I M P L I F Y I N G. Engineering a Process with FOUNDATION Fieldbus. By William R. Hodson, P.E. Honeywell Industrial Control September, 2001

Transcription

1 S I M P L I F Y I N G the of Engineering a Process with FOUNDATION Fieldbus By William R. Hodson, P.E. Honeywell Industrial Control September, Simplifying the Complexity of Engineering a Process with FF

2 Simplifying Engineering with FF What is FF Technology? What Needs to be Engineered? What Documentation Needs to be Changed? Making it Bearable with Tools DCS PAS F F 2 Simplifying the Complexity of Engineering a Process with FF

3 What is FF Technology? Dramatically Different Digital, Process Control Low Speed w/ bus power High Speed w/o(?) power Robust User Layer Extendible & Add l Function Blocks ice Description Files Data Link Synchronization 3 Simplifying the Complexity of Engineering a Process with FF

4 What Needs to be Engineered? Wiring Topology Home run, spurs, multi-drop, not ptto-pt 1900m + 120m total spurs (fn of number of ices) DCS/ PAS T T JB JB T 4 Simplifying the Complexity of Engineering a Process with FF

5 What Needs to be Engineered? Power Distribution Cost Savings Adequacy Redundancy DCS/ PAS 24vdc JB JB 5 Simplifying the Complexity of Engineering a Process with FF

6 What Needs to be Engineered? Function Block Residency IN with input and OUT with output Control-in-the-Field? The Rest? Best-of-Class Control Latency Co-location vs. Bridging AI DCS/PAS PID? AO 6 Simplifying the Complexity of Engineering a Process with FF

7 What Needs to be Engineered? Network Scheduling Macrocycle Sub-schedules Latency Bandwidth Usability 7 Simplifying the Complexity of Engineering a Process with FF

8 What Needs to be Engineered? Network Scheduling Macrocycle Sub-schedules Latency Bandwidth Usability 8 Simplifying the Complexity of Engineering a Process with FF

9 What Needs to be Engineered? VCRs DCS/ PAS I A M M M M M A JB M A M A JB M A 9 Simplifying the Complexity of Engineering a Process with FF

10 What Needs to be Engineered? VCRs S S S DCS/ PAS S P I A P M M M M S P M A e.g., 12 VCRs JB P M A M A P JB S P M A 10 Simplifying the Complexity of Engineering a Process with FF

11 What Needs to be Engineered? VCRs Address Limitations 11 Simplifying the Complexity of Engineering a Process with FF

12 What Needs to be Engineered? VCRs Address Limitations Overall System Capacity Traffic Routing Weakest Links The Pyramid 13 Simplifying the Complexity of Engineering a Process with FF

13 What Oper/App Needs to Oper/App be Engineered? VCRs Address Limitations Overall System Capacity Traffic Routing Weakest Links The Pyramid Server Controller Controller Controller Oper/App Networks Fieldbus Networks Oper/App Plant Info Network Oper/App Supervisory Network Fig 1 Generalized System Communications Architecture 14 Simplifying the Complexity of Engineering a Process with FF

14 What Oper/App Needs to Oper/App be Engineered? VCRs and Link Objects Address Limitations Overall System Capacity Traffic Routing Weakest Links The Pyramid Server Controller Controller Controller Oper/App Networks Fieldbus Networks Oper/App Plant Info Network Oper/App Supervisory Network Fig 1 Generalized System Communications Architecture 15 Simplifying the Complexity of Engineering a Process with FF

15 What Oper/App Needs to Oper/App be Engineered? VCRs and Link Objects Address Limitations Overall System Capacity Traffic Routing Weakest Links The Pyramid Server Controller Controller Controller Oper/App Networks Fieldbus Networks Oper/App Plant Info Network Oper/App Supervisory Network Fig 1 Generalized System Communications Architecture 16 Simplifying the Complexity of Engineering a Process with FF

16 What Oper/App Needs to Oper/App be Engineered? VCRs and Link Objects Address Limitations Overall System Capacity Traffic Routing Weakest Links The Pyramid Server Controller Controller Controller Oper/App FIM FIM Networks Fieldbus Networks Oper/App Plant Info Network Oper/App Supervisory Network FIM To/from another system Fig 1 Generalized System Communications Architecture 17 Simplifying the Complexity of Engineering a Process with FF

17 Dealing With All This! Lots of Benefits, but Lots of Responsibilities too! 18 Simplifying the Complexity of Engineering a Process with FF

18 Dealing With All This! Lots of Benefits, but Lots of Responsibilities too! Hundreds of parameters per device Physical ice Parameters Network & System Parameters Transducer Parameters Function Block Parameters PID AO Need to Change Documentation Need Tools to Help! TB AI RB NMIB SMIB Arith ISel 19 Simplifying the Complexity of Engineering a Process with FF

19 Changing Documentation? P&ID Drawings Loop Drawings SAMA or Control Strategy Drawings Data Sheets System Drawings 20 Simplifying the Complexity of Engineering a Process with FF

20 Changing Doc n - P&ID Drawings Not much change ISA S5.1 Dotted line with circles to represent the multi-drop signal line. 21 Simplifying the Complexity of Engineering a Process with FF

21 Changing Doc n - P&ID Drawings B FIC B FI TI FV FY Volume UE 101 B Volume UT Mass 101 Density Temp DIC B Mass DV DY TI 222 ZI 215 Fieldbus with PID in the host ZE OHM Thinner TE 222 B UT 201 Temp Viscosity Thick Stuff From Fieldbus User Network, Gary Addison, Equistar Chemicals LP 22 Simplifying the Complexity of Engineering a Process with FF

22 Changing Doc n - P&ID Drawings FV FCY Volume B UE 101 B Volume UT Mass 101 Density Temp B B FI Mass TI FI DI DV DCY TI 222 ZI 215 Fieldbus with PID in the field devices ZE OHM Thinner TE 222 B UT 201 Temp Viscosity Thick Stuff From Fieldbus User Network, Gary Addison, Equistar Chemicals LP 23 Simplifying the Complexity of Engineering a Process with FF

23 Changing Doc n Loop Drawings Conventional ices through marshalling to controller termination 24 Simplifying the Complexity of Engineering a Process with FF

24 Changing Doc n Loop Drawings With FF Segment Drawings Show all devices Show power introduction I. S. barriers (optional) Terminator locations Length of home runs Length of each spurs Types of wires used Used by Technicians Engineering 25 Simplifying the Complexity of Engineering a Process with FF

25 Changing Doc n Loop Drawings 24vdc Power Terminators & Expanders ices Power Conditioners From Fieldbus User Network, Bud Szoke, Keyspan Energy Canada 26 Simplifying the Complexity of Engineering a Process with FF Lengths

26 Changing Doc n Control Strategy Function Blocks Interconnections Location of Blocks!! Creation: By Configuring Engineer Using Control System Builder Look for a Single Drawing (integrated) 27 Simplifying the Complexity of Engineering a Process with FF

27 Changing Doc n Data Sheets As useful as ever, but More data!!! Current Draw Network Addresses VCRs available & Used Permanent Function Blocks Instantiated Function Blocks Now Self-Documenting: Serial Numbers Model Numbers Revision Numbers 28 Simplifying the Complexity of Engineering a Process with FF

28 Changing Doc n System Drawings Part of DCS All nodes of all networks Op stations Application Stations Printers, Servers Controllers Chasses Interfaces 29 Simplifying the Complexity of Engineering a Process with FF

29 Making It Bearable with Tools Is Fieldbus Complex or Simple? It s complex! but.. Tools can make it look simple! Look for help from experienced DCS/PAS system vendors. Look to see if Fieldbus is integrated or merely interfaced. Does it provide off-line (before device availability) configuration support? 30 Simplifying the Complexity of Engineering a Process with FF

30 Making It Bearable with Tools Does it provide device templates and block templates? to avoid re-defining every parameter value for every instance? Can user establish/override values? Can user add non-device-vendor supplied attributes? Can user drag-and-drop templates onto a drawing to create elements of an interconnected control strategy? 31 Simplifying the Complexity of Engineering a Process with FF

31 The Physical Tree Microsoft Explorer Familiarity Start at Interface Module. Links are Subordinate to FIMs ices are Subordinate to Links. Blocks are Subordinate to ices. Parameters are Subordinate to Blocks. Interface Module Link Interfaces Function blocks ices Transducer 32 Simplifying the Complexity of Engineering a Process with FF

32 The Physical Tree Microsoft Explorer Familiarity Start at Interface Module. Links are Subordinate to FIMs ices are Subordinate to Links. Blocks are Subordinate to ices. Parameters are Subordinate to Blocks. 33 Simplifying the Complexity of Engineering a Process with FF

33 The Strategy Tree Microsoft Explorer Familiarity Start at Controller Control Modules are Subordinate to Controller Function Blocks are Subordinate to Control Modules Parameters are Subordinate to Function Blocks. Controller Function Blocks Control Module 34 Simplifying the Complexity of Engineering a Process with FF

34 The Strategy Tree Microsoft Explorer Familiarity Start at Controller Control Modules are Subordinate to Controller Function Blocks are Subordinate to Control Modules Parameters are Subordinate to Function Blocks. 35 Simplifying the Complexity of Engineering a Process with FF

35 ice Object Instantiation Create an instance of a device model that corresponds to a device being delivered. Drag and drop onto appropriate link. 36 Simplifying the Complexity of Engineering a Process with FF

36 ice Commissioning Place the available device on the link. Find the device on the Physical tree. PD_TAG Address Unique ice ID Match it up with pre-configured device. Commission it (loads it). Start up device & blocks 37 Simplifying the Complexity of Engineering a Process with FF

37 ice & Block Monitoring Monitor the Physical Tree for link, device, and block status 38 Simplifying the Complexity of Engineering a Process with FF

38 ice & Block Monitoring Monitor the Physical Tree for link, device, and block status Monitor the Strategy Tree for control strategy and block status. 39 Simplifying the Complexity of Engineering a Process with FF

39 ice & Block Monitoring Monitor the Physical Tree for link, device, and block status Monitor the Strategy Tree for control strategy and block status. See live values and statuses on chart. 40 Simplifying the Complexity of Engineering a Process with FF

40 Exception Reporting Process Alarms detected by device fully integrated with DCS/PAS process alarms. ice Alarms detected by device fully integrated with device hardware and alarms. ice Alarms detected by interface fully integrated with device hardware and alarms. 41 Simplifying the Complexity of Engineering a Process with FF

41 Maintenance Data Access Reports from database of devices 42 Simplifying the Complexity of Engineering a Process with FF

42 Maintenance Data Access Reports from database of devices Bad & Uncertain values Propagation and reaction 43 Simplifying the Complexity of Engineering a Process with FF

43 Maintenance Data Access Reports from database of devices Bad & Uncertain values Propagation and reaction Events recorded on change Integrated with conventional 44 Simplifying the Complexity of Engineering a Process with FF

44 Maintenance Data Access Reports from database of devices Bad & Uncertain values Propagation and reaction Events recorded on change Integrated with conventional 45 Simplifying the Complexity of Engineering a Process with FF

45 ice Replacement Replacing Similar ices Decommission Old 46 Simplifying the Complexity of Engineering a Process with FF

46 ice Replacement Replacing Similar ices Decommission Old Commission New 47 Simplifying the Complexity of Engineering a Process with FF

47 ice Replacement Replacing Similar ices Decommission Old Save image Replace: Reconcile Differences Commission New Reclaim parameter values Note Differences 48 Simplifying the Complexity of Engineering a Process with FF

48 Simplifying Engineering with FF What is FF Technology? What Needs to be Engineered? What Documentation Needs to be Changed? Making it Bearable with Tools DCS PAS F F 49 Simplifying the Complexity of Engineering a Process with FF

49 Simplifying the Complexity of Engineering a Process with FOUNDATION Fieldbus Summarizing FF Technology Is Complex Is Cultural Change Requires Advanced Tools Tools are Growing in Strength Goal is Engineeringless Interoperability (ELI) 50 Simplifying the Complexity of Engineering a Process with FF

50 Simplifying the Complexity of Engineering a Process with FOUNDATION Fieldbus William R. Hodson, P.E. Honeywell Industrial Control 51 Simplifying the Complexity of Engineering a Process with FF

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