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DCS and Fieldbus Foundation
Shivaji Day
Process Automation, ABB
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© 1994 – 2011 Fieldbus Foundation 3 © ABB
July 17, 2012 | 3
FOUNDATION Fieldbus HSE - Server Integration
- HSE is the “Open Common” interface for access to the server
- All H1 and HSE data are available on the server
- Application packages give information for the MIS (Management Information System)
- Servers provide the platform for application packages (e.g. HMI, configuration, diagnosis, ...)
FOUNDATION Fieldbus HSE - Subsystem Integration
- Communication between control level and Linking Device H1 (field level)
- Quick data exchange, High Performance Control Backbone (100 Mbit/s)
- Standard Ethernet accessories and cables
- Redundant HSE devices and interfaces
- Standard „Function Blocks“ plus flexible „Function Blocks“
FOUNDATION Fieldbus H1 – Device Integration
- Communication and power supply via one 2-wire cable
- Transmission rate fixed 31.25 kbit/s
- Installation in Zone 1 (Intrinsic Safety EEx i)
- “Function Blocks“ run in the field devices
- Supports control functions in the field device, device-to-device communication,
LAS Backup, time stamp
P L
P L
P L
P L
APPLICATION
PACKAGES
MIS
IEC 61158
Foundation Fieldbus Specification
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© 1994 – 2011 Fieldbus Foundation 4 © ABB
| 4
H1/HSE
PHYSICAL LAYER 1
2
3
4
5
6
7
USER LAYER
COMMUNICATION
STACK
H1 HSE
H1 PHY @ 31.25 kbit/s
H1 DLL
1
2
3
4
5
6
7
USER LAYER
TCP/UDP
Ethernet/IEEE 802
IP
1
2
3
4
5
6
7
USER LAYER
FMS FDA FMS
TRANSPORT LAYER
SESSION LAYER
PRESENTATION LAYER
APPLICATION LAYER
PHYSICAL LAYER
DATA LINK LAYER
NETWORK LAYER
1
2
3
4
5
6
7
OSI Model
Fully integrated Foundation Fieldbus architecture
FAS
Ethernet/IEEE 802
@ 100 Mbit/s
ISO/OSI Layer Model for Foundation
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© 1994 – 2011 Fieldbus Foundation 5 © ABB
July 17, 2012 | 5
Ethernet / IEEE 802 / FO
FOUNDATION Fieldbus HSE
OPC
Server
Ethernet TCP/IP
IEC 61158-2
Engineer
FOUNDATION Fieldbus H1
Linking
Device
PS
Operate
Engineer
Control
Field
Foundation Fieldbus Network
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© 1994 – 2011 Fieldbus Foundation 6 © ABB
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100 Mbit/s
FF HSE
HSE
Remote IOs
Field Devices
FF-H1
P
L
Plant
P
L
P
L
FF-H1
Linking
Device
Gateway
Other Networks
OPC
Server Operate
Engineer
Control
Field
HSE Controller
OPC
Server
HSE - High Speed Ethernet Topology
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© 1994 – 2011 Fieldbus Foundation 7 © ABB
July 17, 2012 | 7
232 subscribers per link
T R R R
FO
Seg. 4
32 subscr.
Seg. 2
32 subscr.
Seg. 3 Segment 1
32 subscribers, incl. repeater
FOUNDATION H1
FOUNDATION HSE
Operate
Engineer Control
Field
Linking
Device
T
OPC
Server
Ethernet TCP/IP
T
PS
In applications the number of subscribers per H1 link is limited to < approx.12 by: - too high data refresh times (cycle times)
- energy requirement of the subscribers
- set-up in Ex area (IS)
- max. 12 per segment is a recommendation of Fieldbus Foundation
Subscribers – Foundation Fieldbus-H1
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© 1994 – 2011 Fieldbus Foundation 8 © ABB
July 17, 2012 | 8
FOUNDATION HSE
Operate
Engineer Control OPC
Server
Ethernet TCP/IP
For the use
of passive T-junctions
in the Ex (Haz.) area:
8 H1 field devices
acc. to FISCO
Field
Us 12,6 VDC
Is 100mA
[EEx ia]
Linking
Device
T
LT 1.000 m
LS
30 m
Ltotal = LT+ ( LS) 1.000 m
T T 4-fold
IEC 61158-2: FF-H1
Transmission rate fixed 31.25 KBit/s
max. segment length for copper cable Type A
Non-Ex Area: 1.900 m
Ex Area: 1.000 m
Caution !
Segment length (H1 cable)
considerably reduced by
…the voltage drop
…the limited supply current
…the cable diameter
…the number of H1 Slaves
FOUNDATION H1
T
PS
Line Lengths, Transmission Rate – FF-H1 [Ex (Haz.) Area]
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© 1994 – 2011 Fieldbus Foundation 9 © ABB
July 17, 2012 | 9
FieldBarrier*)
LS
12
0 m
Ltotal = LT+ ( LS) 1.900 m
LT 1.900 m
Field
EEx e
EEx ia
For the use of the
FieldBarrier in the Ex area:
16 H1 field devices
acc. to FISCO
IEC 61158-2: FF-H1
Transmission rate fixed 31.25 KBit/s
max. segment length for copper cable Type A
Non-Ex Area: 1.900 m
Ex Area: 1.000 m (with FieldBarrier 1.900 m)
Us 28 VDC
Is 500 mA
Linking
Device
FOUNDATION H1
FOUNDATION HSE
Operate
Engineer Control OPC
Server
Ethernet TCP/IP
*) max. four FiedBerrier per segment
T
PS
Line Lengths, Transmission Rate – FF-H1 [Ex (Haz.) Area]
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© 1994 – 2011 Fieldbus Foundation 11 © ABB
July 17, 2012 | 11
Operate Engineer
Control
Field
Ethernet / IEEE 802 / FO
FOUNDATION Fieldbus HSE
Linking
Device
OPC
Server
Ethernet TCP/IP
EDD / CF-Files: For display and
configuration of FF device parameters
IEC 61158-2
FOUNDATION Fieldbus H1
EDD – Electronic Device Description, CF – Capability File
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© 1994 – 2011 Fieldbus Foundation 12
Foundation Fieldbus
with 800xA
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© 1994 – 2011 Fieldbus Foundation 13
800xA – DCS with integrated FF
High availability means
redundancy at all levels:
System servers and
workplaces
Controllers
Communication
interfaces
Remote I/O
Linking devices
Media/cable redundancy
Linking
Device
Drives
AC800M
RLM01
Remote IO
PROFIBUS DP
PROFIBUS PA devices
FF HSE
FF H1 devices
Linking
Device
OPC Server FF
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© 1994 – 2011 Fieldbus Foundation 14
Foundation Fieldbus redundancy
Redundant
Linking device
FF HSE
HSE / H1
Linking
Device Multi Barrier Multi Barrier
Redundant FF
OPC servers
FF H1
FF H1
Ethernet TPC/IP
Redundant
Communication
to Controllers
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© 1994 – 2011 Fieldbus Foundation 15
FF Device Integration FF is an integrated architecture for
distribution of control applications
Two different fieldbus networks supported:
H1 Link with 31.25 kbit/s
HSE Subnet with 100 Mbit/s
Controller connection to HSE via CI860 (optionally redundant)
LD 800HSE: gateway between H1 and HSE (optionally redundant)
Asset Optimization and Process Portal application connected via OPC Server FF
Device Integration Library comprises FF field devices and its aspects for easy Drag´n Drop configuration
H1 Devices
4x H1 Links
Fieldbus Builder FF
AC 800M
CI860
LD 800HSE
HSE Subnet
OPC Server FF
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© 1994 – 2011 Fieldbus Foundation 16
Fieldbus Builder Foundation Fieldbus
Fieldbus Builder FF performs the
configuration and commissioning of FF
network and application
Management of FOUNDATION Fieldbus for
entire FF network with HSE subnets and
H1 Links
Configuration and loading of OPC Server FF
Engineering tasks
Application configuration
Automatic schedule generation
Device parameterization
Commissioning
Diagnostics
Incremental Download also for complete HSE subnets
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© 1994 – 2011 Fieldbus Foundation 17
FF Device Integration Library (1)
Library contents:
FF Block Library with FF standard
blocks and device specific blocks
HSE Device Library with ABB
Linking Device LD 800HSE
H1 Device Library with ABB FF field
devices
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© 1994 – 2011 Fieldbus Foundation 18
FF Device Integration Library (2)
Asset monitoring
Asset tree viewer
Asset reporter
Asset alarms / notification
Maintenance management
(CMMS connectivity)
Faceplates
Device documentation
access
The devices offer all aspects required for field device management
Latest Device List at
www.abb.com/controlsystems
-> System 800xA -> Device Management
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© 1994 – 2011 Fieldbus Foundation 19
FF Faceplates
Header: display of process tag and its description
Indicator bar: display of function block status (MODE_BLK.Actual)
Faceplate element: display and operation of process values and parameters
Process value (Pv)
Output value (Out)
Simulate value (Sim)
Parameters
Operator bar: operation buttons for switching the block mode (MODE_BLK.Target)
Different faceplates for
Analog input (AI) and output (AO)
Discrete input (DI) and output (DO)
PID control (PID)
FF Faceplates comply the IndustrialIT standards
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© 1994 – 2011 Fieldbus Foundation 20
FF System Structure
AC 800M
FF HSE Link
FF H1 Links
Pub/Sub Pub/Sub HSE
Linking Device
FF HSE Link
FF H1 Links
Pub/Sub
Fieldbus Builder FF
Pub/Sub
Pub/Sub
Pub/Sub
Pub/Sub Pub/Sub
Pub/Sub Pub/Sub
FF HSE Link
LD 800HSE
800xA Workplace
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© 1994 – 2011 Fieldbus Foundation 21
FF HSE application
H1 link A
OUT AI PID
BK_CAL IN
OUT
IN
H1 link B
OUT AI
PID BK_CAL IN
OUT IN
CAS_ IN
CAS_IN AO
BK_CAL OUT
BK_CAL OUT
FF HSE Link
FF H1 Link FF H1 Link
Pub/Sub Pub/Sub Pub/Sub
Pub/Sub
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© 1994 – 2011 Fieldbus Foundation 22
FF Parameter Displays
Display and operation of block parameter
All parameters listed
Predefined tabs for the main parameter groups
Device and Block dependent
Adaptation via block library for all instances
Import/export capabilities
Tabs with structured
parameters
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© 1994 – 2011 Fieldbus Foundation 23
FF Network Components
Device 1
Device 2
Device n
Spur Blocks
Power Supply
Power
Conditioner
H1 Link
HSE Subnet
Redundant Linking Devices
Two LD 800HSE build up a redundant Linking Device
Module redundancy
HSE interface redundancy
H1 interface redundancy
Power Supply
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© 1994 – 2011 Fieldbus Foundation 24
Foundation Fieldbus Basic Layout
Max. 4000 devices per connectivity server
(application dependent)
Max. 30 Linking Devices
per HSE subnet
Max. 16 field
devices per H1
Link (application
dependent)
40 signals per second per H1 link
between H1 and HSE
CI860 1000 signals overall
Max. 6 (12) CI860
at CEX Bus
• max 1000 for analog input
• max 500 for analog output
• max 500 for discrete input
• max 250 for discrete output
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© 1994 – 2011 Fieldbus Foundation 26
FF Installation - References
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© 1994 – 2011 Fieldbus Foundation 27
• Client The Reliance Group, is India's largest private sector enterprise, with businesses in the
energy and materials value chain. Group's annual revenues are in excess of US$ 58 billion. The flagship company,Reliance Industries Ltd., is a Fortune Global 500 company and is the largest private sector company in India.
The Group's activities span exploration and production of oil and gas, petroleum refining and marketing, petrochemicals (polyester, fibre intermediates, plastics and chemicals), textiles, retail, infotel and special economic zones.
• Application • Automation of Butene Plant.
• Site • Reliance Industries Ltd.,Hazira
• Scope The ABB Scope of supply includes 2 set of redundant controllers,around 1600 I/Os,
Redundant set of Aspect cum Connectivity Server, 1 Engineering Station, 4 operator workplace, 1 IM server and 1Web Server.
The System has FF solution with 300 FF devices connected to System
HART communication with Field Devices ( Around 450 Devices)
Performance of PST for 18 Emerson DVC ( for the 1st time on 800xA Platform)
Asset Optimization,Alarm Management & Information Management system
Remote Connectivity of Plant Data through CPM Smart Client
In Operation • Oct- 2011
Reliance Industries Ltd,India Butene Plant
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© 1994 – 2011 Fieldbus Foundation 28
• Client Jindal Steel West(JSW) Limited, are Specialized manufacturer and supplier of Steel
Products.
JSW group with turnover of 7 BUSD has diversified interests in Steel, Energy, Minerals and mining, Aluminium, Infrastructure and logistics, Cement and Information Technology.
• Application • Complete automation of Sinter Plant.
• .
• Site • JSW Steel Ltd, Thoranagallu
• Scope JSW Steel Ltd chose ABB System 800xA as DCS package for the Sinter Plant
Automation.
The ABB Scope of supply includes 2 controllers, around 8,000 I/Os, 7 operator workplace, Redundant aspect & connectivity servers, 400 devices on Profibus and 80 devices on FF.
• In Operation • June- 2006.
JSW,India Sinter Plant
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© 1994 – 2011 Fieldbus Foundation 29
References for Foundation Fieldbus installation
1 Tata Steel, Jamshedpur Sinter Plant#3 5000 IO on Profibus, 7OS Mar-05
80 FF H1 devices
2 Reliance Patalganga Conitnuous Polymerisation Plant - 7 4500 IO, 1ES/OS+5OS, FF, IM Mar-06
150 FFH1 devices
3 Reliance Hazira Conitnuous Polymerisation Plant - 10 4400 IO, 1ES/OS+5OS, FF, IM April-06
275 FFH1 devices
4 Reliance Hazira Conitnuous Polymerisation Plant - 11 6600 IO, 1ES/OS+5OS, FF, IM June-06
50 FFH1 devices
5 JSW, Bellary Sinter Plant #1 5000 IO on Profibus, 7OS Aug-06
80 FF H1 devices
6 JSPL, Raigarh Sinter Plant 5000 IO on Profibus, 7OS Sep-06
80 FF H1 devices
7 JSPL, Raigarh Coke Oven 800 IO 2OS Mar-06
250 FF H1 devices
8 Tata Steel, Jamshedpur Sinter Plant#4 5000 IO on Profibus, 7OS March-08
80 FF H1 devices
9 JSW, Bellary Sinter Plant #2 5000 IO on Profibus, 7OS Aug-09
80 FF H1 devices
10 JSW, Bellary Sinter Plant #4 5000 IO on Profibus, 7OS Dec-11
80 FF H1 devices
11 Reliance Hazira Butene Plant 1600 IO on Profibus, 5OS Oct-11
300 FF H1 devices
© 1994 – 2011 Fieldbus Foundation 30
THANKS
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