enhancing usability through physical layer diagnostics · 2014-12-17 · foundation fieldbus -...

Foundation Fieldbus - Looking Forward….

Enhancing Usability

Through

Physical Layer Diagnostics

Unnikrishnan R

Pepperl+Fuchs (India) Pvt. Ltd.

2 © 2014 by Fieldbus Foundation

FF Usability

What is Usability??

Usability is all about how easy, effective and pleasant the

features are for the end customer to use

Simplicity, logical, orderly processes that are well defined and

organized steps to use the digital network

The objective is to make FF easier than conventional

instrumentations.


FF Usability - Simplicity

Iphone

Simple

Apps usability and vendor participation

Adaptable

Constant improvements

Blackberry

The iPhone did not introduce

anything particularly new or

exciting to the mobile industry

upon its release.


FF Usability

Interoperability

Automated Device replacement

Backwards compatibility

PV Interchangeability

Device Templates

Managing Diagnostics


FF Usability – New ITK 6.2+ profile

New ITK 6 profile improves device commissioning

Improves Maintenance activities

Improves self monitoring and diagnostics of field devices ( diagnostics

alerts)

Device replacement

Supports new EDDL features ( integrating data from multiple blocks,

multiple views, mode control etc)


FF Usability – Physical Layer Diagnostics

End users require actionable diagnostics information from physical layer

Expert systems advices

Components level diagnostics

Relevant tools to help the plant during installation / operation / maintenance

Integrating the physical layer diagnostics into the AMS.


Device

Coupler

(Zone1 – Exd)F

ield

De

vic

es

Fie

ld D

evic

es

Fie

ld D

evic

es

TerminatorSurge

Protec.

Surge

Protect.

Fie

ld D

evic

es Fieldbus

Process

Interfaces

Fieldbus Physical layer

Power

Supplies

– Types and Causes of faults

– Components with a view on availability

– Assessment of risk of failure

Device

Coupler

(Zone2 – ExiC)

Device

Coupler

(Zone1 – Exia)


Corrosion

8


Hazardous safety rules not followed

Ground faults

Fieldbus and power cables tied together


Poor cable installation


Poor cable installations

Cable gland not tight

Seal missing


Poor Device Installation


Poor maintenance


Typical locations and Fieldbus issues


Diagnostics Tools

Integrated single tool for commissioning, monitoring, and

troubleshooting. Versions to suit your every need


Diagnostics Tools – Handheld


Advanced Diagnostic Options

A single tool for commissioning, monitoring, and troubleshooting. Versions to

suit your every need

Handheld

Portable

Integrated version


Fieldbus Diagnostic Handheld

Display interface for stand-alone operation

Multi-language support

Intrinsically safe fieldbus interface (Ex ia)

FISCO, Entity, DART

Operation in Zone 1/Div. 1

Focused on practical application

Operating modes for novice and expert users

With expert system advice

Data backup and documentation on PC


Suitability check for existing cable


Failure margin check

Communications check


Device coupler short-circuit check


Oscilloscope

Built into the Hand Held Tool

Many trigger conditions selectable

Operation on the display or via software

Trigger output for external oscilloscope


Intuitive Handling

One-button, quick check

with NAMUR signals (NE 107)

Recording and storage for

32 segments with 32 devices each

Data backup on laptop/PC


Expert system on board

Interprets raw physical layer measurements

Translates into possible causes

Suggests corrective action

NAMUR NE 107 status


Diagnostic Manager Software

User interface in the control room:

Display of values

Warnings with actionable information

Color coding for easy recognition

Value-add:

Automated commissioning procedures

and documentation

Live segment monitoring with alarms

Expert troubleshooting tools

Embedded expert-knowledge


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

Asset Management Integration


Example ADM and DCS integration

Diagnostics at

DCS Station

Rela

y c

on

tac

t

op

tio

na

l)

RS485

Industrial Switch

Ethernet or

FF H1

Address switches



Operator

station

Rela

y c

on

tac

t

op

tio

na

l)

RS485

Ethernet

VnetIP

AMS


Operator

station

Rela

y c

on

tac

t

op

tio

na

l)

RS485

Ethernet


VnetIP

AMS


Cabinet Control via Diagnostic Gateway

Inputs for monitoring the control cabinet

– Namur sensors / Frequency input (6x)

– Analog input for temperature (2x)

– Humidity sensor on board

Power outputs (240 V, 2x)

On/Off controller

Configurable via Foundation Fieldbus H1

Fan is not working

Door not closed

Water ingress


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


Diagnostic Segment Protector

Improved and innovative spur fault protection:

Progressive spur short-circuit protection

Jabber protection – cuts off devices talking too much

Maintenance work causing contact bounce or short-circuits

Reliable containment of gradual overload conditions

Protects operations from manual intervention and device failure

Loose wire strands

Bad installations causing multiple devices to talk at the same time

Water ingress with ground faults or corrosion


Water Ingress


Water Ingress Sensor

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


Simple Commissioning Steps with ADM

Verify address setting

Wire up devices in the right location

Check shielding

Activate communication

Use automated work procedures

– Testing

– Documentation

All devices at once

Wiring remains undisturbedCommissioning Wizard

Test

Report

x


Commissioning Wizard

With Expert System Support

Takes snapshot

Identifies wiring errors

Ensures compliance with

AG181 and IEC 61158-2

Recommends limits for ADM messages

Stores limits in non-volatile memory

Automatic Tag Readout

Creates baseline report:

Snapshot of all measurements

Complete documentation

Saves significant (almost 80%) of pre-commissioning time


Online monitoring as per NAMUR

ADM increases the number of detectable faults

Displays measurement values

Issues warnings and alarms

Highlights violations with color coding:

Good value

Maintenance required

Out of specification

The segment is still operating with good performance


Diagnostic Menu

ADM delivers actionable information

for fast fault finding

1 Active messages

2 Actionable information with

solution guideance based on expert

knowledge

3 History with timestamps

When the failure…

… occured

… disappeared

Export function for external

analysis and storage

1

22

3


Spurs

Field Instruments

Basic Principles: Typical Topology

Segment Protectors

Trunk

Surge Protector

Terminator

Plant Asset

Management

Diagnostic Gateway


Poor Wiring


Practical Example of Frequency disturbance

In this example the frequency of noise was approx. 150Hz

7 ms


Not a good device location

FF Device Moved away from Drive


Surge Protection


Diagnostic in 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

At Junction box Trunk

input

At junction box Spur

output

At Power supply output at

Control room


Diagnostic Surge Protection On Device Coupler


Diagnostic Surge Protection On IS Device Coupler


Surge Protection at PowerHub


Integrated Diagnostic


Summary

Advanced Diagnostics tools and components for physical layer have reduced

physical layer commissiong time and provide online monitoring and reporting

system that brings savings at CAPEX and OPEX

Most 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 early

Many 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

USABILITY of Foundation Fieldbus physical is greatly improved


Thank [email protected]

08.12.2014Unnikrishnan 58

enhancing usability through physical layer diagnostics · 2014-12-17 · foundation fieldbus -...

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