H1 + HSE FFB Integrated Architecture Demonstration

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Lee Carroll
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1 WHITE PAPER FOUNDATION Fieldbus H1 + HSE FFB Integrated Architecture Demonstration International Specialty Products (ISP) Lima, Ohio

2 Abstract What End Users have asked for The challenge facing industry today requires end users to approach process automation with a business focus. This focus brings the operating objectives of the corporation into the selection process for technology. To meet these objectives End Users want an automation system built on open standards, significantly reducing the high cost of maintaining proprietary integration software and hardware. To operate more efficiently, these users require knowledge workers that can utilize the capabilities of the technology to enable improvements in plant productivity and return on assets through improvements in asset utilization and equipment life extension, true distributed control leading to increased system availability, reductions in fixed and variable maintenance costs, system wide, reduction or elimination of non-scheduled shut downs and flexible configuration to meet the dynamics of market demand The forward thinking specification developed by ISP reflects these modern day requirements and their confidence that Foundation fieldbus enables the successful attainment of the requirements to provide the CAPEX and OPEX improvements that support the technical and business metrics of the corporation. By partnering with the Fieldbus Foundation and its member companies, ISP recognized the opportunity to meet their objectives as well as support the Foundation s Key Objectives

3 Key Objectives Demonstrate FOUNDATION fieldbus capabilities and benefits in complex applications Catalyze HSE product development Aid in marketing and globalization of FOUNDATION fieldbus technology Show High Speed Ethernet and Flexible Function Blocks in a live plant environment Show integration of diverse and disparate control systems and subsystems (Foundation Fieldbus and non-foundation fieldbus control systems Introduction The ISP (Formerly BP) Lima, Ohio project is the result of a valid end user specification driven by ISP engineering reflecting the technology and operating requirements of the facility. When a specification is delivered by the end user or customer, all aspects of the deliverables are affected. The ISP Lima, Ohio, project defined its specification to bring a clean, world class manufacturing process on line. This specification produced an automation solution with more impact and importance than originally planned, with no schedule impact to the demonstration, product displays, or the overall project. The fieldbus ISP demonstration project provides valuable, clear experience for end users seeking to replace or augment proprietary control systems with an open, interoperable fieldbus architecture, enabling robust, reliable control at the field level.

4 Flexible Function Blocks As identified earlier, FFBs are a key component of the FOUNDATION fieldbus architecture for plant wide integration. MIS APPLICATION PACKAGES DATA SERVERS HSE High Speed Control and Integration Backbone H1 INSTRUMENTATION Developed for the FOUNDATION fieldbus HSE (100 Mbps) technology program, but also compatible with H1 (31.25 kbps) fieldbus systems, FFBs, which are application-specific, bring the full instrumentation integration part of the fieldbus solution into play. FFBs reside at the fieldbus User Layer along with standard Function Blocks and enable control strategies such as supervisory data acquisition, batch control, Programmable Logic Controller (PLC) sequencing, and Input/Output (I/O) interfacing, including gateways to other plant device networks. The use of FFBs enhances the ability to move control functionality to the fieldlevel. For example, with FFBs running in an HSE linking device, a single physical device can support batch and logic control. With this approach, users can often eliminate the need for proprietary unit controllers. Unlike other solutions requiring a master-slave link, this technology places process node-aware logic local to the task. Two types of FFBs pre-configured and fully-configurable versions are available.

5 Pre-configured FFB Pre-configured FFBs have a pre-defined number/type of I/O parameters like standard function blocks, but the algorithm is configurable. Since the I/O is predefined, the Electronic Device Description (EDD) is also predefined. The initial FFBs with Multiple Input/Output (MIO) blocks have eight analog or discrete parameters per block: MAI, MAO, MDI, and MDO. MIO blocks are used for remote I/O interfacing and simple gateway applications. The Fieldbus Foundation released specifications for the pre-configured FFBs in March Inputs ALGORITHM Example: PID Outputs Contained Parameters (Manual, Auto, etc.) Fully-configurable FFB Fully-configurable FFBs are used for more complex applications, and allow both the number/type of I/O parameters and the algorithm to be configured. In this case, the EDD is generated on the fly by the configuration tool. FFBs are created using programming tools based on standards such as IEC Once created, FFBs are instantiated and connected to other blocks just like standard Function Blocks. Specifications for the fully-configured FFBs were released in September 2001 after completion of field tests at the Lee College Fieldbus Center in Baytown, Texas, USA Inputs Outputs AI MAI ALGORITHM IEC Application AO MAO

6 Open Design For the live demonstration application in Lima, a FOUNDATION fieldbus system consisting of H1 field devices and HSE linking devices was installed on a filter cleaning system. The demo highlighted implementation of complex logic in HSE FFBs in the field. The logic utilized both discrete and analog I/O residing on H1. The co-existence of diverse control systems from various manufacturers using HSE, and the interoperability of HSE linking devices and associated controllers between different suppliers was demonstrated. In addition, the demonstration showed the suitability of existing FOUNDATION fieldbus devices for high-speed batching and sequencing of discrete systems. The HSE devices and media were also redundant to ensure high system availability. This ISP demonstration showed how FOUNDATION fieldbus H1 and HSE FFB technology integrate with OPC, forming an open, interoperable plant infrastructure applicable for either Brownfield or Greenfield projects improving process performance and delivering significant Operating Expense (OpEx) and Capital Expense (CapEX) savings. FOUNDATION fieldbus was specifically developed as an open environment providing the ability to integrate multiple disparate systems, subsystems, applications and devices. The technology provides the Freedom to Choose and the Power to Integrate across the plant enterprise, enabling end users to choose best-in-class automation solutions that work together seamlessly regardless of their supplier. Application Reference As an application reference, the Lima BDO technology demonstration was a joint project initiated by BP Amoco Chemical Company, an indirect subsidiary of BP plc., and the Fieldbus Foundation. ISP, through a subsidiary, acquired BP s BDO operations in March BDO product is a key building block for specialty chemical products used in pharmaceutical, personal care, food, beverage, coatings, oil field and other related products. Present Day The Lima, Ohio, facility hosts the newest FOUNDATION fieldbus technology demonstration in a plant environment in its world class BDO production facility. This effort was made possible through the dedication and support of BP management, BDO facility management, plant engineering and operations, and the cooperation of over seventeen Fieldbus Foundation team members.

7 Live Demonstration The ISP-licensed Maleic Anhydride manufacturing process utilizes in-line filters to remove fine particulates from an intermediate process stream. The process operator chooses a cycle time to perform a periodic blowback and dump on three particulate filters. Each filter has ten 8 quarter-turn automated butterfly valves that are controlled by Sequential Function Charts (SFC) in the Distributed Control System (DCS) using existing DCS permissives. The control logic runs on a Foundation fieldbus H1, HSE and FFB integrated architecture. For the demonstration, the DCS discrete I/O to the valves is replaced with H1 fieldbus devices. The SFC logic for one filter has been moved from the DCS to FFBs resident in HSE field devices. These devices are installed in a junction box mounted in the plant near the middle filter. The DCS control runs the overall sequence, which invokes the HSEresident scheme at the appropriate time. The HSE/FFB devices were located remotely at the filter deck itself to demonstrate how a packaged systems vendor could integrate an HSE/FFB control scheme. The HSE link to the field is accomplished using Commercial Off-the-shelf (COTS) fiber optics and network devices. The FFB logic is configured by the HSE FFB device supplier s engineering tool. Example configurations are shown below.

8 Conclusion The integrated instrumentation system deployed at the facility and detailed in this report demonstrates and proves that an optimum automation architecture exists today; that Control on the Wire is a safe, reliable strategy for operation; that open standards can be employed to accomplish enterprise integration; that what was once only a specification is now an operating reality, and finally that Foundation Fieldbus is applicable and beneficial for either retrofits and modernizations and/or Greenfield projects. The members of the Fieldbus Foundation bring you the Freedom to Choose and the Power to Integrate best-in-class automation solutions, seamlessly, around the world regardless of your choice of supplier. FOUNDATION fieldbus is a technology with the technical depth to enable true flexibility in solving your process challenges, regardless of industry, including legacy system integration with an open, world class standard. FOUNDATION fieldbus HSE and Flexible Function Blocks build on H1 + Function Blocks to deliver CAPEX savings for less wiring and equipment, smaller footprint, reduced engineering and commissioning manpower and time; and OPEX savings through increased reliability and system availability (Control in the Field), advanced diagnostics leading to improved asset utilization and asset life extension, reduction in fixed and variable maintenance costs and reductions in unscheduled shutdowns. The integrated FOUNDATION fieldbus solution of H1, HSE and FFBs, combined with strong product design and good engineering practices, have defined a plant environment that moves beyond the confines of previous engineering limitations. FOUNDATION fieldbus enables seamless integration across multiple vendor offerings and multiple applications bringing a best-in-class, fully-integrated solution meeting the end user requirements for both technical and operational excellence. About the Fieldbus Foundation The Fieldbus Foundation is a not-for-profit corporation consisting of over 350 leading process and manufacturing automation companies worldwide whose major purpose is to provide an open and neutral environment for the development of a single, international, interoperable fieldbus. In this environment, end users, manufacturers, universities and research organizations are working together to develop the technology, provide development tools, support and training, coordinate field trials and demonstrations, and enable product interoperability. Visit our web site at

9 Appendix FOUNDATION fieldbus and Function Block (terminology see definitions), About Function Blocks Implementing Control 7C0000EC9B? Other Install references can be found at:

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