advancements in physical layer with ff - fieldbus · 2013-02-08 · © 1994 – 2011 fieldbus...
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Advancements in Physical layer with FF
Unnikrishnan R
Technical Support
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© 1994 – 2011 Fieldbus Foundation 2
Agenda
Introduction to FF and FF Physical Layer
FF Physical Layer Components
FF Concepts
FF Wiring Topologies
FF technology and maintenance
Technology developments
Summary
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© 1994 – 2011 Fieldbus Foundation 3
What is Fieldbus?
HOST
Field Device
Fieldbus is an all-digital, serial, two-way communication protocol that
interconnects devices in the field such as sensors, actuators, and controllers.
FOUNDATION fieldbus also has the capability to distribute control applications across its
network in the field. Furthermore, it enables advanced diagnostics for all fieldbus
components and asset management tools resulting in higher plant availability.
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© 1994 – 2011 Fieldbus Foundation 4
Main components of physical layer
FF - Power Supply, Cables, Surge Protector, Terminators, Wiring Blocks,
Process interfaces etc
Wiring Block
HOST
Wiring Block FIELDBUS
TERMINATOR
SURGE PROTECTOR
PROCESS
INTERFACE
Ff POWER
SUPPLY
CONVENTIONAL
FIELD DEVICES
FIELDBUS
DEVICES
JUNCTION
BOX
Home Run Spurs
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© 1994 – 2011 Fieldbus Foundation 5
How to optimize FF Physical Layer?
Optimization of field devices by using proper segment design methodology
as well as segment revalidation tools where we can optimize loop checking
and commissioning time.
Usage of digital communication to achieve predictive intelligence through
advanced diagnostics and asset management of the plant.
Usage of features of the device to effect control in field which will optimize
lower bandwidth of 31.25kb/sec.
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© 1994 – 2011 Fieldbus Foundation 6
Fieldbus in Hazardous Area
The first step
Simplifying
validation
MAX power + FISCO
Re-inventing Intrinsic Safety
Redundant
FISCO
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© 1994 – 2011 Fieldbus Foundation 7
Enhancements in Fieldbus Technology
Ex-i (Entity) Concept
10.6 V @ 70 mA (Ex ia IIC)
Very Less No. of instruments,
very short trunk cable length,
complex proof of intrinsic safety
Ex-i (FISCO) Model
● 12.8 V @ 100 mA (Ex ia IIC)
● Less No. of instruments, short
trunk cable length , simple
proof of intrinsic safety
High Power Trunk Concept
● 28 V @ 500 mA
● Changeover to IS in the field
in acc. with FISCO Model
(physical layer)
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© 1994 – 2011 Fieldbus Foundation 8
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© 1994 – 2011 Fieldbus Foundation 9
FF Wiring Topologies in Hazardous Area
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© 1994 – 2011 Fieldbus Foundation 10
Spurs
Field Instruments
Basic Principles: Typical Topology
Power Supply
Advanced Diagnostic Module
Device Couplers with
Short-circuit protection
Trunk
Surge Protector
Terminator
Host
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© 1994 – 2011 Fieldbus Foundation 11
Spurs
Field Instruments
Basic Principles: Typical Topology
Segment Protectors
Trunk
Surge Protector
Terminator
Plant Asset
Management
Diagnostic Gateway
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© 1994 – 2011 Fieldbus Foundation 12
Spurs
Field Instruments
Basic Principles: Typical Topology
Segment Protectors
Trunk
Surge Protector
Terminator
Plant Asset
Management
Diagnostic Gateway
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© 1994 – 2011 Fieldbus Foundation 13
Why do we need Predictive Intelligence?
Maintenance Cost Reduction Drives End Users
40% of Mfg. Cost is Maintenance
50% of Maintenance is Corrective
10 times More expensive than preventative
maintenance
Preventative Maintenance is Done 25% of Time
5 Times More costly Than Predictive
Maintenance
60% of Preventative Maintenance is
Unnecessary
Lack of Proactive Maintenance strategy
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© 1994 – 2011 Fieldbus Foundation 14
What Does Foundation Fieldbus Enable?
FF is a digital plant architecture that uses the power of Predictive intelligence to
improve plant performance
FF Predictive intelligence helps to detect and correct potential problems before
they can affect Plant Performance
FF Predictive Diagnostics will help users develop a proactive maintenance
strategy
FF Predictive Diagnostics avoid unplanned shutdown and help end-user's reap the
real cost benefit of FOUNDATION technology during the operational phase of
the plant
Goal = Improved operational efficiency
Result = increase plant availability
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© 1994 – 2011 Fieldbus Foundation 15
Strategies to Minimize unplanned shutdowns
Time
Equipment health
100%
Minimum Device Health
FAILURE
Warning Level
Time to respond
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© 1994 – 2011 Fieldbus Foundation 16
Basic Principles: Diagnostic Functions Today
At the power supply
Measure signal level, noise, jitter, earth leakage…
At the operator station
Simple summary alarms
At the maintenance station
Expert system interprets measured data
Produce actionable information in clear text
Increase availability through pro-active handling of fieldbus as
manageable asset
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© 1994 – 2011 Fieldbus Foundation 17
FF Physical Layer Monitoring and Diagnosis
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© 1994 – 2011 Fieldbus Foundation 18
Recommendation for an ideal FF physical layer diagnostic tool
Measurements
Multi-meter Handheld
Tester
Handheld
Communicator
Oscilloscope Note-book
Bus Analyzer
Advanced
Diagnostic
Module
Segment voltage ● ● ● ●
Segment current ◙
Segment noise (low freq.) ● ● ●
Segment noise (high freq.) ●
Segment signal level ● ● ●
Segment signal jitter ●
Instrument signal level =
Instrument signal jitter
Instrument noise (individual)
Fieldbus termination = = ●
Segment earth fault (imbalance)
Device communication ● ●
Communication faults ●
Cable degradation (trending)
Device configuration ● ●
Remote access
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© 1994 – 2011 Fieldbus Foundation 19
Are you protected from EMI?
Ground faults
Fieldbus and power cables tied
together
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© 1994 – 2011 Fieldbus Foundation 20
Did they get it right?
Cable gland not tight
Seal missing
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© 1994 – 2011 Fieldbus Foundation 21
And corrosion as a consequence
Water ingress or worse:
Aggressive media
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© 1994 – 2011 Fieldbus Foundation 22
Will it hold next time?
Wear of surge protectors unknown
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© 1994 – 2011 Fieldbus Foundation 23
Fieldbus Cabinet Too hot? Unauthorized access?
Fan is not working
Door not closed
Water ingress
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© 1994 – 2011 Fieldbus Foundation 24
Is your topology protected?
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© 1994 – 2011 Fieldbus Foundation 25
Diagnostic Device Couplers
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© 1994 – 2011 Fieldbus Foundation 26
Diagnostic Device Couplers
Improved and innovative spur fault protection:
Progressive spur short-circuit protection
Jabber protection – cuts off devices talking too much
Contact bounce protection – suppresses unintentional bounce
Reliable containment of gradual overload conditions
Protects operations from manual intervention and device failure
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© 1994 – 2011 Fieldbus Foundation 27
Jabber protection
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© 1994 – 2011 Fieldbus Foundation 28
Diagnostic Device Couplers
Measures in the field:
Measures fieldbus signal conditions at the spur level
Reports changes all the way to Plant Asset Management
Feeds the expert system
Better advice – better knowledge – focused plant upkeep – fewer trips to the
field
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© 1994 – 2011 Fieldbus Foundation 29
Diagnostic Surge Protector
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© 1994 – 2011 Fieldbus Foundation 30
Diagnostic Surge Protector
Condition-based replacement
Monitors strike severity and count
Reports end of functional reserve to AMS
Instead of repetitive scheduled maintenance
Surely protects you from the next strike
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© 1994 – 2011 Fieldbus Foundation 31
Diagnostic Device Coupler + SPD
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© 1994 – 2011 Fieldbus Foundation 32
Water Ingress Sensor ELS-1
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© 1994 – 2011 Fieldbus Foundation 33
Water Ingress Sensor ELS-1
Monitoring the inside of the enclosure
Placed inside the enclosure of choice
Connects in parallel to the fieldbus segment
Sends alarm all the way to plant asset management
Know what the housing looks like on the inside
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© 1994 – 2011 Fieldbus Foundation 34
Take Control of your Control Cabinet
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© 1994 – 2011 Fieldbus Foundation 35
Take Control of your Control Cabínet
Diagnostic Gateway
With FF-H1 integration and Ethernet
Discrete, frequency, temperature and humidity inputs
Solid state high-power outputs
The cabinet becomes a supremely managed asset
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© 1994 – 2011 Fieldbus Foundation 36
With Diagnostics of Physical Layer We Can….
SEE what's going on in your physical layer
KNOW when and how to act
ACT in your Asset Management tool
Commission Segments
Monitor Segments Online
Predictive Fault finding of Segments
SEE KNOW ACT
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© 1994 – 2011 Fieldbus Foundation 37
Asset Management Integration
One Plant Asset Management
Includes fieldbus now as asset
Customary look and feel
Reduces required training
Reduces potential for errors
Open Architecture Integration:
AMS Suite
PRM
FieldCare
FieldMate
PACTware
OPC Interface
Automatic
Setup
Included
Experion PKS Station
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© 1994 – 2011 Fieldbus Foundation 38
Fieldbus in Hazardous Area
The first step
Simplifying
validation
MAX power + FISCO
Re-inventing Intrinsic Safety
Redundant
FISCO
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© 1994 – 2011 Fieldbus Foundation 39
General Purpose Area
Zone 2 To DCS
Zone 1
DART: Intrinsically safe High-Power Trunk
Redundant, three-port isolated
DART Power Supply
DART Segment Protectors
The intrinsically safe High-Power Trunk
protected by DART®
Intrinsically safe spurs
Ex ib IIC
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© 1994 – 2011 Fieldbus Foundation 40
Zone 1
DART: Intrinsically safe High-Power Trunk
More cable distance (compared to FISCO)
Higher device count (compared to FISCO)
Same installation throughout
Hot work on supplies, couplers, devices
For any fieldbus device:
Ex ib IIC
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© 1994 – 2011 Fieldbus Foundation 41
Comparison of Various Concepts
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© 1994 – 2011 Fieldbus Foundation 42
Summary
Fieldbus technology reduces effort in every phase of a project
Fieldbus is established as reliable technology
Advanced Diagnostic Tools bring transparency and simplicity
HPT and DART concept depending on power requirement
Various devices to provide maintenance information
Fieldbus itself is now an Asset in plant management