commissioning simplified - fieldbus...opc server hart hart device library hart multiplexer connect...

Commissioning SimplifiedARASU THANGAI – PEPPERL+FUCHS

Fieldbus Infrastructure

Commissioning Benefits

• Commissioning - Device integration• Commissioning - Physical layer


• Commissioning - Device integration

Device Integration

Continuous Productivity Improvements• Integrated system environment• Freedom of choice• Information availability• Fieldbus solutions to meet all plant requirements

Plug and produceDevice Integration

FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand

Easier - Real Number Engineering Unit

No range mismatchUnit downloaded when device is replaced

Transmitter PositionerFF FF

BUSFF

CTRL

CPU

CPU

CPUDigital

Digital

DigitalDigital

TransmitterRange0-800 kPa

SystemRange0-400 kPa

8 mAProcess200 kPa

Reading100 kPa...alarms and tripsnot working

AIA/D

D/A 4-20 mA

AOD/A

A/D4-20 mA

RangeRange

Range mismatch

Range exceed (more than100%)


Lower Cost & Faster

Traditional: 2 hours / device for 2 technicians

(Calibration)Attach deviceVerify 4-20 mA signal

» five pointsVerify link to control strategyCheck device parameters with handheld

Foundation fieldbus: 25 minutes / device for 1 technician (Remote)

Attach deviceDrag-and-drop commissioning wizardCompare configuration faster on computer

•Devices are auto-recognized•Devices are auto-addressed•Devices identify themselves

Plug-n-Play

Only FF has automatic addressing


Fieldbus Maintenance Made Easy:Device Commissioning Wizard


Fieldbus Maintenance Made Easy:Protective Decommission

Removing device in an orderly fashion

“Safely remove hardware”Temporary removal

To remove for calibration etc. with intention to put back into same place soon after

Permanent removalTo remove for replacement etc.

Control-in-the-field does not mean just “simple” PID


Easier FF Device Commissioning and ReplacementCommission or replace device without

touching the softwareSystem automatically logs process in

background

Automatic configuration reconciliation with device database

Automatic configuration download

View details in historian and log


Faster Project StartupExpress and Batch DownloadReduced commissioning time

•Initiate multiple downloads at the same time•Runs unattended•At pre-commissioning need not run as a background communication to real-time control

Intelligent Devices via Fieldbus is a MustProcess Industries worldwide require

fieldbus based systems because of cost reduction

Reduction of wiring and cabinet costsLess system and instrumentation hardwareReduced commissioning time

Intelligent devices enable Asset Optimization

Increase of maintenance effectivenessImproves process availabilityEnhances productivity

Aventis says: Fieldbus technology saves costs and enables innovative applications. Future plant will be equipped with fieldbus

Incorporating intelligent devices via fieldbus integration streamlines work processes, improves process and product quality, maximizes plant availabilityintegrates fieldbus seamlessly

Exploiting new levels of field device informationMaking device resident information available to the right people at the right time

Device Management lowers costs over life cycle in design, implementation, operation and maintenance

Device Management

Expectations on Fieldbus Technology• Industry proven and

reliable• High system availability

through redundancy concepts

• Intrinsically safe solutions• Seamlessly integrated

into control system • Access to device internal

data• Openness for all device

manufacturers• Easy to use

Optimization Engineering Operations

ControllerDiagnosisMaintenanceCalibration

ConfigurationParameterizationCommissioning

OperationDisplayAlarm signals

Process variablesTime synchronizationStatus

07

Field Devices

Fieldbus and Field Device Configuration• Integrated fieldbus

management tools and comprehensive Device Libraries for– Configuration of function

block applications– Device parameterization

with graphical user interfaces

– Online and offline configuration

• All devices accessible from a central workplace

• Early plausibility checks ensure proper and fast configuration

Fieldbus and Change History

Maintenance Event & Work Order History

Calibration Changes

Operator Changes

Configuration Changes

Process Event & Alarm History

Audit List

Intelligent Devices Enable Asset OptimizationOK!Oops!BAD!

• Scheduled monitoring of asset health status• Smart condition reporting• Notification of key personnel independent of their location• Generation of fault reports and submission to CMMS

Device Management

Device Management HART Fieldbus Builder PROFIBUS/HARTBasic HART DTM / HART DTM BuilderOPC Server HARTHART Device LibraryHART Multiplexer Connect

Device Management FOUNDATION Fieldbus

Fieldbus Builder FOUNDATION FieldbusOPC Server FOUNDATION Fieldbus FOUNDATION Fieldbus Device Library

Object Types

800xA

System


• Commissioning - Physical layer

Physical Layer Commissioning Guidelines

• IEC 61158-2 – Physical Layer standard

• AG 181 (Rev-3.2.1) – System Engineering Guidelines


User Benefit : Design guidelines

The physical layer – alive and well?

Proper terminationWater ingressGround faultsLoose wiring Faulty devices

The physical layer – alive and well?Proper terminationWater ingressGround faultsLoose wiring Faulty devicesUnstable communicationShort circuitsBulk power failure…

Typical locations and Fieldbus issues


Advanced Commissioning for physical layerIntegrated single tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need


Advanced Commissioning for physical layerA portable tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need


Commissioning Tools expectations

User interface in the control room:

Display of values Warnings with actionable informationColor coding for easy recognition

Value-add:Automated commissioning procedures and documentationLive segment monitoring with alarmsExpert troubleshooting tools

Embedded expert-knowledge


Commissioning Tools Expectaions

Design Verification tools: design of the physical layer

Verify against original design Automated checkout procedures

Longer plant uptime Know before you act Actionable information in clear text

TroubleshootMonitorCommission

Cas

h Fl

ow

Plan and purchase

Install and commission Operate and maintain


Commissioning in the pastAlways on the critical pathManual, step-by-step procedureLabor intensiveRequires

» Screw driver» Check sheet» Pencil» Multimeter» Oscilloscope

Connect one device at a timeDisconnect after testing

Test Report


Commissioning nowVerify address settingWire up devices in the right locationCheck shieldingActivate communicationUse automated work procedures

» Testing » Documentation

All devices at onceWiring remains undisturbed

Commissioning Wizard

Test Report

Cable

Type A Type B

Cable structure Twisted wire pair, shielded

One or more twisted wire pairs, complete shielding

Conductor cross-section (nominal) 0,8 mm² (AWG 18) 0,32 mm² (AWG 22)

Loop resistor (direct current) 44 Ω/km 112 Ω/km

Wave resistance at 31.25kHz (direct current) 100 Ω ± 20% 100 Ω ± 30%

Wave attenuation at 39kHz 3 dB/km 5dB/km

Capacitive asymmetry 2 nF/km 2nF/km

Group runtime distortion (7.9 … 39 kHZ) 1.7 µs 1.7us

Covering level of the shield 90 % 10%

Max. extent of the network for non IS applications 1900 m 1200 m

Max. extent of the network for IS applications (e.gusing FISCO power supplies)

Suitability check for existing cable

Failure margin checkCommunications check

Device coupler short-circuit check

Surge Protector health check

Water Ingress

38

Water Ingress in Junction Box

39

Water Ingress in Junction Box

40

Water Ingress information at DCS level


Commissioning based on StandardsSimple to useEliminates manual test procedures Ensures compliance with AG181 and IEC 61158-2Creates baseline report:

» Snapshot of all measurements » Complete documentation

Recommends warning and alarm limits for the ADMStores limits in non-volatile memoryReduces pre-commissioning time by up to estimted 80%

Commissioning saves time and money

A few mouse clicks conduct automatic testing Reports on the actual installation with all devices connectedAutomatic setting of warning and alarm limits


Online monitoring

Advanced Commissioning tools increases the number of detectable faults

Monitors continuous operation Notifies when deviations occur Enables proactive plant up keep Keeps the plant up and running

The Advanced Commissioning Tools helps to:Monitor the health condition of the physical layer Detect changing conditionsReport limit violations with time stampsAlert operators before the segment fails


Online monitoring – Continuous health check – Inline with NAMUR

Commissioning Tools increase the number of detectable faults

Displays measurement values Issues warnings and alarmsHighlights violations with color coding:

Good value

Maintenance requiredOut of specification

Fault Finding is Easier

•Commissioning Tools delivers actionable information to minimize the time spent for fault finding

1 Active messages2 Actionable information with solution guideance based on

expert knowledge3 History with timestamps

When the failure…… occured… disappeared

Export function for external analysis and storage

Bad cable impedance

Loose wire

Troubleshooting is easier

•Advanced Diagnostics Tools provide expert tools for fast fault finding

Simplifies testingCaptures intermittent problemsPinpoints the issue Guides to potential solutionsIs accessible from remote for

consultation with fieldbus experts.

Simplified commissiong leads CAPEX and OPEX savings

Rapid commissioning: Accelarates loop checkLonger operation: Warns before failureFaster troubleshooting: Assists with actionable information

Conclusion- DeviceFoundation Fieldbus Simplifies device commissioning and saves time. Device integaration into the control system environment made fool proof.

Fieldbus devices transmit measurements are unaltered.

For most Fieldbus transmitters there is no need to set a range. Avoids Rang mismatch, the reading for controls and alarms in the system will be correct. Therefore, traditional five point loop test can be replaced by a simple plausibility check thus speeding up project completion

Fieldbus devices have no error due to analog signal calibration (4-20 mA) differences between transmitter output and DCS input, saving time on re-calibration

Conclusion- DeviceFoundation Fieldbus address assignment is automatic and error free. Some systems have wizards to guide the technician, even commission the devices without using software, thus demystifying Fieldbus commissioning

The configuration for all Fieldbus devices is maintained in a database and can be downloaded remotely in a single click saving time as compared to checking devices one by one, parameter by parameter, with a handheld field communicator and maintaining documentation separately.

Conclusion – Physical Layer

Advanced Diagnostics tools for for physical layer reduced physical layer commissiong time and provided online monitoring and reporting system that saves CAPEX and OPEXMost problems at early bus installations were due to poor installation. However, simple, user-friendly, Fieldbus testers are now available, allowing the installation crew to easily check the wiring, and the device commissioning crew to check network operation, spotting any problems earlyMany contractors and Technicians are trained and are skilled in Fieldbus installation and commissioning, and have the test equipment and in-house procedures to ensure reliable operation

QUESTIONS?

commissioning simplified - fieldbus...opc server hart hart device library hart multiplexer connect...

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