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 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 31.25 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, 2012 3 P L MIS IEC 61158 APPLICATION PACKAGES P L P L P L
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 6 6 6 6 SESSION LAYER TRANSPORT LAYER 5 4 COMMUNICATION STACK 5 4 5 4 TCP/UDP 5 4 NETWORK LAYER 3 3 3 IP 3 DATA LINK LAYER 2 2 H1 DLL 2 Ethernet/IEEE 802 2 B 4 4 PHYSICAL LAYER 1 PHYSICAL LAYER 1 H1 PHY @ 31.25 kbit/s 1 Ethernet/IEEE 802 @ 100 Mbit/s 1
Foundation Fieldbus Network Operate Engineer Ethernet TCP/IP Control Linking Device OPC Server Ethernet / IEEE 802 / FO FOUNDATION Fieldbus HSE Engineer Field PS IEC 61158-2 FOUNDATION Fieldbus H1 B 5 July 17, 2012 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
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. 2 32 subscr. Seg. 3 Seg. 4 32 subscr. B 7 July 17, 2012 7 232 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
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 61158-2: FF-H1 Transmission rate fixed 31.25 KBit/s max. 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.) 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 1.000 m B 8 July 17, 2012 8 L total = L T + ( L S ) 1.000 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 31.25 KBit/s max. segment length for copper cable Type A Non-Ex Area: 1.900 m Ex Area: 1.000 m (with FieldBarrier 1.900 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 1.900 m *) 9 max. four FiedBerrier per segment B July 17, 2012 9 L total = L T + ( L S ) 1.900 m
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 61158-2 FOUNDATION Fieldbus H1 B 11 July 17, 2012 11
Foundation Fieldbus with 800xA 12
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
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 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 31.25 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 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
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
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 www.abb.com/controlsystems -> System 800xA -> Device Management
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)
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
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
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 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
Foundation Fieldbus Basic Layout Max. 4000 devices per connectivity server (application dependent) CI860 1000 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
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 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 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- 2006. 28
References for Foundation Fieldbus installation 1 Tata Steel, Jamshedpur Sinter Plant#3 5000 IO on Profibus, 7OS Mar-05 80 FF H1 devices 2 Reliance Patalganga Conitnuous Polymerisation Plant - 7 4500 IO, 1ES/OS+5OS, FF, IM Mar-06 150 FFH1 devices 3 Reliance Hazira Conitnuous Polymerisation Plant - 10 4400 IO, 1ES/OS+5OS, FF, IM April-06 275 FFH1 devices 4 Reliance Hazira Conitnuous Polymerisation Plant - 11 6600 IO, 1ES/OS+5OS, FF, IM June-06 50 FFH1 devices 5 JSW, Bellary Sinter Plant #1 5000 IO on Profibus, 7OS Aug-06 80 FF H1 devices 6 JSPL, Raigarh Sinter Plant 5000 IO on Profibus, 7OS Sep-06 80 FF H1 devices 7 JSPL, Raigarh Coke Oven 800 IO 2OS Mar-06 250 FF H1 devices 8 Tata Steel, Jamshedpur Sinter Plant#4 5000 IO on Profibus, 7OS March-08 80 FF H1 devices 9 JSW, Bellary Sinter Plant #2 5000 IO on Profibus, 7OS Aug-09 80 FF H1 devices 10 JSW, Bellary Sinter Plant #4 5000 IO on Profibus, 7OS Dec-11 80 FF H1 devices 29 11 Reliance Hazira Butene Plant 1600 IO on Profibus, 5OS Oct-11 300 FF H1 devices
THANKS 30