the fieldbus monster - jaomad fieldbus monster... · remote i/o with foundation fieldbus (ff)...
TRANSCRIPT
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The Fieldbus Monster
Samuel M. Herb, PE owner
March 18, 2014
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Hmmm! When Warrior get too old to hunt… …he just teach young braves how to read buffalo dung !!
Your Presenter’s REAL bio…
Copy of pdf for this presentation on website: http://jaomad.com/presentations.htm
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• The confusion over PAC & DCS Monster……….
• The Acronym Monster…..
• The Configuration Monster………………
• The Network Monster….
• The Fieldbus Monster……………………….
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From Central to Distributed Control System
Distributed
• Central
– Many wires
– Programmed
– Vulnerable
CENTRAL CONTROL ROOM
COMPUTER
CENTRAL CONTROL ROOM
UNIT CONTROL ROOM
CONTROLLER
CONTROLLER
CONTROLLER
CONTROLLER
DATA
HIWAY
Data highway
Configured
Less risk
Functional
Physical
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Process Automation Controller (PAC)*
* Some call this Programmable Automation Controller …especially if their product competes with PLCs
Defined by: ↓ ↓ ↓
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Acronym Monsters
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Some more maddening acronyms • BCS – Basic Control System • CDAS – Collaborative Discrete Automation System • CIF – Control in the Field • CNC – Computerized Numeric Control • CPAS – Collaborative Process Automation System • DAC – Data Acquisition & Control • DAQ – Data Acquisition • DCS – Distributed Control System • ECS – Enterprise Control System • ERP – Enterprise Resource Planning • ESD – Emergency Shut Down (system) • FCS – Fieldbus Control System • FPGA– Field-Programmable Gate Array; (controller on a chip for OEMs) • PAS – Process Automation System • PC Controller – Personal (Professional) Computer Controller • SBC – Single Board Computer (Controller) • SCADA – Supervisory Control and Data Acquisition • SLC – Single Loop Controller
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Traditional Process Control
Process Variable (PV)
Output
Set point (SP)
Process
Analog Loop
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(Digital Communications)
“Data Highway”
Shared Processing
Typical Distributed Control Loops
Control Room
Field Signals (Analog or Digital)
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Conventional Signals
• One variable
• Much wiring
• Not reliable
• Not secure
• Limited accuracy
• Limited precision
• Limited Control
1-5 v
4-20 ma
Controller
Trans- mitter
Actuator
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Conventional vs Fieldbus Signals
Digital instrumentation technology
4-20 mA
Digital-to-Analog
Signal Conversion
Analog-to-Digital
Signal Conversion
Microprocessor-
Based
Transmitter
Microprocessor-
Based
Instrument
Fieldbus
or
Fieldbus
Controller
with analog communications technology?...
or... digital communications technology!
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Control Room
Analog Signal
Local Control & Monitoring
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Maint. Dept.
Analog Signal Digital Signal
Control Room
Centralized (DDC)Control & Monitoring
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Maint. Dept.
Control Room
Analog Signal
Digital Signal
Distributed (DCS)Control & Monitoring
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Control Room
Maint. Dept.
Digital Signal
Fieldbus (FCS)Control & Monitoring
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Fieldbus: Better All Around!
Better !
Better !
Better !
Better !
Inter-operability
Scalability
Capabilities
Wiring Costs
Failure Risk Better !
Local Central Distrib. Fieldbus
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Installation Benefits
• Less wiring
• Remote configuration
• Automated documentation
• Multiple suppliers
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Remote I/O with Foundation Fieldbus (FF) Wiring Savings - 72%
3 Fiber Optic Ethernet I/A Fieldbus
Remote I/O
in Div. 2 Area
FF H-1
Remote I/O with Foundation Fieldbus $671,162
and Conventional Wiring For Discrete I/O
Point to Point Discrete
Wiring From I/O to
Field Devices
All Process Points IS
Fieldbus Tree Topology
8 Instruments per H-1 Seg.
& 4 Devices per IS spur
1 Multi-Core Cable
Process
“J” Box
Conventional Wiring $2,365,490 Point to Point Analog
& Discrete I/O Wiring
From I/O to Field Devices
All Process Pts. IS
Pharmaceutical Plant 1122 Analog I/O, 2798 Discrete I/O
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Operating Benefits
• More accurate
• More precise
• Better & safer control
• Increased information
• More reliable and secure
• Less down-time
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Avoid calibration scaling/clipping with digital signals
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Maintenance Benefits
• Increased reliability
• Competitive replacements
• Automated documentation
• Remote diagnostics
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Fieldbus: Remote Diagnostics
Control Room
Maint. Dept.
Digital Signal
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Fieldbus Provides Interoperability
• By defining: – electrical signal
– media access protocol
– communications handshaking protocol
– supported data types
– method to describe the device over the wire
– comprehensive function blocks
– modes and status
– cascade initialization, fail-safe propagation
– the alarm & event reporting mechanism
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Differentiating Field Device Vendors
• Quality of sales, training, service, and support
• Quality of the product
• Superior measurement/actuator technology
• Functions beyond the standard
• Application expertise
• Value
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OSI Reference Model by ISO
Provides all services to the Application program (e.g. Windows)
Function
Physical transmission medium ( e.g. coaxial, twinaxial cable)
Restructures data to/from standardized form
Provides user-to-user connections (e.g. Winsockets, NetBios, NetX)
Provides transparent data transfer-Node to Node (e.g. TCP/UDP, NetBeui, IPX/SPX)
Provides routing of data through the network (e.g. IP)
Provides link access control and reliability (e.g. token pass, CSMA/CD, etc.)
Provides an interface to the physical medium (e.g. connectors, cable type, impedance)
Layer 6
Presentation
Node A
Layer 7
Application
Layer 5
Session
Layer 4
Transport
Layer 3
Network
Layer 2
Data Link
Layer 1
Physical
User program
Layer 6
Presentation
Node B
Layer 7
Application
Layer 5
Session
Layer 4
Transport
Layer 3
Network
Layer 2
Data Link
Layer 1
Physical
User program
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OSI Analogy: Mailing Letter
OSI Layer Postal System Equivalent
7-Application Letter contents within envelope
6-Presentation Format & language of letter, including proper translation into another language, if needed
5-Session Name, address, zip code of both sender & receiver
4-Transport Certified or registered mail; verification to sender that letter arrived at correct destination
3-Network Distribution transfer to outside local system to another city or country
2-Data Link Distribution within same local system, or within local system in that other city or country
1-Physical Conveyance: postman, truck, train, plane…..
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OSI Reference Model
Physical transmission medium ( e.g. coaxial, twinaxial cable)
Layer 6
Presentation
Node A
Layer 7
Application
Layer 5
Session
Layer 4
Transport
Layer 3
Network
Layer 2
Data Link
Layer 1
Physical
User program
Layer 6
Presentation
Node B
Layer 7
Application
Layer 5
Session
Layer 4
Transport
Layer 3
Network
Layer 2
Data Link
Layer 1
Physical
User program User data
User data
User data
User data
User data
User data
User data
User data
Each
Lay
er A
dd
s M
ore
H
ead
ers
...
…&
Fo
ote
rs
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LAN Interconnection Devices
Repeater - Connects two or more LANs of same technology
or extends distance of a LAN.
Bridge - Interconnects LANs, but only forwards data destined for device on other side of bridge. Can only connect two similar LANs. (such as Ethernet)
Router - Connects to several networks and forwards data packets using the Network Level addresses. Can connect two LANs of different topologies but same protocol.
Gateway - Protocol conversion device to interconnect networks or devices which uses different communications protocols. Gateways function at all seven layers. Can be used to connect DECnet device to TCP/IP device.
Layer 5
Session
Layer 4
Transport
Layer 3
Network
Layer 2
Data Link
Layer 1
Physical
Layer 7
Application
Layer 6
Presentation
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How Fieldbus Works
7
2
1
Device 1
User
Appl’n.
Data Link
Physical
Device 2
User
Appl’n.
Data Link
Physical
7
2
1
Subset of the ISO’s OSI Reference Model:
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Function Blocks within Devices
• Analog input
• Analog output
• Discrete input
• Discrete output
• Pulse input
• PID
• Step PID
• Manual loader
• Ratio station
• Bias/gain station
Inputs Outputs
Algorithm
Parameters:
• Control selector
• Lead-lag
• Dead-time
• set point generator
• Signal characterizer
• Signal selector
• Device controller
• Timer/counter
• Arithmetic
• Calculator
• Integrator
• Complex analog out
• Complex discrete out
• Analog alarm
• Discrete alarm
• Analog human I/F
• Discrete human I/F
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The Virtual Fieldbus Device
“REAL” TRANS- MITTER
Obj. Dict.: AI1 - PV - HI_LM - HI_HI_LM - ALM_SUM - PV_SCALE - CHANNEL - L_TYPE - ...
AI1
AI2
AI3
“VIRTUAL” Presentation of
Function Blocks & Attributes to
FIELDBUS Network
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The Virtual Fieldbus Device
Obj. Dict.: PID1 - SP - GAIN - RESET - DV_HI_LM - ... PID2 - SP - GAIN - RESET - DV_HI_LM - ...
“REAL” Controller
PID3
PID2
PID1
“VIRTUAL” Presentation of
Function Blocks & Attributes to
FIELDBUS Network
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The Virtual Fieldbus Device
Obj. Dict.: AO - CAS_IN - OUT_SCALE - FSAFE_VAL - ... AO
“REAL”
ACTUATOR
“VIRTUAL” Presentation of
Function Blocks & Attributes to
FIELDBUS Network
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The Virtual Fieldbus Device
Obj. Dict.: AO - CAS_IN - OUT_SCALE - FSAFE_VAL - ... PID - SP - GAIN - RESET
PID “VIRTUAL” Presentation
of Function Blocks & Attributes to FIELDBUS
Network
“REAL”
ACTUATOR AO
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“REAL” TRANS- MITTER
Obj. Dict.: AI1 - PV - HI_LM - HI_HI_LM - ALM_SUM - PV_SCALE - CHANNEL - L_TYPE - ...
AI1
AI2
AI3
Obj. Dict.: PID - CAS_IN - GAIN - RESET AO - CAS_IN - EU_0 - EU_100 - ...
PID
AO
The Virtual Fieldbus Device
“REAL”
ACTUATOR
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Field Based Control Example
Controller
Controller
Cascaded !
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DCS vs. PLCs with PCs as a System
Typical PLC System Configuration:
Typical DCS System Configuration:
Controller
Proprietary Network, often based upon a Physical Standard
PC as HMI
Workstation as HMI
Controller Controller Controller
PLC
Some Proprietary Network that passes as de facto Physical & Communication Standard PC
as HMI PLC PLC PLC
Each Individually Configured
Must configure to communicate with each PLC, to link views, etc.
Single database configured for all stations
“Add-on” configured separately
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FOUNDATION Fieldbus itself can be controller
Sensors Analyzer Valves Motors
Fieldbus Open Network Flexibility
Smart Transmitters, Sensors , End Elements:
• Multivendor within same system
• Common Function Blocks
• configuration
• documentation
• tag names & HMI “calls”
• peer - to - peer links for complex strategies
Multivariable Controller
PC
as HMI
User Choice;
Configures control
database and:
• Screen Views
• Trends
• History
• etc.
Control network Linking device
(Control Network)
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Process automation protocols • FOUNDATION Fieldbus
• Profibus - by PROFIBUS International.
• PROFINET IO
• CIP (Common Industrial Protocol) - Can be
treated as application layer common to
DeviceNet, CompoNet, ControlNet and
EtherNet/IP
• Controller Area Network utlised in many
network implementations, including CANopen
and DeviceNet
• ControlNet - an implementation of CIP,
originally by Allen-Bradley
• DeviceNet - an implementation of CIP,
originally by Allen-Bradley
• DirectNet (CCM protocol) - supported by
Automationdirect \
• EtherNet/IP - IP stands for "Industrial Protocol".
An implementation of CIP, originally created by
Rockwell Automation
• EtherCAT
• EGD (Ethernet Global Data) - GE Fanuc PLCs
(see also SRTP)
• PoE, PoE+ - Power over Ethernet
• HART Protocol
• PieP - An Open Fieldbus Protocol.
• FINS - Omron's protocol for communication over
several networks, including ethernet.
• Host Link - Omron's protocol for communication
over serial links.
• Interbus - Phoenix Contact's protocol for
communication over serial links, now part of
PROFINET IO
• Mechatrolink - open protocol originally developed
by Yaskawa.
• MelsecNet/10 - supported by Mitsubishi Electric.
• Modbus RTU or ASCII
• Modbus-NET - Modbus for Networks
• Modbus/TCP
• Modbus Plus
• Optomux - Serial (RS-422/485) network protocol
originally developed by Opto 22 in 1982. The
protocol was openly documented and over time
used for industrial automation applications.
• SERCOS interface - Open Protocol for hard real-
time control of motion and I/O
• GE SRTP - GE Fanuc PLCs
• Sinec H1 - Siemens
• SynqNet - Danaher.
• BSAP - Bristol Standard Asynchronous Protocol,
developed by Bristol Babcock Inc.
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Which path to take?
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Don’t want conflicting interests!
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IEC 61158 specification
Original
• Type 1 FOUNDATION Fieldbus H1
• Type 2 ControlNet
• Type 3 PROFIBUS
• Type 4 P-Net
• Type 5 FOUNDATION Fieldbus HSE (High Speed Ethernet)
• Type 6 SwiftNet (a protocol developed for Boeing, since withdrawn)
• Type 7
• Type 8 INTERBUS
Recent or planned additions
• Type 10 PROFINET IO
• Type 12 EtherCAT
• Type 13 Ethernet Powerlink
• Type 16 SERCOS_interface
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The Fieldbus Monster
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Process Control User Layer
PROFIBUS
DeviceNet
FIP
SDSnet
LONworks
FF Fieldbus
etc.
PHS
Layer
D-L
Layer
Appl.
Layer
User.
Layer
Function Blocks
“Mode” “Status”
Alarm
Support
Trend
Support
Device
Description
Language
Foundation Fieldbus has Process Control USER LAYER!
PA
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Cost – Function – Data – Complexity
Ne
two
rk S
pe
ed
LOW
HIGH
HIGH
Figure A.18 Example of field bus trade-offs
Fieldbus Hierarchy
(BIT)
(BYTE)
(BLOCK)
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Digital Networks for Control Systems
X
X HSE
Source: Control Engineering Magazine
DP = Decentralized Periphery
PA = Process Automation
FMS = Fieldbus Messaging
Specification
HSE = High Speed Ethernet
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PROFIBUS-PA
FDT/DTM
FF – H1
PROFIBUS-DP
HART
Installed 2005 Plan for 2006
Used in 2003
DeviceNet
4-20 mA
Ethernet
Past, Present, Future Use of Fieldbuses, Network Methods
CONTROL magazine survey 132 respondents who buy, recommend or specify industrial networks
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Industrial network development– 2009
1975 1985 1995 2008
Technology Development
Growth
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Fieldbus - User Group Focus
India
SEA
Canada
USA
Brasil
Argentina
Europe
India
SEA
Japan
Food & Beverage Chemistry
Water / Waste
Petro & Chemistry Pulp & Paper Food & Beverage
RSA
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Fieldbus - meets the Customer needs
(*****) = best suitable
Industry
System
Availabilty
Reliability
Costs
Technical features ***** **** ** ****
**** ***** ** *****
* ***** ****
PLC
DCS *****
Petrochemical
Power
Chemistry i.s.
Food & Beverage
Waste- / Water
*
***** ***
****
***** **
***** **** **
*** Solids * ** ****
Chemistry non i.s. *** ***
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Fieldbuses in Process Industry
• Large installed base – >2/3 of all “smart” instruments shipping are HART capable
– >20 million HART-enabled devices installed world-wide
– >700,000 FF compliant devices; 10,000 systems
– >700,000 PROFIBUS PA compliant devices
• Mega-systems (>10K devices) becoming common
• Companies standardizing on fieldbus for control – Higher availability, lower variability, reduced
commissioning time
– Mandated for new projects
– Several use “control-on-the-wire”
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Which Fieldbus to use?
• Each have different strengths, limitations – Host system support! – Area classification – Distance limitations – Equipment cost – Signal mix – “analog” (numerical) vs. discrete – Facility history/legacy – Process needs & speed of response – Availability of devices capable of desired measurements
• Best choice is often combination of buses – Different processes in different parts of operation – Different end uses = motor controls vs. process controls – Trade-off: system more complex with more buses
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Bottom Line Thoughts from Large User
• Biggest potential return for fieldbus lies in – Reduction of process upsets
– Maintenance costs through effective use of device data
• FDT is great enabler to obtain these functions! – FDT—Field Device Tool
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However… My Plant
• Runs continuously
• With many different field devices
• On several different networks
• With more than one control system…
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when a problem occurs
• No matter who responds
• No matter where their mind is at the time
• No matter how much their experience with
THIS problem …or THIS equipment
• No matter how rarely it happens…
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my people QUICKLY need to
• Always see information the same way
• Know what is wrong
• Know how to act
• Be consistent
…WHOEVER responds
…WHENEVER they respond…
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with a SINGLE tool
• That works with any field equipment
• From any supplier
• That reduces device commissioning time
• Supplies meaningful
Asset Management information
• On ALL my EXISTING systems
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EDDL • EDDL - Electronic Device Description Language
– Descriptive characteristics of a device
• In compressed binary format; cyber safe
• Not executable code to not impact stability of operating system
– Graphical elements for device maintenance and configuration
• Specified by the Instrument Protocol foundations
– Foundation Fieldbus
– HART Communication Foundation
– PNO - PROFIBUS
• Required for instrument certification by the respective foundations
• Foundations working to establish a common EDDL standard
– ECT – “EDDL Cooperation Team”
– IEC standard
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EDDL – Data Description
• The EDDL provides a texted description
– Device
– Block
– Parameters
#define LINEAR 0 VARIABLE trans1_temperature_unit { LABEL [digital_units]; HELP [temperature_unit_help]; CLASS CONTAINED; HANDLING READ & WRITE; TYPE ENUMERATED (2) { DEFAULT_VALUE 32; { 32, [degC], [degC_help] }, { 33, [degF], [degF_help] }, { 34, [degR], [degR_help] }, { 35, [Kelvin], [Kelvin_help] } IF (trans1_sensor_type == LINEAR) { { 36, [mV], [mV_help] }, { 37, [Ohm], [Ohm] }, { 39, [mA], [mA_help] }, } } }
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Another Solution…
FDT is an “open” standard
for device integration that:
– Is viewed on any windows workstation
– Provides consistent graphic presentations
– Is supplier, system, & protocol independent
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FDT based tools
• Support Consistent workstation views
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• Compatible with existing & future automation equipment • Upgrade all your existing networks • Manage multiple generations of devices over life of plant
• Graphical support for start up and commissioning • Intuitive HELP functions for troubleshooting • Monitor efficiency during operations
• Same look & feel on every system • Best advanced diagnostics …specific know-how
…from each device supplier …who can easily upgrade you with new information
FDT based tools
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FDT connects with 12 different protocols
AS-interface
ContolNet
DeviceNet
EtherNet/IP
FOUNDATION Fieldbus
High Speed Ethernet
HART
INTERBUS
IO Link
MODBUS SL/TCP
PROFIBUS DP/PA
PROFINET I/O
CIP Annex configuration
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Endorsed over 66 users & suppliers and growing!
®
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67
VALIDATED user results show
• 40% reduction in commissioning time Note! Commissioning is usually the CRITICAL path of the project! (Dow 9/07)
• 80% reduction for last minute engineering modifications (Dow 9/07)
• Much faster resolution of typical instrument problems during startup (example false echo’s with radar level meters)
• 60-70% reduction in scheduled plant downtime (Clariant GmbH 9/06)
“Instrument
Technicians LOVE this tool!”
Feedback from commissioning team:
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Who Benefits From FDT Technology?
All departments • -Operations • -Engineering • -Maintenance All industries • -Process / continuous automation • -Factory / discrete automation All phases of the facility life cycle New and existing facilities • -independent of size!
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EASILY Integrate into your system
ANY field DEVICE
From ANY supplier
Into ANY host system (DCS, PAC, PLC, etc.)
Using ANY protocol
With FULL device functionality
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Survive change
• Your markets are in continual change
• Your staff will not be there forever
• Your suppliers will change
• Your plant will change
• Don’t let your productivity change…
…use the one tool that will help you survive change
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The Adventure Goes on…