The Fieldbus Monster

Samuel M. Herb, PE owner

March 18, 2014

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

• The confusion over PAC & DCS Monster……….

• The Acronym Monster…..

• The Configuration Monster………………

• The Network Monster….

• The Fieldbus Monster……………………….

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

Process Automation Controller (PAC)*

* Some call this Programmable Automation Controller …especially if their product competes with PLCs

Defined by: ↓ ↓ ↓

Acronym Monsters

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

Traditional Process Control

Process Variable (PV)

Output

Set point (SP)

Process

Analog Loop

(Digital Communications)

“Data Highway”

Shared Processing

Typical Distributed Control Loops

Control Room

Field Signals (Analog or Digital)

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

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!

Control Room

Analog Signal

Local Control & Monitoring

Maint. Dept.

Analog Signal Digital Signal

Control Room

Centralized (DDC)Control & Monitoring

Maint. Dept.

Control Room

Analog Signal

Digital Signal

Distributed (DCS)Control & Monitoring

Control Room

Maint. Dept.

Digital Signal

Fieldbus (FCS)Control & Monitoring

Fieldbus: Better All Around!

Better !

Better !

Better !

Better !

Inter-operability

Scalability

Capabilities

Wiring Costs

Failure Risk Better !

Local Central Distrib. Fieldbus

Installation Benefits

• Less wiring

• Remote configuration

• Automated documentation

• Multiple suppliers

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

Operating Benefits

• More accurate

• More precise

• Better & safer control

• Increased information

• More reliable and secure

• Less down-time

Avoid calibration scaling/clipping with digital signals

Maintenance Benefits

• Increased reliability

• Competitive replacements

• Automated documentation

• Remote diagnostics

Fieldbus: Remote Diagnostics

Control Room

Maint. Dept.

Digital Signal

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

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

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

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…..

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

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

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:

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

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

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

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

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

“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

Field Based Control Example

Controller

Controller

Cascaded !

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

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)

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.

Which path to take?

Don’t want conflicting interests!

THE GOOD NEW$ I$…

I can Save you $$$$

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

The Fieldbus Monster

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

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)

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

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

Industrial network development– 2009

1975 1985 1995 2008

Technology Development

Growth

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

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. *** ***

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”

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

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

However… My Plant

• Runs continuously

• With many different field devices

• On several different networks

• With more than one control system…

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…

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…

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

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

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] }, } } }

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

FDT based tools

• Support Consistent workstation views

• 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

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

Endorsed over 66 users & suppliers and growing!

®

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:

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!

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

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

The Adventure Goes on…