NeSSI Gen 2 Status of the Sensor Actuator Manager (SAM): Overcoming - - PowerPoint PPT Presentation

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NeSSI™ Gen 2 Status of the Sensor Actuator Manager (SAM): “Overcoming the Perception of Complexity”

Patrick Lowery 1/26/2009

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GEN 2 Bus is Done!

Two options, one based on open standard Multi-drop, hot-swappable Deterministic, auto-fault tolerant Multi-variable data capabilities Self diagnostics and asset management An entire IS CANbus solution package is

literally weeks away from IS certifications!!

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A “Complete Solution” was required:

The ability to integrate pressure, temperature, flow,

• ther

multi-variable sensors, valve control and ALL of the associated equipment, power supplies, and cables that are needed. The GEN 2 bus lays the groundwork for more sophisticated low-powered sensors for the next phase of GEN 3. But how can the end user implement today?

Challenge

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The Embedded SAM

ABB PGC-5000 style implementation shown Siemens Maxum GC has a version also

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What if a Smart GC is not available?

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What if a non Smart GC is not available?

Must have some sort of “bus master”

“Missing Link” that could stop implementation of GEN2

in the field outside of Smart GC’s (or other analyzers w/ embedded SAM’s)

Must have the Sensor Actuator Manager or “SAM”

Lesson from the past (GEN1):

Must have the entire solution figured out & available Must overcome the strong perceptions in the industry

Too complex to understand by the norm More expensive than traditional methods

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Myth Busting

“Too complex”

The core value proposition of GEN2 is to

provide information from SHS to act proactively to avoid process down time

If the core value is information, must put

sensors on the SHS

This has been accomplished by many end

users with the GEN 1.5 methodology

PLC or Industrial PC with analog I/O and digital

I/O

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Myth Busting

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Myth Busting

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Original SAM definition

Going back to the original NeSSI™ Gen 2 draft, SAM was defined

roughly as a device which needed to have the following features:

Graphical HMI Local (short range) Wireless Maintenance Tool Host to the IS Sensor/Actuator (GEN2) Bus Gateway to an Ethernet LAN and DCS/maintenance systems Must support multiple communication protocols

OPC HTTP FF, etc.

Software Applets for Sample System Repetitive Tasks

(Application Interface)

Provides “Open” Development Space for Custom Software”

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The main problem with the “ideal” NeSSI vision

• f SAM is one must

Develop such a product, $$$ Direct connections to the DCS require

Data historians Firewalls OPC gateways Non volatile memory and automatic backup Robust network security

Must circumnavigate the plethora of different corporate security

IT issues

Quote from one of the NeSSI visionary founders at

ExxonMobil, “ExxonMobil is locked down tighter than the National Security Agency”

Myth Busting

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Realistic Definition of SAM

CIRCOR has made a “bridge” to link GEN2 bus to the SAM

• Bridge between C1D1 (Zone 1) and C1D2 (Zone 2) for CAN

communications

• Integrated analog I/O to digitize 4-20mA devices
• Obtains inventory of all CAN networked devices using electronic data

sheets

• Monitors total system “inventory” and health
• Has a basic application interface that can pass alarm triggers and set

points down to devices and pass alarms and data up to GC

• GC is not the sample system master per se, but a data server
• Future upgrade path for CAN device metadata to provide system

configuration data up to HMI at GC interface or “stand alone SAM”

• Still need a corporate IT approved link to the DCS

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CIRCOR CIM76

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CIM76 and SMART Module

AVAILABLE FOR CONNECTION TO ABB FIBER CANopen, PROFINET, ETHERNET, AND MODBUS

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Too Expensive

Today, in order to build an “analog sensor” you must:

convert an analog signal to digital Implement calibration and DSP algorithms Re-convert into analog Commonly must use expensive DAC’s and amplifiers Also must commonly provide galvanic (mini-transfomer) isolation to

prevent ground loops

To implement digital sensors

Only need to convert analog sensor to digital Convert core TTL logic level information into a “bus structure” Off the shelf chips exist today for many bus flavors CANbus is the flavor of choice because

• Inexpensive, 200M+ CAN chips sold per year
• Easy to implement
• Open standard
• Off the shelf tools
• Can be linked to many industrial fieldbuses

Myth Busting

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Too Expensive

Cost comparison of GEN1.5 (using distributor list price) to

GEN2 system (using CIRCOR list price of CANbus device)

Myth Busting

These benefits are based on a 1 stream GC system, w/ bypass with all of the minimally needed sensing points to avoid a system failure or filter blockage, using a ProfiNET enabled PLC (digital cost also includes a very expensive, triple fault tolerant power supply)

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PLCs: Good or Bad?

What is the difference between a PLC, hybrid

controller, and RTU?

Really nothing nowadays All are based on solid state logic, FPGA and have solid state

backup memory

The are the only link allowed to the DCS in most

plants outside the GC

Come with seamless HMI and programming tools Ladder logic has evolved to “function block”

programming, internationally standardized

Therefore they are good, but is some cases not

preferred if Smart GC is available

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PLCs: Good or Bad?

Using the CIRCOR CIM76 module

Sample system configuration I/O comes preloaded

for many PLC automation programs:

Allen Bradley Siemens SIMATIC Honeywell Modicon

All sample system CAN and analog nodes come pre-

loaded with ranges, ID’s, alarms, and graphics into the PLC application programming interface

Analytic techs/engineer/chemist will not need to

become expert in industrial automation

Companies can pick the PLC and HMI of their choice

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PLC Alternatives

Industrial PC’s

Not preferred in some circles due to:

Expense Size MTBF (many moving parts)

• PLC MTBF is much much longer

PLC is therefore the SAM of choice by

the majority of users and fits the reality

• f the market

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Summary

The GEN 2 book should be closed The SAM is the smart GC or a PLC (maybe an

industrial PC)

IS CANbus will become an open international

physical layer

Free and other tools are available today to configure

any type of CAN device

IS CANbus backbone can be used for CANopen and

Devicenet application layers

CIRCOR can link this to any industrial fieldbus Let’s move onto the fun stuff, GEN3!!!

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