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INDUSTRY 4.0/IIOT


THE ABILITY TO VERIFY MEASUREMENT DEVICES


The importance of regular testing and verification of digital measurement devices cannot be understated, as David Lincoln, ABB Measurement & Analytics Digital Lead, explains...


M


odern digital measurement devices have opened vast new possibilities for optimising the efficiency, performance


and reliability of industrial operations through the intelligent utilisation of data. And, as the frontline in any industrial process, instrumentation provides an invaluable starting point for gauging performance, safety and compliance, as well as identifying potential efficiency improvements. Accurate measurement is paramount in


many industrial processes, as even small errors and misreads can have consequences, with latent issues potentially snowballing into big problems if left undetected. With the advent of digitalisation, modern measurement techniques can not only achieve unprecedented accuracy, but provide diagnostic information that may previously have gone unnoticed when relying on analogue and/or manual inspection alone. One of the key benefits of digitalisation in


the field of instrumentation is its enhanced potential for integration with higher level control and automation systems, which can draw on multiple instruments installed around a production facility and use the data to provide a more complete picture of operating conditions, while also providing better visibility on any process aspects that may be running outside of normal parameters.


The ability to overlay data from normal


operating conditions allows anomalies to be quickly detected and acted upon if required, ensuring better, more informed decision making. With a predictive maintenance approach, maintenance teams can be sent to where they are needed, while ensuring time is not wasted on non-urgent duties, and avoiding duplication of efforts. Digitalisation also facilitates more remote monitoring. Digital devices open up new avenues for the


automation of maintenance processes, and a shift towards predictive maintenance, but the accuracy of the data they produce is still critical to the efficient and safe operation of processes. While measurement accuracy may be improving all the time, the measurement devices themselves still need to be checked, particularly if operating in relative isolation without a control measurement to compare with. As such, devices need to be tested regularly, particularly those operating in harsh conditions such as the chemicals or oil & gas industries. New digital solutions are being developed to verify the accuracy of measurements. For instance, measurement device


verification is an in-situ tool for checking instrument accuracy and performance. During a verification test, on-board diagnostic information is used to ascertain the condition


Digital measurement solutions for


industrial applications can save huge amounts of time and money, while


facilitating a shift towards predictive maintenance for systems


of the device and assess whether it is within its original calibrated values. This information can include snapshots of key parameters such as: - Sensor transducer internal measurements


(e.g., resistance, capacitance, inductance, frequency) - Meter output accuracy (analogue pulses


or 4-20mA, digital outputs) - Cable insulation resistance Comparing the results of the verification test


with those of the original fingerprint tests carried out when the device was manufactured or commissioned will help to identify any drift in performance, which can then be dealt with appropriately. Verification can be carried out by on-board systems, which provide continuous self-checking of the device with the resulting data being relayed to higher level systems, avoiding the need to store it on the device. Alternatively, on-demand verification software can be used on a PC to communicate independently with the device, comparing a current test with previous test results to detect performance drift over time. On-demand verification still requires some


degree of manual input, as well as historical records of data from which to carry out trend analysis. Automated remote verification is an alternative method which uses a server or cloud-based version of the verification software. Systems like ABB Ability Verification for measurement devices can access archived test data, and generate an alert in the event of deviation from the original fingerprint test. Although modern measurement devices are


typically not fit-and-forget solutions, new verification technologies can help to reduce the maintenance burden on personnel, without compromising accuracy or reliability.


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MAY 2022 | PROCESS & CONTROL 11


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