper mill saves with IR window program
    December 2018, R&C Instrumentation, Maintenance, Test & Measurement, Calibration
    In search of alternate methods for conducting safer inspections, the reliability engineer investigated how infrared inspection windows (IR windows) might be utilised.
  • Endress+Hauser plans new regional centre near Houston
    December 2018, Endress+Hauser, News
    Endress+Hauser has announced its plan to build a new Gulf Coast Regional Centre Campus outside Houston, Texas, located in close proximity to the company’s oil and gas customer base. Construction is currently ...
  • Picomag for utility measurement
    December 2018, Endress+Hauser, Flow Measurement & Control
    In industrial process measurement and automation, demand is steadily rising for simple, reliable and maintenance-free measuring instruments in a pocket-sized format. The new Picomag from Endress+Hauser ...
  • Industrial videoscope for equipment inspection applications
    December 2018, RS Components SA, Maintenance, Test & Measurement, Calibration
    RS Components has introduced the rugged diagnostic videoscope from Fluke that targets maintenance engineers and other professionals needing to undertake equipment inspections and diagnose problems in ...

 
 
         
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