Foundation Fieldbus - Working Today, Preparing for tomorrow

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1 Foundation Fieldbus - Working Today, Preparing for tomorrow Standards Certification Ian Verhappen Director, Industrial Networks MTL Instrument Group Education & Training Publishing Conferences & Exhibits

2 Today s Agenda Fieldbus Global Projects Global Projects Middle East Fieldbus Solutions Today EDDL H1 and HSE Digital Control System Trends EDDL Improvements Fieldbus Safety HSE

3 Fieldbus Implementation Standards Certification Education & Training Publishing Conferences & Exhibits

4 Distribution of Device Types 255 unique and 378 total devices registered HSE LD Flow Pressure Temperature Valve Controller Other Analytical Level PS 81

5 Fieldbus Today Markets Served 600,000 devices 9000 Systems

6 Market Distribution Industry LA 12% Global Mining and Metals 3% Education 3% Other 8% Chemical 22% Pulp and Paper 4% AP 13% NA 43% Food & Beverage 9% MEA 7% EUR 25% Pharmaceutical 9% Power 13% Oil & Gas 29%

7 Installed Devices Fieldbus Devices Global Middle East

8 Today s Fieldbus Solutions Standards Certification Education & Training Publishing Conferences & Exhibits

9 FOUNDATION Fieldbus H1 4-20mA fieldbus P.S. P.S. Fieldbus devices are connected in parallel on the bus, which carries digital data from/to all the devices on the bus. Fieldbus devices provide information to all other devices on the network.

10 High Speed Ethernet 11 New FF Specifications New Protocol Specifications for HSE System Architecture Addendum System Management Addendum Network Management Addendum Data Link Addendum - Bridging Ethernet Presence Field Device Access Agent Redundancy FUNCTION BLOCKS HSE APPLICATION PROTOCOL STANDARD ETHERNET STACK Ethernet Physical Layer New Function Block Specifications for HSE Flexible Function Block (MIO) Flexible Function Block (61131 ) FFB Application Guide Multi - Variable Optimization Commercial, Off The Shelf (COTS) Ethernet Equipment

11 FF Bridges Between FF Networks Linking Device FIELDBUS H1 FIELDBUS H1 DEVICES ON DIFFERENT NETWORKS

Live Plant Demo Integrated Architecture Fiber Presentation Room Live Video Display Presentation Filter Deck in Plant Control House Ethernet Switches Turck, Hirschmann Configuration Smar, Softing DCS

12 Live Plant Demo Integrated Architecture Fiber Presentation Room Live Video Display Presentation Filter Deck in Plant Control House Ethernet Switches Turck, Hirschmann Configuration Smar, Softing DCS Emerson Yokogawa Field Eye HSE Fiber OPC Servers Smar, Softing Plant HSE Ethernet Switches Hirschmann HSE FFB Smar, Softing H1 Plant H1 HSE Linking Devices Smar, Softing Blowback and Dump Process Filter B Invensys, P+F, Westlock, Yamatake, Yokogawa

Live Demo Modified Logic Filter B Sequence Logic Runs in HSE FFBs Filter A Filter B Filter C Filter A 1 Filter B 4 Filter C Run in DeltaV Run in HSE FFBs Run in DeltaV 2 1 3 4 DeltaV Commands Smar

13 Live Demo Modified Logic Filter B Sequence Logic Runs in HSE FFBs Filter A Filter B Filter C Filter A 1 Filter B 4 Filter C Run in DeltaV Run in HSE FFBs Run in DeltaV DeltaV Commands Smar FFB to run HSE 2 Smar FFB operates 5 valves and then passes control to the Softing FFB Softing FFB operates 5 valves and then passes control back to DeltaV HSE Emerson DeltaV HSE 3 Smar FFB Junction Box Softing FFB H1 H1 H1 Nitrogen Pressure Invensys Pressure across Filters Yamatake Nitrogen Temperature Yokogawa Permissives Westlock Positioners Driving 8 Butterfly Valves

14 HSE Not The End of H1 H1 HSE Speed kbit/s 10 Mbit/s or 100 Mbit/s Distance (per segment) 1,900 m (1.2 miles) 100 m (300 ft) Two-wire Yes No Multidrop Yes No (UTP) Bus-power Yes No Intrinsically safe Yes No Redundancy No Yes Deterministic Yes Yes (with switches) H1 used for field instruments HSE used at the host-level H1 and HSE complement each other

15 Operations & Maintenance Longer duration to scheduled outage Faster time-to profit Safer operation Cash Flow Higher sustained production with minimize costs Shorter scheduled outage Fewer unscheduled outages

16 Expanded System View 15.3 ma TAG = LIC-012 VALUE = UNITS = m 3 STATUS = GOOD ALARM = Y/N DCS: Limited system view. Does not include diagnostics and other information from field devices. FCS: Expanded view. Field devices are part of the system.

17 Increased Information Information is available for decision making Conventional analog system 4-20 ma has very limited information content (PV only) Fieldbus system instrument identification, location status of PV ambient conditions diagnostics configuration instrument characteristics calibration information: date, method, location, etc.

18 Typical Refinery Instruments Distribution Flow 9% Level 8% Others 37% Pressure 11% Flow 1128 Level 931 Pressure 1379 Temp Valves 2404 Others 4566 Temperature 15% Valve 20%

19 Areas of failures Actuators - 30% Wiring - 5% I/O - 15% CPU - 2% Sensors - 48%

20 Device Maintenance Effort Zero Drift, 6% Process Interface, 6% Failure, 4% Routine Check, 35% ReRanging, 20% No Problem, 28% 63% of time is spent investigating problems that do not exist. Fieldbus will tell you this so it will no longer be necessary to check these reports.

21 Asset Management Drivers Maintenance Cost Reduction Drives 45 End Users 40 40% of Mfg. Cost is Maintenance 50% of Maintenance Is Corrective times More Costly Than Preventative 30 Maintenance Preventative Maintenance is Done 20 25% of Time 5 Times More costly Than Predictive Maintenance 60% of Preventative Maintenance is 5 Unnecessary Correct Prevent Predict From ARC Independent Research

22 Maintenance Savings Estimated 10-20% saving in maintenance Assignment of maintenance tasks to operators / right people to do the task Better field diagnostics Better preventative maintenance data Less false alarms Faster troubleshooting

23 Operations & Maintenance Operational efficiency improved by up to 2% Predictive maintenance schedule maintenance based on device diagnostics increase plant availability

24 Characterizing Change Mean Standard Deviation: σ 68% 3σ 2σ 1σ 95% 1σ 2σ 3σ >99%

25 Impact of Tighter Loop Control Control Limit Digital Analogue Pneumatic Manual Digital Analogue Pneumatic Manual

Maintenance Expandability and long term maintainability sensors are field-upgradeable open, interoperable technology buy spares from third

26 Maintenance Expandability and long term maintainability sensors are field-upgradeable open, interoperable technology buy spares from third parties to keep price down buy spares from those who stock, i.e. user need not keep stock best of its kind device may be used independent of manufacturer

diagnostics) power supply system wiring components

27 Periodic diagnostic monitoring Host control system Instrument Management Software (including fieldbus diagnostics) power supply system wiring components Controller I/O Fieldbus Hand-held Diagnostic Module

28 Commissioning procedure Connect fieldbus tester at each field device and at rack room record readings in each location Upload readings to PC

29 On-line diagnostic monitoring Host control system Instrument Management Software (including fieldbus diagnostics) F800 Series fieldbus power supply system Segment 1 of 8 Field junction box H1 Fieldbus Controller I/O Basic failure alarms F809F on-line Diagnostic Monitor

30 MTL F809F on-line monitoring Continuously monitors segment parameters Monitors 8 fieldbus segments Reports parameters over FOUNDATION fieldbus TM H1 Module is a Fieldbus device Diagnostic software Integrated in Asset Manager system instrument management software

31 MTL F809F on-line monitoring Open solution FOUNDATION fieldbus TM H1 device easily integrates with Honeywell Experian PKS system Full device description support Future proof architecture Fieldbus DTM support planned Enhanced eddl support planned Minimises total cost of ownership by integrating into fieldbus H1 system No additional hardware costs No additional costs in installing, commissioning and maintenance of separate network Instrumentation team use same software for physical layer and fieldbus device diagnostics

32 MTL F809F prototype results Resource block F809FS device segment transducer blocks Discrete input block

33 Fieldbus Future Standards Certification Education & Training Publishing Conferences & Exhibits

34 EDDL Cooperation Team

Maintain Enhancements in IEC Format Phase 1 Enhancements Graphing Use EDDL for graphical

from device Enhanced User Interface Use EDDL to describe screen layout Enhanced Data Storage-

Enhanced User Interface Phase 1 Specification in IEC 61804-3 Edition 1 CDV Phase 1 Approved

35 Maintain Enhancements in IEC Format Phase 1 Enhancements Graphing Use EDDL for graphical display of static Y-t and XY data Charting Use EDDL for graphical display of real-time data from device Enhanced User Interface Use EDDL to describe screen layout Enhanced Data Storage- Use EDD to securely store data on the host Graphs Charts Images Enhanced Data Storage Enhanced User Interface Phase 1 Specification in IEC Edition 1 CDV Phase 1 Approved Change Requests in IEC Edition 1 CDV Phase 1 Interoperability Guideline is IEC Edition 1 DTR

36 DD Cooperation Project Visualization Extensions for Sensor/Actuator Configuration, Motor Control, Radar Level Configuration, Valve Signatures and Other Complex Configuration and Diagnostic Applications Parameter organization Windows, dialogs, group boxes Integration of images Support for charts and graphs Multiple plots Interactive zooming Direct editing of graphs Emphasis, key points, notes

37 DD Cooperation Project Extensions for Improved Control of Data Storage on the Host System by the Field Device for Complex Valve Diagnostics, Sensor Drift, Sensor/Actuator Diagnostics and Archived Valve Signatures Applications Independent of host operating system Independent of host file system

38 DD Cooperation Project Enhanced User Interface Example Dialogs Group Boxes Window Parameter Organization

DD Cooperation Project Radar Gauge Example Configuration of thresholds and false echo areas GRAPH DD Cooperation Project Radar Gauge Threshold

39 DD Cooperation Project Radar Gauge Example Configuration of thresholds and false echo areas GRAPH DD Cooperation Project Radar Gauge Threshold Calibration Echo Curve Filter WAVEFORM (Data from Device) AXIS MENUS & METHODS (Enhanced UI) ARRAY(s) (Device Data) FILE/LIST (Persistent Data)

40 DD Cooperation Project Valve Step Example Real-time Step Response of a valve. Valve Step Response Diagnostics Blue line is a reference retrieved via FILE and ARRAY Travel (From device) SOURCEs (Stored Data and Data from Device) CHART AXIS Setpoint (Stored) MENUS & METHODS (Enhanced UI) ARRAY(s) (Device Data) FILE (Persistent Data)

41 DD Cooperation Project Valve Signature Example Valve Signature (Hysteresis) as a measure of the air pressure to stroke the valve open and close Valve Signature Blue line is a reference retrieved Open Stroke via FILE and ARRAY WAVEFORM (Data from Device) GRAPH AXIS Close Stroke MENUS & METHODS (Enhanced UI) ARRAY(s) (Device Data) FILE/LIST (Persistent Data)

42 DD Cooperation Project Best Fit Example Best Fit line can be drawn using new features in DD Methods. Valve Signature Blue line is a reference retrieved via FILE and ARRAY Best Fit GRAPH WAVEFORM (Data from Device) AXIS MENUS & METHODS (Enhanced GUI) ARRAY(s) (Device Data) FILE (Persistent Data)

43 DD Cooperation Project Motor Control Example Display motor starts, operating hours, number of overload trips, etc. MOTOR SYMMETRY Image MOTOR PARAMETERS

44 EDDL Phase 2 Scaleable Device Integration Simple and complex device integration requires only EDDs Advanced requirements utilize OPC UA client applications driven by OPC UA server resident EDDs for online and offline data access... Client-Specific Features OPC UA Client OPC UA Server (UA = Unified Architecture) Simple Complex Device Device.. EDD EDD EDD. EDD.

45 Fieldbus Safety Standards Certification Education & Training Publishing Conferences & Exhibits

Phase 2 Application Architecture Client Applications HSE + OPC UA Web Services OPC UA Enhanced Procedural Support for Complex Devices Off-Line Configuration + HSE Remote I/O OPC UA Client(s) Operator

46 Phase 2 Application Architecture Client Applications HSE + OPC UA Web Services OPC UA Enhanced Procedural Support for Complex Devices Off-Line Configuration + HSE Remote I/O OPC UA Client(s) Operator HMI HSE OPC UA Server(s) EDD HSE HSE FFB EDDL Cooperation Project Configuration/ Maintenance HSE Linking Device HSE HSE Field Device Blue line is a reference retrieved via FILE and ARRAY Trend/Historian. Asset Management H1 FFB Plant/Enterprise L H1 H1 Remote I/O FFB e.g. MRP,ERP, Optimization

47 Fieldbus Safety Design to IEC FF-SIS Communication Diagnostics Black Channel Design to IEC New SIS Function Blocks & Function Block Diagnostics

48 Example SIS Application Analog 2 out of 3 Voter SIS_ WL SIS_ RB SIS_ AI SIS_ WL SIS_ RB SIS_ AI SIS_ AVTR SIS_ DO SIS_ DI SIS_ WL SIS_ RB SIS_ AI SIS_ WL SIS_ RB Write Lock (WL) S

49 New Fieldbus Initiatives Standards Certification Education & Training Publishing Conferences & Exhibits

50 Fieldbus Wireless Communications of Diagnostic Data for Maintenance Integrate with Asset Management solutions Accessible by Technicians in the field Build on work of HART Wireless and ISA-100 Committees

51 HSE Remote I/O Requirements for High Speed Ethernet Remote I/O (HSE-RIO) discrete I/O gateways to other lower level networks HART Profibus Modbus AS-I DeviceNet, etc. Preliminary Schedule Started January 2007 Completion Q4 2008

52 FOUNDATION Foundation Fieldbus Today s Solution The platform for Tomorrow Standards Certification Education & Training Publishing Conferences & Exhibits

53 Questions Ian Verhappen Director Industrial Networks Phone:

54 Economic Life Cycle Engineering, Construction, & Commissioning/Start-up Operations & Maintenance Replace Cash Flow Time Analog fieldbus

55 Fieldbus Project Costs Estimated Project Savings Materials/Field Devices: Increased by 25% Installation Labor: Reduced by 50% Commissioning: Reduced by 75% Engineering: Reduced by 50% Overall Capital Savings of 25 30% However savings will only be realized if the project is planned as a fieldbus project.

56 Fieldbus as a Cable Multiplier J-Box Fieldbus devices Three existing 4-20 ma Pairs T T J-Box Three existing pairs, one used for fieldbus

57 Termination count Field FT-100 FCV-100 TT-100 PT Junction Box Marsh Cab Marshalling done in Junction Box with Fieldbus so Marsh Cab is optional I.S. Barrier Totals: Analog 34 Fieldbus I/O Assembly Conventional analog termination Fieldbus termination (also included in conventional termination count)

58 Multivariable Measurements Conventional: 1 measurement / device Penetration / signal Fieldbus: Multiple measurement / device Fieldbus: Multiple measurements Pressure Temperature Mass Flow Volumetric Flow Conventional: 1 measurement

59 Reduced Space Requirements Wiring & Rack Conventional System Cabinet Cable Cable cost Junction box Cable Conduit Processing of cable Marshalling Barrier Fieldbus System Case of 350 I/O points Courtesy of Emerson Process Managment

60 I/O Reduction Courtesy of Shell Deer Park Courtesy of Shell Deer Park Courtesy of Cargill Courtesy of Shell Deer Park Courtesy of Shell Deer Park Courtesy of Cargill

61 Project Cost Benefits Commissioning Costs Without fieldbus: 2 hours / device for 2 technicians Individually ring out wiring Attach device Verify communications Verify link to control strategy

62 Project Cost Benefits Commissioning Costs With fieldbus: 25 minutes / device for 1 technician Check segment wiring Attach device Drag-and-drop commissioning

Electronic Device Description Language

International Standards Electronic Device Description Language Martin Zielinski 1 FOUNDATION fieldbus & Standards OSI Model USER LAYER USER LAYER DD IEC 61804 USER LAYER DD IEC 61804 7 APPLICATION LAYER