Diagnosis Concepts for Foundation H1 Physical Layer Diagnosis: from simple & effective to powerful & sophisticated
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1 Fieldbus Foundation India Committee Diagnosis Concepts for Foundation H1 Physical Layer Diagnosis: from simple & effective to powerful & sophisticated 1
2 Contents Why should we use diagnosis? What to diagnose on the physical layer? FF and diagnosis Various solutions and levels of diagnosis Summary & recomendation 2
3 Types of Maintenance Activities Source: Rong Gul, Shell Global Solution, Diagnostics from Safety Devices using FOUNDATION Fieldbus. 3
4 Opportunity based Maintenance for field devices Maintenance Alarm Failure Alarm 4
5 What to diagnose on the physical layer? 5
6 Recommendations from NAMUR an international user association of automation technology in process industries NAMUR represents approx. 15,000 PCS experts, of whom approx. 300 are active in 33 working groups NAMUR is engaged in the following key activities: pooling experiences among its member companies compiling aids and check lists for member companies setting user requirements on new devices, systems and technologies participating in national and international R. STAHL standardization India Jayanta Ghosh bodies 6
7 NAMUR and the Foundation 7
8 The Physical Layer Host Computer 24VDC PS+T Power Supply + Terminator Connection Block + Terminator T H1 Interface Home Run or Trunk Spurs Common Physical Layer Problems Wiring shorts Broken connection Ageing of cables Corrosion of connectors Noise from environment Extra/missing terminator Physical layer equipment fault Not enough device power Device 1 Device 2 Device 3 Note: one of the best trouble indicators is the jitter. Nearly all problems on a fieldbus do have an influence on the jitter 8
9 NAMUR NE107 Self-Monitoring and Diagnosis of Field Devices 9
10 NAMUR recommendation NE 107 Diagnosis categorized into 5 status signals Status signal Color Symbol Normal; valid output signal Maintenance required; still valid output signal Out of specification; signal out of the specified range Function check; temporary non-valid output signal Failure; non-valid output signal 10
11 Foundation & Diagnostics 11
12 Example: process picture 12
13 Various solutions and levels of diagnosis 13
14 Description of the 3 diagnosis concepts 1. Diagnosis for installation & trouble shooting All physical layer values are monitored and can be displayed on a screen or PC; experienced service people can evaluate the values and take appropriate action; 2. Diagnosis for background monitoring & pro-active alarming All physical layer values are monitored during operation; adjustable warning levels used for fieldbus quality deviation is detected and signalled by e.g. LEDs and a relay contact 3. Online diagnosis with permanent access to physical layer values All physical layer values are monitored and send continously to a host and/or asset management system for further evaluation, trending, history etc. Alarming procedure typically handled by host or asset managament system. Diagnosis Concepts H1 14
15 Installation & trouble shooting some available tools Oscilloscope Fieldbus Monitor Field Communicator Fieldbus Power Supply with integrated diagnosis & PC-interface; incl. redundant diagnosis Mobile Advanced Diagnostic Kit 15
16 background monitoring & alarming some available tools Fieldbus Power Hub, Advanced Diagnostic-Modul, Relay Output Fieldbus Power Supply with integrated diagnosis & PC-interface plus physical layer monitoring & alarming; incl. redundant diagnosis Diagnosis Concepts H1 16
17 Example: quality levels based on practical experiences Signal quality IEC minimum requirement >17
18 Online diagnosis with permanent access to physical layer values Fieldbus Diagnostics Module 8 Segments H1-interface Fieldbus Power Hub, Advanced Diagnostic-Module 4 Segments RS485-interface Diagnosis Communication Module 8 Segments H1-interface FOUNDATION fieldbus Diagnostic module 4 Segments HSE-interface Diagnosis Concepts H1 18
19 Various structures online diagnosis 1) separate network topology; w/o DCS integration - high software integration requirements (DTM, OPC), - no direct interface to DCS (no operator info) - additional network required - complex topology, difficult to maintain (updates etc.) + fast access to diagnosis data due to RS485/Ethernet topology + good user interface due to DTM technology 19
20 Various structures online diagnosis 2) separate network topology; with DCS integration - additional network required - additional serial interface in DCS required - additional data mapping in DCS Diagnosis Concepts H1 + direct integration into DCS (operator information acc. NAMUR) + native DCS link to Asset Management tools + fast access to diagnosis data due to Ethernet topology 20
21 Various structures online diagnosis 3) data transmission via H1 - H1 used with additional diagnostics data; function blocks etc. required (bus load) - slower access to live data + direct integration into DCS (operator information acc. NAMUR) + native DCS link to Asset Management tools + no additional network topology required + native H1 engineering Diagnosis Concepts H1 21
22 Summary & recomendation Diagnosis Concepts H1 22
23 Physical Layer Diagnostics Different principles Re-active diagnostics minimum requirement if there is a failure on the segment that stops communication (overload; short circuit; cable break) the operator needs to get immediate information. "maintenance required now" Pro-active diagnostics recommended for as much segments as possible if the signal quality deteriates (aging of cables, corrosion) the operator needs to get information before the segment stops working "maintenance required soon" Online diagnostics recommended for critical loops and if trained personal is available all quality relevant parameters can be remotely monitored & analyzed, alarm level settings can be configured, history files can be stored etc. 23
24 Trend? Keep It Simple! Diagnosis Concepts H1 24
25 Comparison of diagnosis solutions effectiveness in relation to each other increase of costs increase of availability size of bubble = degree of compelxity 25
26 Diagnostic then & now.. Foundation technology offers you a lot of possibilities to optimize your processes and increase the availability of your installations Now it is your turn to decide how to use it in a most efficient way Diagnosis Concepts H1 26
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