DCS and Fieldbus Foundation. Shivaji Day Process Automation, ABB

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1 DCS and Fieldbus Foundation Shivaji Day Process Automation, B

Foundation Fieldbus Specification 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

..) FOUNDATION Fieldbus HSE - Subsystem Integration - Communication between control level and Linking Device H1 (field level) - Quick data exchange, High Performance Control Backbone

Integration - Communication and power supply via one 2-wire cable - Transmission rate fixed 31.

2 Foundation Fieldbus Specification 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 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 B 3 July 17, P L MIS IEC APPLICATION PACKAGES P L P L P L

3 ISO/OSI Layer Model for Foundation Fully integrated Foundation Fieldbus architecture OSI Model H1/HSE H1 HSE USER LAYER USER LAYER USER LAYER APPLICATION LAYER 7 7 FMS FAS 7 FDA FMS 7 PRESENTATION LAYER SESSION LAYER TRANSPORT LAYER 5 4 COMMUNICATION STACK TCP/UDP 5 4 NETWORK LAYER IP 3 DATA LINK LAYER 2 2 H1 DLL 2 Ethernet/IEEE B 4 4 PHYSICAL LAYER 1 PHYSICAL LAYER 1 H kbit/s 1 Ethernet/IEEE 100 Mbit/s 1

IEEE 802 / FO FOUNDATION Fieldbus HSE Engineer Field

4 Foundation Fieldbus Network Operate Engineer Ethernet TCP/IP Control Linking Device OPC Server Ethernet / IEEE 802 / FO FOUNDATION Fieldbus HSE Engineer Field PS IEC FOUNDATION Fieldbus H1 B 5 July 17,

5 HSE - High Speed Ethernet Topology Operate Engineer OPC Server OPC Server 100 Mbit/s FF HSE Gateway Other Networks Control Linking Device HSE Controller FF-H1 FF-H1 P P P Field HSE Remote IOs Field Devices L Plant L L B 6 6

B 7 July 17, 2012 7 232 subscribers per link In applications the number of subscribers per H1 link is limited to < approx.

6 Control OPC Server Ethernet TCP/IP Subscribers Foundation Fieldbus-H1 FOUNDATION HSE Operate Engineer Linking Device PS Field T FOUNDATION H1 T FO R R R T Segment 1 32 subscribers, incl. repeater Seg subscr. Seg. 3 Seg subscr. B 7 July 17, subscribers per link 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

segment length for copper cable Type A Non-Ex Area: 1.900 m Ex Area: 1.000 m Field T Us 12,6 VDC Is 100mA For the use of passive T-junctions in the Ex (Haz.

7 L S 30 m Line Lengths, Transmission Rate FF-H1 [Ex (Haz.) Area] Control OPC Server Ethernet TCP/IP FOUNDATION HSE Linking Device PS Operate Engineer IEC : FF-H1 Transmission rate fixed KBit/s max. segment length for copper cable Type A Non-Ex Area: m Ex Area: m Field T Us 12,6 VDC Is 100mA For the use of passive T-junctions in the Ex (Haz.) area: 8 H1 field devices acc. to FISCO [EEx ia] FOUNDATION H1 T T 4-fold T Caution! Segment length (H1 cable) considerably reduced by the voltage drop the limited supply current the cable diameter the number of H1 Slaves L T m B 8 July 17, L total = L T + ( L S ) m

L S 120 m Line Lengths, Transmission Rate FF-H1 [Ex (Haz.) Area] Control OPC Server Ethernet TCP/IP FOUNDATION HSE Linking Device PS Operate Engineer IEC 61158-2: FF-H1 Transmission rate fixed 31.

8 L S 120 m Line Lengths, Transmission Rate FF-H1 [Ex (Haz.) Area] Control OPC Server Ethernet TCP/IP FOUNDATION HSE Linking Device PS Operate Engineer IEC : FF-H1 Transmission rate fixed KBit/s max. segment length for copper cable Type A Non-Ex Area: m Ex Area: m (with FieldBarrier m) Field T Us 28 VDC Is 500 ma FOUNDATION H1 FieldBarrier *) EEx e For the use of the FieldBarrier in the Ex area: 16 H1 field devices acc. to FISCO EEx ia L T m *) 9 max. four FiedBerrier per segment B July 17, L total = L T + ( L S ) m

9 EDD Electronic Device Description, CF Capability File Operate Engineer Ethernet TCP/IP Control OPC Server Ethernet / IEEE 802 / FO FOUNDATION Fieldbus HSE Linking Device EDD / CF-Files: For display and configuration of FF device parameters Field IEC FOUNDATION Fieldbus H1 B 11 July 17,

10 Foundation Fieldbus with 800xA 12

11 800xA DCS with integrated FF OPC Server FF High availability means redundancy at all levels: AC800M System servers and workplaces Controllers FF HSE PROFIBUS DP Communication interfaces Linking Device RLM01 Remote IO Linking Device Remote I/O Linking devices Media/cable redundancy Drives FF H1 devices 13 PROFIBUS PA devices

12 Foundation Fieldbus redundancy Ethernet TPC/IP Redundant Communication to Controllers Redundant FF OPC servers FF HSE Multi Barrier Multi Barrier FF H1 HSE / H1 Linking Device Redundant Linking device 14 FF H1

15 FF Device Integration Fieldbus Builder FF AC 800M OPC Server FF CI860

architecture for distribution of control applications Two different

25 kbit/s HSE Subnet with 100 Mbit/s Controller connection to HSE via

(optionally redundant) Asset Optimization and Process Portal application

13 15 FF Device Integration Fieldbus Builder FF AC 800M OPC Server FF CI860 HSE Subnet LD 800HSE 4x H1 Links H1 Devices FF is an integrated architecture for distribution of control applications Two different fieldbus networks supported: H1 Link with 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

Fieldbus Builder Foundation Fieldbus Fieldbus Builder FF performs the

of FOUNDATION Fieldbus for entire FF network with HSE subnets and H1

Application configuration Automatic schedule generation Device

14 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 16 Incremental Download also for complete HSE subnets

15 FF Device Integration Library (1) Library contents: FF Block Library with FF standard blocks and device specific blocks HSE Device Library with B Linking Device LD 800HSE H1 Device Library with B FF field devices 17

field device management Asset monitoring

16 FF Device Integration Library (2) The devices offer all aspects required for field device management Asset monitoring Asset tree viewer Asset reporter Asset alarms / notification Maintenance management (CMMS connectivity) Faceplates Device documentation access 18 Latest Device List at -> System 800xA -> Device Management

17 FF Faceplates 19 FF Faceplates comply the IndustrialIT standards 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)

18 FF System Structure Fieldbus Builder FF 800xA Workplace AC 800M FF HSE Link FF HSE Link HSE Linking Device FF HSE Link LD 800HSE Pub/Sub Pub/Sub FF H1 Links Pub/Sub Pub/Sub Pub/Sub Pub/Sub Pub/Sub 20 FF H1 Links Pub/Sub Pub/Sub Pub/Sub

19 FF HSE application FF HSE Link Pub/Sub FF H1 Link FF H1 Link Pub/Sub Pub/Sub Pub/Sub H1 link A H1 link B AI OUT IN OUT CAS_ IN BK_CAL IN PID BK_CAL OUT AI OUT IN BK_CAL IN PID OUT BK_CAL OUT 21 CAS_IN AO

20 FF Parameter Displays Display and operation of block parameter Tabs with structured parameters Predefined tabs for the main parameter groups Device and Block dependent Adaptation via block library for all instances Import/export capabilities 22 All parameters listed

FF Network Components Two LD 800HSE build up

Devices Power Supply Spur Blocks Device 1

21 FF Network Components Two LD 800HSE build up a redundant Linking Device Module redundancy HSE interface redundancy H1 interface redundancy HSE Subnet Redundant Linking Devices Power Supply Spur Blocks Device 1 Power Supply H1 Link Device 2 23 Power Conditioner Device n

22 Foundation Fieldbus Basic Layout Max devices per connectivity server (application dependent) CI signals overall max 1000 for analog input max 500 for analog output max 500 for discrete input max 250 for discrete output Max. 30 Linking Devices per HSE subnet Max. 6 (12) CI860 at CEX Bus 24 Max. 16 field devices per H1 Link (application dependent) 40 signals per second per H1 link between H1 and HSE

23 FF Installation - References 26

Reliance Industries Ltd,India Butene Plant 27 Client The Reliance Group, is India's largest private sector enterprise, with businesses in the energy and

, is a Fortune Global 500 company and is the largest private sector company in India.

plastics and chemicals), textiles, retail, infotel and special economic zones. Application Automation of Butene Plant. Site Reliance Industries Ltd.

Engineering Station, 4 operator workplace, 1 IM server and 1Web Server.

24 Reliance Industries Ltd,India Butene Plant 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 B 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 1 st time on 800xA Platform) Asset Optimization,Alarm Management & Information Management system Remote Connectivity of Plant Data through CPM Smart Client In Operation Oct- 2011

JSW,India Sinter Plant Client Jindal Steel West(JSW) Limited, are Specialized

JSW group with turnover of 7 BUSD has diversified interests in Steel, Energy,

Information Technology. Application Complete automation of Sinter Plant.

package for the Sinter Plant Automation.

25 JSW,India Sinter Plant 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 B System 800xA as DCS package for the Sinter Plant Automation. The B 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

26 References for Foundation Fieldbus installation 1 Tata Steel, Jamshedpur Sinter Plant# IO on Profibus, 7OS Mar FF H1 devices 2 Reliance Patalganga Conitnuous Polymerisation Plant IO, 1ES/OS+5OS, FF, IM Mar FFH1 devices 3 Reliance Hazira Conitnuous Polymerisation Plant IO, 1ES/OS+5OS, FF, IM April FFH1 devices 4 Reliance Hazira Conitnuous Polymerisation Plant IO, 1ES/OS+5OS, FF, IM June FFH1 devices 5 JSW, Bellary Sinter Plant # IO on Profibus, 7OS Aug FF H1 devices 6 JSPL, Raigarh Sinter Plant 5000 IO on Profibus, 7OS Sep FF H1 devices 7 JSPL, Raigarh Coke Oven 800 IO 2OS Mar FF H1 devices 8 Tata Steel, Jamshedpur Sinter Plant# IO on Profibus, 7OS March FF H1 devices 9 JSW, Bellary Sinter Plant # IO on Profibus, 7OS Aug FF H1 devices 10 JSW, Bellary Sinter Plant # IO on Profibus, 7OS Dec FF H1 devices Reliance Hazira Butene Plant 1600 IO on Profibus, 5OS Oct FF H1 devices

27 THANKS 30

FOUNDATION Fieldbus Fieldbus Basics

FOUNDATION Fieldbus Fieldbus Basics Nik Suzaimi Berkat Honeywell Sdn Bhd, MALAYSIA On behalf of Fieldbus Foundation TM End User Seminar 25 Oct 2010 Kuala Lumpur, MALAYSIA Agenda H1 Basic Review. What is