Contributors

2015 - 2 Issue

Chairman’s CornerOver the Horizon

FDT will play a big role in advancing global manufacturing efficiency.

Government led coalitions from around the globe are focused on manufacturing leadership. Whether it’s the US with the Advanced Manufacturing Partnership 2.0, Germany with Industrie 4.0, Manufacturing Innovation 3.0 in Korea, or the China Manufacturing 2025 initiative, they all share a common vision, to increase manufacturing efficiency. As I read through my favorite industry news sources, I am finding more and more references to activities in-progress that are positioned to contribute to this world-wide goal. One activity which will no doubt be part of the solution was described in a recent ARC Advisory Group Strategies Report. In Planning for the Industrial Inter-net of Things, (IIoT) the path forward for the Industrial Internet of Things is described as, “providing remote access to connected machines and

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In This Issue

>> Simplifying RobotConfiguration from ProductionThrough Diagnostics at KUKA

P. 04

>> Plant Life Cycle ManagementSees Increased Value When aProject Starts with the End inMind

P. 06

>> Device Interoperability:The Hidden Layer

P. 10

>> FieldCare 2.10 ProvidesUniversal Device Configuration

P. 14

>> Updated Wastewater SCADASystem Cuts Failures, AddsSecurity

P. 15 Microsite LinkedIn

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Simplifying device-level networking with FDTBrought to you byBrought to you by

FDT Technology removes many of the challenges faced during commissioning and setup.

Industrial robots have very complex motion and control require-ments due to their increasingly advanced kinematics capabili-ties. In addition to a diverse array of drives, encoders, I/O mod-ules, and internal networks, the robot control system must also integrate a wide variety of peripherals on the robot flange such

Article continues on page 4

Simplifying Robot Configuration from Production Through Diagnostics at KUKA

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Over the Horizon continueddevices to enable transformative operational and process performance improvements”. Today, the industrial automation industry is enabling us-ers to put the right infrastructure in place to progressively reap the bene-fits from a higher degree of remote access and connectedness.

The IIoT has increased requirements and technical complexities beyond the Internet of Things to handle the real-time nature of the industrial data that allows intelligent devices to analyze data to predict impending fail-ures, or interact with other devices to create smarter sub-systems. As the IIoT evolves and we apply similar concepts to global manufacturing, we need to recognize the opportunities for improvement that still exist with the broader implementation of the Internet of Things (IoT). Whether it is a smart thermostat, baby camera, home networking router, or refrigerator, the awareness of the important role of network segmentation, defense in depth and general awareness of internal and external security threats is growing. So while someone tapping into a baby monitor is scary, some-one gaining real-time access to critical infrastructure could have more severe implications.

For manufacturing efficiency to improve we all need to enter the conver-sation – automation users, IT, equipment providers, and implementers to define the key resources for a secure industrial infrastructure. Togeth-er, we will focus on using existing proven elements and fill the gaps to strengthen the solution. The FDT Group’s mission centers on developing a standardized, open, but secure integration approach for devices and networks for manufacturers. As a result, we expect to play a crucial role in the IIoT with our applicability across industrial communication networks, automation systems, and device suppliers. Industry leaders, including FDT Group leadership, are engaging with technical experts from a di-verse mix of suppliers, foundations and service providers in order to bet-ter understand the needs to fully enable safe, secure industrial networks. We will be taking what we know today along with technical solutions cur-rently available and connect that to opportunities that still lie “over the horizon”. We see additional opportunity to build bridges between estab-lished technologies to strengthen the IIoT; for example, FDT is working with other standards bodies to find a method to universally enable and abstract device connectivity. Moving forward, the FDT Group is actively pursuing enhancements that will help improve manufacturing with a more agile, more productive environment. As we experience the transformative operational and performance im-provements delivered with IIoT, we will begin to interact with our manu-facturing assets in new ways. Although, I believe the personal comput-er will be part of the landscape for many years, we cannot ignore the influence of mobile platforms such as smart phones and tablets. Two numbers that I am looking at, indicate we will be able to increase our level of interaction with manufacturing assets. 1.) The number of mobile devices in use has surpassed the installed base of PCs. 2.) Mobile device shipments will outpace traditional PCs in 2015. Fortunately, the FDT Group is already working towards understanding the requirements and use cases for mobile device connectivity to the industrial shop floor. Later this year we will be mapping mobility requirements into the FDT

Latest DTM Collection from Yokogawa Enhances Versatility

DTMs come in off- and on-line modes: Yokogawa just released its latest DTM 2014 collections for its HART, FOUNDATION™ fieldbus and PROFIBUS PA field devices. To enable efficient device configuration and management, all DTM’s feature an off-line and on-line mode. They also offer a clear, user-friendly navigation structure. Further, the configuration details both off-line and on-line, which can be printed using an integrated printing module.

Yokogawa Electric Corporation

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Over the Horizon continuedstandard to enable device management ‘on-the-go’. I invite you to share your thoughts on how you and your staff want to interact with industrial field devices on mobile platforms. Visit our mobility survey at mobility survey.fdtgroup.org. We want to hear from you!

The quest for increased productivity will take us down many new paths, parts that could challenge some of us for years to come. I am energized by our shared ambition to increase manufacturing efficiency. At our re-cent FDT General Assembly held on the grounds of Hannover Messe on April 15, 2015, FDT member companies joined together to hear about additional initiatives and changes to the FDT Group organization and technology including; board leadership transitions, announcement of a life cycle policy, an emphasis on security, inclusion of support for mo-bile platforms, FDT2 certification, and FDI Device Package integration into FDT host applications. To learn more about these evolving ventures, please review my short General Assembly video presentation that out-lines these topics. FDT Technology is a leader in device and network integration. Supported by leading suppliers and end users in the process and discrete industries, the FDT Group remains committed to providing open standards and tools that enable the future of industrial automation. Having enhanced and evolved the FDT standard since the late 1990’s, we are continuously listening to the industry. We encourage you to be heard and take an active role in the FDT Group. Consider your impact! Learn about FDT Group membership and the benefits that allow you to help direct the technology by visiting http://www.fdtgroup.org/member ship-benefits.

Lee LaneChairman of the FDT Board of Directors

Motor Starters Protect Induction Motors

Switching and protecting three-phase induction motors can be much simpler when CONTACTRON hybrid motor starters from Phoenix Contact are networked. The starters offer emergency stop function, and easy monitoring through electronic motor management. The CONTACTRON line lets customers easily configure stations via a PROFINET gateway using FDT’s powerful DTM concept. The DTMs can be used without additional costs using the FDT framework applications from different providers.

Phoenix Contact

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2015 - 2 Issue P. 40

Simplifying Robot Configuration from Production Through Diagnostics at KUKA continued

as grippers or weld gun. This complete robotic package is then married to a higher level con-trol system that issues coordinating control sig-nals such as a program number to be executed or an emergency stop. Often multiple field-buses are used in a single robotic application. Amidst this diversity of fieldbuses and devices, a common configuration and management tool is required.

Strengths of FDT/DTM TechnologyAt KUKA, the unifying tool kit includes an FDT Frame Application. This tool saves all fieldbus-specific information that is generated during commis-sioning. The FDT DTMs work seamlessly with one another, even though they are supplied by many different manufacturers. The very complex bus scenarios can be configured across multiple gateways without any difficul-ty using the nested communications capability in the FDT standard.

Initial commissioning and customer changesA robot is commissioned in multiple phases. The initial commissioning takes place in the KUKA factory during the cabinet assembly. Based on the customer order, an FDT project is automatically created with factory

settings. This includes the bus configuration for the drive technology with properly-sized converters, various encoder units, special modules, and optional special accessories, such as I/O modules. After this configuration, the cabinet is fully ready to operate.

System integrators or end us-ers often alter the robot configuration with additional field devices, particu-larly tools that they can buy from third-party suppliers or build themselves. In order to put these into operation, they use the generic, fieldbus-specific device DTM provided by KUKA. This DTM derives the corresponding rep-resentation in the FDT project from a device description file.

If errors like defective wires or peripheral components oc-cur while the robot is working, users have to determine the cause of the errors quickly and reliably. The DTMs are provid-ed with tools for this purpose. These range from monitoring I/Os and analyzing fault memo-ries on the devices all the way to very detailed analyses, such

Track Valves with an Online Signature Using the Neles ND9000

Valve’s advanced features help determine when maintenance is needed. Metso’s ND9000 intelligent valve controller has a Valve Online Signature feature that measures friction of the control valve online whenever the valve is changing position. This new feature gives you constant visibility into control valve conditions under real process conditions. You can also analyze the need of maintenance when you are preparing to shut down the process, or if there is need for process optimization.

Metso Automation

https://www.youtube.com/watch?v=272l5-8Mp3c&feature=youtu.be

2015 - 2 Issue P. 50

as determining envelope de-lay times or damping reserves in fiber-optic cables.

All robot control systems from KUKA that are shipped with Firmware Version 8.0 and new-er are commissioned using FDT Technology. The support-

ed fieldbuses range from conventional DeviceNet, PROFIBUS, and INTER-BUS protocols to newer Ethernet-based systems EtherCAT, PROFINET, and EtherNet/IP. Complex scenarios can be implemented via cascaded gateways and proxies using standard FDT Technology.

To date, implementation scenarios have shown that the main effort in de-veloping DTMs lies in the interpretation of device description files. This is due to the company-specific focus of generic device DTMs. The newer XML- based formats such as GSDML, FDCML, and ESI offer noteworthy simplifications compared to the traditional text-based formats GSD and EDS. That’s because they can rely on tried-and-tested XML parsers. Con-sequently, the interpretation of syntax and grammar is no longer required.

For a control system manufac-turer supporting many different bus systems, FDT Technolo-gy offers great strengths. The high interoperability between the DTMs provides interesting strategic considerations for make or buy decisions.

Simplifying Robot Configuration from Production Through Diagnostics at KUKA continued

Take Being “FDT Connected” to the Next Level

Training course program offers wide range of options.

Want to learn more about FDT connectivity? No Problem! At Endress+Hauser we know field communication like nobody else. Whether you need to design, install or maintain your plant, we have a training course suited for you! Courses can be set up in many different cities in a range of languages and can be focused on a number of technical areas according to your company’s needs. Check us out!

Endress + Hauser

http://www.endress.com/en/events/training

2015 - 2 Issue P. 60

Plant Life Cycle Management Sees Increased Value When a Project Starts with the End in MindPlanning for end goals boosts success rate. Focused strategies improve product selection and simplify industrial commissioning and setup.

Making automation deci-sions for new construc-tion, upgrades or even small retrofit projects takes careful planning and a short / long term strategy that combines what is effective for the operation of the plant today and in the future. These decisions impact all phases of the plant’s life cycle or specifically the industrial automation

life cycle which, in many cases has a shorter life cycle horizon than the other more physical infrastructure elements of the plant.

This article is part 1 of a three part series that will identify the benefits FDT Technology delivers in the first few phases of the life cycle including planning/engineering, installation, commissioning and startup. Part 2 will take an in-depth look at the operational and service/maintenance phase, then part 3 will address device replacement and the on-going services phase of the automation life cycle.

Business DriversWith industry trends toward smaller work force, information access and delivering “actionable” information throughout the enterprise (via the Internet of Things), the automation industry needs to consider a cul-ture change toward modular or more flexible project engineering and construction techniques. In our information-oriented business culture, the project themes seem to be driving toward faster, smarter and low-er cost. With a few work process changes and a focus on the use of the information from your intelligent measurement devices, the earlier phases of a plant life cycle can be dramatically improved by the use of FDT Technology in the form of enabled systems and devices that sup-port the integration of device and process information.

Today’s business drivers include; reduced downtime, improved plant reliability, lower operation costs and regulatory compliance in areas such as safety and environmental. Remaining in compliance requires the selection and use of a technology that is host or control system independent, protocol independent and device supplier independent. FDT-enabled solutions meet all of these requirements delivering value in all phases of the plant life cycle in both new (greenfield) and existing (brownfield) applications.

FDT White Paper:

User Guide Eases Device Management and Maintenance Practices

When a device is suspected of having a problem, don’t grab the work order and go out into the plant to “see what might be wrong.” There is a more produc-tive approach! This “user guide” outlines an alternative proactive maintenance method, using the smarts in your current installed intelligent devices with FDT® Technology doing the trouble-shooting work for you! Focusing on brownfield applications using legacy 4-20mA systems, you can jump start your monitoring and maintenance strategies for your installed assets starting with just a single device (or point to point) connection. This paper will edu-cate maintenance team members to encourage them to use a PC and a FDT enabled stand-alone software application (free), to configure and diagnose a single device to enable lower operating costs and increased plant reliabili-ty with no risk.

http://www.fdtgroup.org/sites/default/files/pages/FDT_WP_Asset_Management_Management_July_2014_Final_Final.pdfhttp://www.automationworld.com/oil-and-gas/asset-management-work-procedures-value-shellhttp://www.fdtgroup.org/sites/default/files/pages/na/USER_GUIDE_EASES_DEVICE_MANAGEMENT_AND_MAINTENANCE_PRACTICES_vFinal.pdf

2015 - 2 Issue P. 70

Plant Life Cycle Management Sees Increased Value When a Project Starts with the End in Mind continued

Begin With the End in MindAlthough Stephen Covey referred to this idea as one of his 7 Habits of Highly Effective People, it applies to many programs and projects we do in the automation industry. When it comes to a plant upgrade, new construction or a simple device replacement, it helps to begin the project with a clear definition of what is expected at the end of the project. When automation decisions are made, considering how the plant will be run, maintained and optimized might provide some guiding practices.

There are many questions to be asked as a project scope is outlined and end is kept in mind. For example, how do we best use intelligent measurement and control devices? With an estimated 80 – 90% of all measurement and control devices shipping today with intelligence, us-ers should start using the full capability of these devices and make effective use of and integrate all the available information that will pos-itively affect your end result. Once we obtain the information from our devices, how will it be used by the different departments or groups in the plant? Who within those groups will use it? The answers to these questions and many more will have a direct impact on many phases of the Plant Life Cycle. FDT Technology is the enabling solution that facil-itates device information integration and helps simplify device/system assimilation at all phases of the plant life cycle. Let’s take a stroll down the life cycle road to see how.

Planning and EngineeringDuring the important planning and engineering phase of a project, keep-ing the end “goal” in mind will help mold a lasting competitive strategy. If the plant is going to be expected to remain competitive for the foresee-able future, decisions on purchase and use of intelligent measurement devices, field protocols, enabled I/O and host systems that can easily integrate the information for the devices need to be made. Including FDT in the requirements documents and specifications is a good way to ensure the right technology is selected.

Here are a few ways FDT Technology provides benefits in the planning/engineering phase of the life cycle:

• Intelligent devices are flexible and forgiving as project specifications and measurement ranges change since many devices can be adjust-ed to accommodate the changes without replacing the device.

• As the engineering is done, topology overview, network configuration, device tags, measurement parameters and other information can be captured and saved to be used for off-line device configuration and access throughout the enterprise.

• When additional measurements are required, it might be possible to use a secondary or tertiary variable from an existing device for that measurement – eliminating the need for multiple devices. This requires an intelligent or multi-variable device connected by a com-munication protocol such as FOUNDATION fieldbus, HART, Profibus or others to access the additional variables.

Technology Tip:

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2015 - 2 Issue P. 80

• When an FDT-enabled host system (referred to as a Frame Application in the FDT Specification) is specified and selected (i.e. DCS, PLC, SCADA, safety, asset management, configuration or other applications), it ne-cessitates the selection of field communication protocol and protocol-enabled I/O or some other means of accessing the device information such as smart multiplexers, wireless or remote I/Os.

InstallationThe installation phase of the plant life cycle also benefits from having intelligent devices that are DTM enabled, a communication protocol, an FDT enabled host system or universal stand-alone configuration application. With the planning and engineering done, devices are being delivered to the project site and ready to be installed.

Here’s how FDT Technology contributes to the installa-tion phase of the cycle:

• Devices can be ordered with their TAG numbers to make identification of the right device for the right installation.

• As devices are installed, they can be easily checked to make sure the correct measurement ranges are avail-able in the device, multi-variables (if required) are included and the revision level of the device confirmed. This is done with a tablet + app or a notebook running an FDT-enabled device configuration application.

• Devices can also confirm their use in specific applications such as Safety, Ex proof, IS rated, etc.• Confirm the device includes the specified configuration and if the options selected are working properly.

Options such as default/failure mode direction (full scale for example), compensations, digital display, wetted parts material, remote seals, math or multifunction capability, etc.

Commissioning /ConfigurationOnce devices are installed, it’s time for the next phase – device commissioning and configuration. This is where the benefits of beginning with the end in mind (sorry, had to say it again) can provide significant benefits.

FDT-enabled applications deliver BIG value during the commissioning/configuration phase in many ways including:• Device FAT (Factory Acceptance Test) and loop checks are done quickly and efficiently because of re-

mote access to the device. Some of the traditional steps in the FAT may be reduced or even eliminated.• Even before the device is installed, the configuration can be created and stored in the host application as

part of the system database. Many applications provide the capability of configuration without the need to have the device connected – known as off-line device configuration. And, with the trend moving from fixed I/O to more intelligent or configurable I/O, additional project savings and benefits can be realized.

• Device configuration can easily be done by a download from the application database to the device – sav-ing time and money because it uses the configuration in the system. Device diagnostics can be quickly checked and in some cases applications simulations can be evaluated.

• Changes to the measurement range or scale can be done without the need to replace the device or to go out in the construction area to access the device. Remote access also saves time and money and eliminates potential safety issues. Depending on the communication protocol (wired and wireless), late additions or changes to the system and auxiliary measurement and control inputs can be implemented without the need for additional wiring or changes to the I/O. Changes can then be documented providing a permanent record.

Plant Life Cycle Management Sees Increased Value When a Project Starts with the End in Mind continued

2015 - 2 Issue P. 90

StartupIf all is done with the (say it with me …) the “end in mind”, startup goes well and the plant is up and running. Well, maybe we should expect a few unexpected events!

Let’s look at how the startup phase of the life cycle can be improved by using FDT Technology.• Last minute changes to device ranges, alarm set points and other parameters can be adjusted from the

safety of the control room, engineering building or the instrument shop. For example, out of measurement range limits or input scales can quickly be addressed.

• Secondary measurements can be used as a debugging tool to help diagnose measurement or device prob-lems.

• Multi-variable device measurements can provide a quick solution when additional values can be helpful. • Other useful data includes diagnostics such as: differential measurement, compensated output, offsets,

linearization, totalization, body temperature, bad electrodes, plugged impulse lines and many more.• If a device replacement is required, since we have gathered this documentation since the beginning of the

project, the switchover can be quick and easy. More details on this phase of the lifecycle will be discussed in part 2 of this series.

The End Influences the BeginningThere are many trends toward modular or more flexible project engineering and construction techniques. With a few work process changes and a commitment to the use of information from your intelligent measurement devices, the first few phases of the plant life cycle can be dramatically improved by specifying and using FDT Technology in the form of enabled host systems and devices that support / implement the technology. When the expected end of a project includes a predictive maintenance strategy, high plant reliability and the need to remain competitive for many years to come, the beginning requires the selection and use of a technology that is system independent, protocol independent and device supplier independent. FDT–enabled solutions meet all of these requirements. Ask your automation providers for their FDT enabled solutions and don’t forget to (you know it’s coming) begin with the end in mind!

Reference: Overcoming Automation Challenges, ARC Advisory Group, January 2015

Plant Life Cycle Management Sees Increased Value When a Project Starts with the End in Mind continued

2015 - 2 Issue P.10

Control and asset management systems are appreciated for their ability to ease configuration, management and diagnostics of intelligent devices in the field. The Field Device Tool (FDT) is the unseen interface that makes it all happen.

By Stephanie Neil, Automation World Senior Editor

Building a new plant can take years and often comes with its share of technology problems related to system configura-tion, network integration and device compatibility. Avoiding technical trouble during design and startup of a new facility is a critical part of the plan. To that end, streamlining the pro-gramming and commissioning of thousands of field devices was on the forefront of Andy Bahniuk’s mind during the ex-pansion of the Shell Canada Scotford refinery and chemicals plant in Fort Saskatchewan, Alberta.

Shell Canada runs the Athabasca Oil Sands Project (AOSP) comprised of two mines excavating ore containing bitumen (a semi-solid form of crude oil) from the tar sands. The surge in oil sands production required an expansion of the process-ing facility. In 2004, Shell Canada began to build out the Scotford Upgrader, the feedstock for the refinery that upgrades bitumen from the Shell Albian Sands and converts it to synthetic crude. The synthetic crude is shipped to refineries, where it is further processed into fuel products like gasoline.

Originally supporting a 155,000 barrel per day (bpd) capacity, in 2010 Shell authorized an additional 100,000 bpd expansion to the Scotford Upgrader facility. That’s when the Shell team got hit with a technology roadblock. The measurement and control devices were supposed to arrive pre-configured, but did not. The challenge: How to safely program and commission more than 1,500 intelligent devices from 26 different vendors in a timely fashion so as to not throw off the engineering schedule.

Working with its distributed control system (DCS) vendor Honeywell, Shell tapped into the company’s Field Device Manager (FDM) software, an asset management system that enables remote configuration and mainte-nance of smart field devices based on HART, Profibus and Fieldbus Foundation protocols.

Using the Honeywell system, the Shell team set up all of the devices in about three months and conducted test-ing for another four to six months, saving the company a lot of time and money, says Bahniuk, a control system specialist and a lead instrumentation technologist at Shell Canada.

The FDM tools simplified the configuration and management tasks for the engineering team. “It is all transpar-ent to the end user,” Bahniuk says. “FDM gathers the HART information and puts it into one place for easier troubleshooting and monitoring.”

It’s true, Honeywell’s FDM asset management system played a huge role in the quick commissioning and start-up of so many different instruments, but it is the technology inside—in the form of the Field Device Tool (FDT) standard—that enables the asset management system to easily configure and maintain intelligent field devices.

FDT creates a common communication method between field devices and control or monitoring systems that are used to configure, operate, maintain and diagnose intelligent field instrumentation in both factory and pro-

Device Interoperability: The Hidden Layer

2015 - 2 Issue P.11

cess automation applications. It is not a communication protocol, but rather an interface that is an IEC standard (IEC 62453) and an ISA standard (ISA 103). In essence, it is the “secret sauce” that regulates data exchange between devices and automation systems. Devices can be configured, serviced and maintained via a stan-dardized interface, independent of manufacturer, device type or communication protocol. And, when device and control system suppliers comply with the FDT standard, achieving seamless interoperability is easy.

“We set out to create a standard that allows device manufacturers and higher-level systems to integrate togeth-er, regardless of the network,” says Glenn Schulz, managing director of the FDT Group AISBL (Association In-ternationale Sans But Lucratif), which developed and maintains the FDT specification. “We focused on process initially, but have now moved into factory automation as well.”

Working undercoverFDT is not a new standard; it has been around for more than 10 years and is supported by more than 7,500 different devices from measurement and control suppliers around the world. But its presence and significance often goes unnoticed by the average end user—and that’s on purpose.

“The customer does not need to know the technology details,” says Manfred Brill, software governance senior manager at Schneider Electric and chairperson of the FDT Group factory automation committee. In some cas-es, such as with Bahniuk, the user is familiar with the vendor’s technology, but FDT is not a familiar term. Nor should it be, Brill says, as it is up to the automation supplier to leverage the FDT standard as an intrinsic part of

its product to deliver a seamless user experience for device commissioning and management.

Florian Grätz, product owner at Kuka Robotics, concurs. “Most of our customers don’t even know they are using FDT,” he says, adding that it is nonetheless an extremely important part of the robot controllers.

“Our customers are using a wide range of fieldbus technolo-gies. In Europe, we find a lot of Profinet and Profibus; and in the U.S., it is mostly DeviceNet and EtherNet/IP,” Grätz says. “We had to find a way to cover all of the fieldbus protocols within our engineering suite.” FDT eased integration for the Kuka engineering team by allowing them to move away from

hardware-based fieldbus integration, in the form of PCI cards, and over to the FDT software specification.

More importantly, Kuka was able to enhance the end user experience. “From the customer point of view, our robot controllers are more reliable because we are using less electronic parts, which decreases the risk of elec-trical breakdown,” Grätz says.

Indeed, end users appreciate the benefits of reliability and easy interoperability. For example, while Shell’s Bahniuk is not familiar with FDT per se, he is well aware of what it can do when embedded in field devices and control systems.

First, FDT is what enables the configuration of device parameters that can be defined even offline. The param-eter set is created or changed and stored, so when the field device is connected during commissioning of the project, the parameter set can be loaded to the device—saving an enormous amount of time.

Device Interoperability: The Hidden Layer continued

2015 - 2 Issue P.12

Second, Shell relies on HART technology to connect field devices monitoring pressure levels and temperature across the pipeline and at the Scotford Upgrader. During the long, cold Canadian winters, the temperature can drop to -45 0C, which could freeze instrumentation in the field. The transmitters, therefore, are mounted in insu-lated enclosures with heaters. The centralized Honeywell asset management system can monitor the status of the heaters and transmitter temperature variables, alerting maintenance if something starts to freeze.

“There are from four to 20 signals coming into the DCS, but we strip off the HART signal to get diagnostics from the device,” Bahniuk says. This preventive maintenance capability has saved the company more than $200,000 per year. “Every fall we would have to send people out to the field to check the thermostats and heat enclosures, but we don’t have to do that anymore because the information from the device tells us if we have an issue.”

How FDT worksFDT technology consists of two main components: the Frame, an embedded component of the control system suite or standalone application; and the Device Type Manager (DTM), a device-specific application that launch-es within the frame.

The DTM is a device driver that gives manufacturers control of the attributes displayed for the device. It in-cludes diagrams and methodologies for configuring FDT-compliant devices. Without FDT, device information access could be restricted by the control system supplier. But with FDT, an end user can pick best-in-class devices and not be constrained by support for that particular product, FDT officials say.

The Frame Application, on the other hand, is a software window that provides the user interface between the DTM and host applications, like asset management tools, PLCs or a DCS. In addition, the Frame Application connects the DTM to the correct communication gateways and protocols. A single FDT Frame Application sup-ports 17 networks and field communication protocols, including HART, Profibus, Foundation Fieldbus, Modbus, DeviceNet, Interbus, AS-Interface, Profinet, IO-Link, CC-Link, ISA-100 wireless, and more.

If there are several networks on the plant floor, no problem, as information will be delivered despite a dispa-rate infrastructure. “The standard is written such that the end user has no awareness that tunneling or routing through different networks is taking place,” FDT’s Schulz says. “To them, it’s as if they are directly connecting to that device and can access all of its intelligent features.”

In the most recent update of the specification, called FDT2, enhancements with security and performance were added, while maintaining backward compatibility to existing DTMs and Frame Applications. Developed on the Microsoft .NET 4.0 framework, FDT2 includes an improved user interface with graphical representations of de-vice parameters, including additional device wizards and diagnostic tools that can be developed by the device supplier. The graphical user interface (GUI) is separate from the business logic, creating a lightweight client that can be automatically updated from the DTM on the server.

A lightweight client may very well be the precursor to an FDT-enabled mobile application, which officials say is currently in the works. “The plan for the mobile app is to enable maintenance people in the field to access other devices and not be bound to an engineering or management system somewhere in the office,” says Schneider Electric’s Brill. “We are also working on an interface between FDT and OPC UA,” he adds, which could be used in a mobile environment, as well as an integration tool to manufacturing execution systems.

Also in FDT2, there are more security safeguards built in, including tamper-proof protection. All applications created in compliance with FDT2 specifications are digitally signed, providing proof of data integrity. And there

Device Interoperability: The Hidden Layer continued

2015 - 2 Issue P.13

is granular DTM security with enhanced user rights added to the security settings.

FDT2 also includes speed and performance improvements, officials say, and a set of common components that provide a supplier with the software needed to start developing FDT2-compliant products. Though all DTMs operate using a similar menu and visualization scheme, not all DTMs are created equal, as some suppliers will develop broader functionality that can help users improve troubleshooting and maintenance.

Though FDT is recognized as a communication catalyst, providing interoperability between disparate devices on different networks, another important—and often overlooked—function is its ability to provide diagnostic infor-mation on devices in the field. “The real benefit from the end user perspective is the diagnostics,” Schulz says.

Digging deep into device diagnosticsAt the MOL Group’s Danube refinery in Százhalombatta, Hungary, FDT has been in use for 10 years specifically for device diagnostics. The FDT rollout in 2005 was initiated to solve a problem related to the refinery’s comput-erized maintenance management system (CMMS), which was not delivering signals, indicating a problem in the field. It was then that the company overhauled its CMMS with a new asset management system that created an online diagnostic system in which control valves and instrument devices send signals directly over HART and Foundation Fieldbus to plant maintenance systems and the three different DCSs in the refinery. “We have completely integrated systems, not for the whole refinery, but for the critical devices in the field which send sig-nals that drive notifications,” says Gábor Bereznai, head of control and electrical engineering at MOL’s Danube refinery. “We use DTM to dig deep into the problems.”

When things are not behaving properly with an instrument or a device, the DTM can indicate that something is not right and provide a list of possible causes.

For example, when the pressure control was slow on one distillation column, it led to the assumption that a valve was stuck and in need of removal and repair. But technicians used device diagnostic data to interrogate the valve and find current-to-pneumatic damage in the intelligent positioner, but not the whole valve. The fix took 30 minutes of work and saved the plant at least two days of unscheduled downtime, which could have been a loss of several hundred thousand dollars.

“The real function of the system is to avoid breakdowns and slowdowns,” Bereznai says.

It is also good for preventive maintenance. Before online device diagnostics, the MOL team would automatically repair or replace about 60 percent of the control valves during a scheduled maintenance shutdown, but some valves were likely removed unnecessarily. Having a better handle on valve performance means pulling fewer valves at turnaround time, reducing maintenance costs. “Ten years ago, we pulled all of the valves,” Bereznai says. “Now, we pull two dozen instead of 200, saving $20,000 to $70,000 per turnaround.”

A substantial savings—all from a deep-seated, and slightly misunderstood, standard called FDT.

Device Interoperability: The Hidden Layer continued

2015 - 2 Issue P.14

FDT-compatible tools simplify integration and network scanning.

Endress+Hauser’s stand-alone engineering software interface, Field-Care (FDT Frame Application), has been updated to Version 2.10. The new version includes a scan interface of FDT 1.2.1 with an en-hancement for configuring Endress+Hauser’s new released Modbus and EtherNet/IP field devices. The scan is further enhanced with “One Touch Network” functionality, which allows a complete network scan with one click. Scanning speed for networks is significantly improved using the PROFIBUS fieldgate SFG500 and its new “Triple-S” (SFG Speed Scan) functionality.

The design of FieldCare was also updated to support smaller form factor devices like tablets. Buttons are larger, icons were updated and all windows are resizable. Additionally, all Comm and Device DTMs now support Windows 8.1 and WinServer 2008 R2. Russian is now supported as new language.

FieldCare supports HART 7 schemas and allows the usage of ling tags, etc. FieldCare includes a Generic HART DTM which enables the configuration of devices without DTMs, such as DD or EDD files. Even more convenient is the inclusion of the iDTM for HART and FF, which enables configuration of devices that don’t provide a native DTM. It’s now possible to configure EDD files with enhancements.

A central focus of the release was to enhance end user, usability. With new and updated options, the user can automate and speed up recurring procedures. Uploading DTM information using PDF or XML format to Endress+Hauser database W@M is faster and the process more simplified. Larger projects can be created based on the im-proved stability. FieldCare can support plants with up to 20.000 tags.

Endress+Hauser partners Rockwell Automation and Schneider Electric provided some of their DTMs on a FieldCare DVD. Users can access

Rockwell’s FlexIO family DTMs and Schneiders CommDTMs for Modbus and EtherNet/IP. Also included are the Softing CommDTMs for Siemens Simatic ET200X Remote IOs, e.g. ET200M, ET200iSP and Siemens DP/PA Link.

FieldCare can be extended for Device Configuration Management with the databases W@M portal and W@M enterprise. Asset health of devices, e.g. NE107 status with cause and remedy, is provided when the optional Condition Monitoring module is used.

The FieldCare software package integrates all Endress+Hauser DeviceDTMs for the HART, PROFIBUS, FF, MODBUS and EtherNet/IP protocols allowing the configuration of Endress+Hauser and 3rd party field devices. Additionally, access to Endress+Hauser field devices is possible using specific protocols like CDI.

A free trial version is available starting in June at https://portal.endress.com/webdownload/FieldCareDownload Gui/.

FieldCare 2.10 Provides Universal Device Configuration

https://portal.endress.com/webdownload/FieldCareDownloadGui/https://portal.endress.com/webdownload/FieldCareDownloadGui/

2015 - 2 Issue P.15

FDT Technology simplifies network configurations, improves efficiency for Colorado treatment plant.

By Grant Gerke, Automation World Contributing Writer

The U.S. continues to see significant infrastructure invest-ments, and the water and wastewater industry is no different. Automation expenditures in this industry will increase by a compound annual growth rate (CAGR) of almost 8 percent over the next five years, according to a 2013 report released by ARC Advisory Group.

The Littleton/Englewood Wastewater Treatment Plant (L/E WWTP), the third largest publicly owned treatment works (POTW) in the state of Colorado, operates a state-of-the-art process automation system. However, constant intermittent net-work problems with its supervisory control and data acquisition (SCADA) created workforce inefficiencies and safety issues.

The wastewater plant serves the cities of Englewood and Littleton, Colo., plus 17 other connector districts, processing 23 million gallons of wastewater each day. The plant’s SCADA technician, Joe Morrissette, is re-sponsible for the management of the entire process control system, including all associated instruments and process networks.

Intermittent network gateway failuresL/E WWTP counts on about 35 network gateway access points to monitor and troubleshoot all the instruments and processes within its industrial networks. “All of our process instruments communicate via Profibus so that we can have remote access to the instruments,” Morrissette says. “We use Profibus-enabled instruments in several critical areas, including our influent channels.”

These industrial network gateways collect and aggregate a wide variety of in-depth, real-time data, but growing communication issues with existing network management put some process control at risk. “The gateway unit was routinely inaccessible,” Morrissette says. “Sometimes, it would take four or five attempts before I could connect at all.” Even when he was able to connect to the network, Morrissette sometimes experienced a dropped connection.

Flow meter communication is vital. “We have a small wet well to hold influent flow in the event that our raw sew-age pumping system failed, so it is absolutely critical that we can depend on the instruments that measure level and flow in these channels,” Morrissette says. “In the event that a flow meter fails, we have immediate remote access through the gateways that allow us to do an in-depth evaluation of the instrument without going into the field and make a quick decision on a solution. These flow meters also determine the revenue that is generated by our influent flow, another critical element.”

Ultimately, these problems caused inconvenient interruptions to a variety of critical tasks and posed a real risk to plant operations.

Side-by-side testWith an eye to finding something to replace the units that were currently putting the plant at risk, Morrissette began researching competitive products and settled on TH Link gateways from Trebing + Himstedt. During this

Updated Wastewater SCADA System Cuts Failures, Adds Security

2015 - 2 Issue P.16

research phase, the supplier of the existing gateway units announced that it was discontinuing the model that had been in use, and invited Morrissette to test drive the new version. He agreed, and the single-product pilot became a side-by-side road test.

“The installed base of process instruments at our plant is 99 percent Endress+Hauser,” Morrissette says. “Endress + Hauser has such a large product line that offers Profibus as a communication option, and thus works very well with FieldCare, because of the certified DTMs.  The Trebing + Himstedt’s TH Link gateway was chosen to stream-line the communications from the Profibus network back to the Endress+Hauser’s Fieldcare software interface.”

Fieldcare is device configuration and asset management software that is based on the field device tool (FDT) standard and delivers robust configuration and diagnostics application at the device level through smart device type managers (DTMs).

“It’s all about the DTMs. We provide a certified CommDTM for our gateway hardware—TH Link Gateways—and device vendors offer Device DTM for their field devices and they operate together in an FDT Frame Applica-tion, which is Fieldcare from Endress+Hauser in this case,” says Bernd Kremer, general manager at Trebing + Himstedt. “So our TH Link plus the reliable CommDTM software is a sort of enabler for a very efficient device management and device diagnosis down in the field from the maintenance room.”

“One example of how important a certified DTM is can be seen with our chemical metering pumps for our disinfection system,” Morrissette adds. “The manufacturer of the pump does offer a Profibus option, but their DTM—not FDT-certified—is horrible and has no functionality through a gateway, so without the benefits of re-mote accessibility, we do not use their Profibus version in critical areas.”

With the ultimate goal of remote monitoring for critical applications, the wastewater plant was encouraged with the pilot project and what Fieldcare software could offer in the control room. Fieldcare’s robust functionality serves a wide range of process applications, such as the ability to choose from a list of standard fluids or import custom data from an Excel spreadsheet to calculate the required coefficients. From the control room, then, the correct coefficients can be downloaded directly into the flow meter.

Quick integrationThe TH Link gateway impressed both Morrissette and his network integra-tor with its simple and efficient implementation. “We really liked the self-di-agnostic features of the setup,” Morrissette says. “Usually, if one of your setup parameters is wrong, the system just says, ‘Failed to go online with bus.’

This new gateway highlights the exact parameter that needs to be adjust-ed and how. For instance, it might tell you, ‘You need to adjust your target rotation time to be between x and y.’

This level of detail makes the setup process go much more quickly and efficiently, even if the technician doing the setup is less advanced.”

Morrissette also appreciated the compact design of the TH Link unit. “The space limitations of our control cabinets can become a problem with larger units, but the streamlined design and smaller physical footprint of the TH Link model made that a non-issue,” he says.

Updated Wastewater SCADA System Cuts Failures, Adds Security continued

2015 - 2 Issue P.17

Safety ramificationsThe L/E WWTP systems that Morrissette manages are process-critical systems that require close monitoring and quick resolutions if anything goes wrong. “The consequences of an issue going undetected or undiag-nosed are not just financial, but have serious safety and environmental repercussions as well,” he says. “In the same way that you don’t want to wonder if the fire truck is going to start when the alarm goes off, I don’t want to have to wonder if my gateway is going to connect when I need to check an issue.”

In one example during the pilot project, Morrissette was able to address and resolve a network issue while away on vacation. The mobile accessibility provided by TH Link made it possible for him to remotely access the Profibus network through the gateway and go online to the instrument having problems, all from his hotel room.

L/E WWTP has been using TH Link for a year, and has continued to receive consistent, reliable performance. “I wasn’t expecting either product to outperform the other, but I’m glad I opted to test them both,” Morrissette says. “The test made it clear which product was the best fit for my needs, and now we have a system that is more secure, more responsive, and easier to manage.”

Updated Wastewater SCADA System Cuts Failures, Adds Security continued

Product News

Just-In-Time DTM DevelopmentUtthunga framework for FDT 2.0, 1.2.x offers versatility.

Utthunga DTM development framework is a compre-hensive set of reusable components that enables you to build DTMs up to 60% lesser cost & up to 48% faster development time. Key features of this development framework include:

• Supports FDT 2.0, 1.2.x standards• Build C++,Net DTMs• Supports DD source code input• Easy migration to build PC / Mobile apps• Complies to FDT style guide• Supports development of device DTMs, Communi-

cation DTM and Gateway DTMs. • Protocol support includes Modbus, HART, Profibus,

Ethernet/IP, Profinet, ISA 100 Wireless, Foundation Fieldbus• DTMs developed using Utthunga DTM development framework have been tested with all major FDT Frames

& HOST systems for standards compliance & interoperability• Major process instrument manufacturers have leveraged Utthunga DTM development framework to develop

over 50 DTMs.

The framework is implemented using a DRY (Do Not Repeat Yourself) concept. It is architecturally designed in a modular format for application flexibility. The various components include UI, protocols, generic controls, standards libraries, custom controls, and FDT DTM interfaces for FDT 1.2/ 1.2.1 and 2.0 (powered by FDT 2.0 common components).

The DTMs developed using this framework can be extended to build PC applications or a mobile app (iOS, Android, Windows). It also provides easy maintenance and scalability with respect to FDT standards, device firmware versions, and protocol additions.

Utthunga’s DTM development framework capabilities continue to grow with upgrades that will include support for FDI DTMs.

For further information please contact us at contact@utthunga.com

2015 - 2 Issue P.18

mailto:contact@utthunga.comhttp://www.utthunga.com

Product News

New DTM Broadens OS, Network SupportDTM Library adds WinServer, Windows 8.1 and more.

Softing Industrial Automation GmbH is releasing a new version of its DTM Library. It will support WinServer 2012 and Window 8.1 operating systems as well as Siemens ET200iSP HART EX modules.

The DTM Library consists of three communication DTMs for Siemens components (CommDTM DP/PA LINK, CommDTM ET200M, CommDTM ET 200iSP) and a communication DTM for the TH LINK PROFIBUS gateway (CommDTM PROFIBUS DP-V1). It is part of Softing’s product portfolio for plant asset management solutions, which includes gateways and the PACTware Frame Application. The Softing product portfolio enables users in the process industry to access and operate a broad range of field devices reliably and efficiently. It seamlessly integrates with third party applications such as Endress+Hauser - FieldCare or Yokogawa - FieldMate. In addition, it offers features and functions for PROFIBUS diagnostics. Planned release date for the new DTM Library version is June 2015.

For more information, please visit URL: http://industrial.softing.com/en/products/plant-asset-management.html?wmc=FDT_%20201505_NL

2015 - 2 Issue P.19

http://industrial.softing.com/en/products/plant-asset-management.html?wmc=FDT_%20201505_NLhttp://industrial.softing.com/en/startpage.html

Product News

Lab Accredited to Test FDT2 DTMsWell-established FDT test site passes scheduled audit and gains approval to test in conformance to the FDT2 standard.

Schneider Electric’s FDT testing site has been re-accredited and has expanded its capabilities to provide FDT2 DTMs testing. The lab has a long track record for certifying FDT enabled solutions, it began certifying FDT 1.2 six years ago.

The lab, which tests all Schneider Electric DTMs before they are released to the market, opened in 2008 in Seligenstadt/Germany. It was moved to the Machine Solution Headquarters in Mark-theidenfeld/Germany in 2013.

In accordance to the rules of the FDT Group, test centers are required to be re-certified every three years. The Schneider Electric test center successfully passed its audit and is now one of the first test sites performing FDT2 conformance testing.

For more information, visit: www.schneider-electric.com

2015 - 2 Issue P.20

http://www.schneider-electric.com/site/home/index.cfm/ww/http://www.schneider-electric.com/us/en/

Product News

AADvance Expands Process Safety Control System FunctionsRockwell Automation system lets users select safety, fault tolerance levels.

AADvance is the next step in Safety Instrumented Systems (SIS), offering a truly distributed, scalable architecture. A hardware controller and a software environment allows us-ers to specify the level of safety integrity and availability you need throughout your plant. AADvance from Rockwell Automation offers a high level of flexibility, going from small quantity I/O to large systems; non-safety to SIL 3, and fail-safe to multiple fault tolerant including TMR.

The AADvance controller supports the use of HART on each analog input and output channel. The application can use HART data to monitor and respond to device conditions and to supply diagnostic information such as data comparison and error reporting. This is a useful increase in the level of safety system diagnostics.

Asset Management FeaturesThe intelligence of the HART devices can be shared using FDT Technology. The HART feature allows the use of an external asset management system to manage HART compatible field devices connected to an AADvance controller. HART uses the Device Type Manager (DTM) software component, defined by the FDT Technology standard, to enable using an asset management system using an FDT Frame Application, such as FactoryTalk Asset Centre by Rockwell Automation.

For more information, visit: http://www.rockwellautomation.com/rockwellautomation/icstriplex/aadvance.page

2015 - 2 Issue P.21

Product News

http://www.rockwellautomation.com/rockwellautomation/icstriplex/aadvance.page

Product News

M&M Software’s diSTORE Online Store Simplifies Storage & Management of DTMsExtended tools ease setup and updating.

M&M Software GmbH’s cloud-based software product, diSTORE, enables plant operators and device producers to administrate their FDT® 1.2 and FDT2™ DTMs from a central repository. Moreover, device manufacturers can place their DTMs in customized, company-specific areas at the clients’ disposal.

The service, unveiled at the Hanover Fair 2015, will be a standard component of the fdtCON-TAINER application. It also supports functions such as installing and updating DTMs as well as searching and finding all necessary DTM setups. At the same time, interfaces for the integration of this cloud-service in foreign applications will be available. In the future, diSTORE may support device description files and FDI packages in addition to DTMs, thereby covering everything that is needed for device integration. Anything stored using the diSTORE portal can be segmented in private or public repositories. M&M Software uses Microsoft Azure™ for this solution in order to ensure a high level of safety, stability, reachability and per-formance.

For more information, visit: http://mm-software.com/en/news/distore-first-online-store-dtms

2015 - 2 Issue P.22

http://mm-software.com/en/news/distore-first-online-store-dtms.http://mm-software.com/

Product News

HART Communication DTM for FDT2Release of popular HART Communication DTM supporting FDT2 planned for spring, 2015.

Since the release of FDT, the CodeWrights HART Communica-tion DTM has been one of the most-used DTMs in the market. Soon the new version of this DTM for FDT2 will be made avail-able. It is based on the proven HART driver, which works with most of the HART Modems (serial or USB) on the market. The User Interface was replaced by a new design, and the appli-cation has been optimized for today’s users. HART_BASIC, HART_FSK are supported by this DTM, making it backward compatible with existing FDT1.2.x DTMs. The configuration al-lows Point-to-Point connections as well as multi-drop modes with an extended address range. For developers of HART DTMs, the Communication-Log function has been improved.

As with the current version, the Basic Version will be released as freeware. A fee-based version will be made available for certification tests with dtmINSPECTOR and for production use. The release is planned for end of second quarter 2015.

For more information visit: http://www.codewrights.de

2015 - 2 Issue P.23

http://www.codewrights.de

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>> Sept 15 FDT Developer Forum USA Foxboro, MA >> Sept 29-30 FDT User/Developer Seminar Kyurian, Ooimachi, Tokyo

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