11 Successful Implementation & Improved Operation
Fieldbus Foundation Seminar Mumbai – 16th Oct 2014
Enhancing Usability Through Physical Layer Diagnostics
Arasu Thanigai
22 Successful Implementation & Improved Operation
FF Usability
What is Usability
Usability is all about how easy, effective and pleasant the features are for a human 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.
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FF Usability - Simplicity
Iphone
Simple Apps usability and vendor participation Adaptability
Blackberry
The iPhone did not introduce anything particularly new or exciting to the mobile industry upon its release.
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FF Usability
Interoperability
Automated Device replacement
Backwards compatibility
PV Interchangeability
Device Templates
Managing Diagnostics
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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)
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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.
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DeviceCoupler(Zone1 – Exd)
Fiel
d D
evic
es
Fiel
d D
evic
es
Fiel
d D
evic
es
TerminatorSurgeProtec.
SurgeProtect.
Fiel
d D
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es FieldbusProcessInterfaces
Fieldbus Physical layer
PowerSupplies
– Types and Causes of faults– Components with a view on availability– Assessment of risk of failure
DeviceCoupler(Zone2 – ExiC)
DeviceCoupler(Zone1 – Exia)
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Hazardous safety rules not followed
– Ground faults– Fieldbus and power
cables tied together
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Poor cable installations– Cable gland not tight– Seal missing
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Diagnostics Tools
Integrated single tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need
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Advanced Diagnostic Options
A single tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need
Handheld
Portable
Integrated version
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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
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Oscilloscope
Built into the FDH-1 Many trigger conditions selectable Operation on the display or via software Trigger output for external oscilloscope
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Intuitive Handling
One-button, quick check with NAMUR signals (NE 107)
Recording and storage for32 segments with 32 devices each
Data backup on laptop/PC
Multi language support: ENG+GER
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Expert system on board
Interprets raw physical layer measurements Translates into possible causes Suggests corrective action NAMUR NE 107 status
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Handheld Power
Power modes for every situation: segment power, intrinsically safe USB port internal rechargeable battery:
power for an entire work day
Selectable power modes
2929 Successful Implementation & Improved Operation
Mobile Diagnostic Module– Portable module for 1 segment, mainly for
field usage– Powered via USB or bulk power– Nearly identical to the Power Hub
Diagnostic Module
USB interface
Bulk PowerFieldbus interface
3030 Successful Implementation & Improved Operation
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
3131 Successful Implementation & Improved Operation
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
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Example ADM and DCS integration
Diagnostics atDCS Station
Rel
ay c
onta
ctop
tiona
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RS485
Industrial Switch
Ethernet or FF H1
Address switches
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Example ADM and DCS integration
Operatorstation
Rel
ay c
onta
ctop
tiona
l)
RS485
EthernetVnetIP
AMS
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Operatorstation
Rel
ay c
onta
ctop
tiona
l)
RS485
Ethernet
Example ADM and DCS integration
VnetIP
AMS
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The Solution
Operatorstation
Rel
ay c
onta
ctop
tiona
l)
RS485
EthernetEthernet (optional)
AMS
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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
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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
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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
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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
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Older way of Commissioning– Always on the critical path– Manual, step-by-step procedure– Labor intensive– Requires
• Screw driver• Check sheet• Pencil• Multimeter• Oscilloscope
– Connect one device at a time– Disconnect after testing
Test Report
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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 undisturbed Commissioning Wizard
Test Report
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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 ReadoutCreates baseline report:
– Snapshot of all measurements – Complete documentation
Saves significant (almost 80%) of pre-commissioning time
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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 valueMaintenance required
Out of specification
The segment is still operating with good performance
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Diagnostic Menu
ADM delivers actionable information for fast fault finding
1 Active messages2 Actionable information with
solution guideance based on expert knowledge
3 History with timestampsWhen the failure…
… occured… disappeared
– Export function for external analysis and storage
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33
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Spurs
Field Instruments
Basic Principles: Typical Topology
Segment Protectors
Trunk
Surge Protector
Terminator
Plant Asset Management
Diagnostic Gateway
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Practical Example of Frequencey disturbance
In this example the frequency of noise was approx. 150Hz
7 ms
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Not a good device location
FF Device Moved away from Drive
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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
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Diagnostic Surge Protection On IS Device Coupler
5959 Successful Implementation & Improved Operation
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