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S I M P L I F Y I N G the of Engineering a - - PowerPoint PPT Presentation

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S I M P L I F Y I N G the of Engineering a Process with F OUNDATION Fieldbus By William R. Hodson, P.E. Honeywell Industrial Control September, 2001 ISA The Instrumentation, Systems, and Automation Society 1

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SLIDE 1

ISA–The Instrumentation, Systems, and Automation Society

1 Simplifying the Complexity of Engineering a Process with FF

the of Engineering a Process with FOUNDATION™ Fieldbus

By William R. Hodson, P.E. Honeywell Industrial Control September, 2001

S I M P L I F Y I N G

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SLIDE 2

ISA–The Instrumentation, Systems, and Automation Society

2 Simplifying the Complexity of Engineering a Process with FF

Simplifying Engineering with FF

 What is FF Technology?  What Needs to be Engineered?  What Documentation Needs to be

Changed?

 Making it Bearable with Tools

F F

DCS PAS

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SLIDE 3

ISA–The Instrumentation, Systems, and Automation Society

3 Simplifying the Complexity of Engineering a Process with FF

 Dramatically Different  Digital, Process Control  Low Speed w/ bus power  High Speed w/o(?) power  Robust User Layer  Extendible & Add’l Function

Blocks

 Device Description Files  Data Link Synchronization

What is FF Technology?

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SLIDE 4

ISA–The Instrumentation, Systems, and Automation Society

4 Simplifying the Complexity of Engineering a Process with FF

What Needs to be Engineered?

 Wiring Topology

 Home run, spurs,

multi-drop, not pt- to-pt

 1900m + 120m

total spurs (fn of number of Devices)

DCS/ PAS JB T T JB T

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SLIDE 5

ISA–The Instrumentation, Systems, and Automation Society

5 Simplifying the Complexity of Engineering a Process with FF

What Needs to be Engineered?

 Power Distribution

 Cost Savings  Adequacy  Redundancy

JB DCS/ PAS JB

24vdc

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SLIDE 6

ISA–The Instrumentation, Systems, and Automation Society

6 Simplifying the Complexity of Engineering a Process with FF

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 AO PID? DCS/PAS

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SLIDE 7

ISA–The Instrumentation, Systems, and Automation Society

7 Simplifying the Complexity of Engineering a Process with FF

What Needs to be Engineered?

 Network Scheduling

 Macrocycle  Sub-schedules  Latency  Bandwidth Usability

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SLIDE 8

ISA–The Instrumentation, Systems, and Automation Society

8 Simplifying the Complexity of Engineering a Process with FF

What Needs to be Engineered?

 Network Scheduling

 Macrocycle  Sub-schedules  Latency  Bandwidth Usability

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SLIDE 9

ISA–The Instrumentation, Systems, and Automation Society

9 Simplifying the Complexity of Engineering a Process with FF

What Needs to be Engineered?

 VCRs

DCS/ PAS JB JB M A M A I M M M M A M A M A

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SLIDE 10

ISA–The Instrumentation, Systems, and Automation Society

10 Simplifying the Complexity of Engineering a Process with FF

What Needs to be Engineered?

 VCRs

DCS/ PAS JB JB M A M A I M M M M A M A M A P P P P S S S S P P S S

e.g., 12 VCRs

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SLIDE 11

ISA–The Instrumentation, Systems, and Automation Society

11 Simplifying the Complexity of Engineering a Process with FF

What Needs to be Engineered?

 VCRs  Address Limitations

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SLIDE 12

ISA–The Instrumentation, Systems, and Automation Society

13 Simplifying the Complexity of Engineering a Process with FF

What Needs to be Engineered?

 VCRs  Address Limitations  Overall System Capacity

 Traffic Routing  Weakest Links  The Pyramid

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SLIDE 13

ISA–The Instrumentation, Systems, and Automation Society

14 Simplifying the Complexity of Engineering a Process with FF

What Needs to be Engineered?

 VCRs  Address Limitations  Overall System Capacity

 Traffic Routing  Weakest Links  The Pyramid

Oper/App Node Server Node Controller Node Controller Node Controller Node I/O Node I/O Node I/O Node I/O Node I/O Node I/O Node I/O Node I/O Node I/O Node

Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Fig 1 – Generalized System Communications Architecture

Oper/App Node Oper/App Node

Plant Info Network Supervisory Network I/O Networks Fieldbus Networks

Oper/App Node Oper/App Node

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SLIDE 14

ISA–The Instrumentation, Systems, and Automation Society

15 Simplifying the Complexity of Engineering a Process with FF

What Needs to be Engineered?

 VCRs and Link Objects  Address Limitations  Overall System Capacity

 Traffic Routing  Weakest Links  The Pyramid

Oper/App Node Server Node Controller Node Controller Node Controller Node I/O Node I/O Node I/O Node I/O Node I/O Node I/O Node I/O Node I/O Node I/O Node

Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Fig 1 – Generalized System Communications Architecture

Oper/App Node Oper/App Node

Plant Info Network Supervisory Network I/O Networks Fieldbus Networks

Oper/App Node Oper/App Node

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SLIDE 15

ISA–The Instrumentation, Systems, and Automation Society

16 Simplifying the Complexity of Engineering a Process with FF

What Needs to be Engineered?

 VCRs and Link Objects  Address Limitations  Overall System Capacity

 Traffic Routing  Weakest Links  The Pyramid

Oper/App Node Server Node Controller Node Controller Node Controller Node I/O Node I/O Node I/O Node I/O Node I/O Node I/O Node I/O Node I/O Node I/O Node

Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Fig 1 – Generalized System Communications Architecture

Oper/App Node Oper/App Node

Plant Info Network Supervisory Network I/O Networks Fieldbus Networks

Oper/App Node Oper/App Node

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SLIDE 16

ISA–The Instrumentation, Systems, and Automation Society

17 Simplifying the Complexity of Engineering a Process with FF

What Needs to be Engineered?

 VCRs and Link Objects  Address Limitations  Overall System Capacity

 Traffic Routing  Weakest Links  The Pyramid

Oper/App Node Server Node Controller Node Controller Node Controller Node I/O Node I/O Node I/O Node I/O Node I/O Node I/O Node I/O Node

Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Dev Node Fig 1 – Generalized System Communications Architecture

Oper/App Node Oper/App Node

Plant Info Network Supervisory Network I/O Networks Fieldbus Networks

FIM FIM FIM

Oper/App Node Oper/App Node

To/from another system

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SLIDE 17

ISA–The Instrumentation, Systems, and Automation Society

18 Simplifying the Complexity of Engineering a Process with FF

Dealing With All This!

  • Lots of Benefits, but…
  • Lots of Responsibilities too!
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SLIDE 18

ISA–The Instrumentation, Systems, and Automation Society

19 Simplifying the Complexity of Engineering a Process with FF

AO

Dealing With All This!

  • Hundreds of parameters per device
  • Physical Device Parameters
  • Network & System Parameters
  • Transducer Parameters
  • Function Block Parameters
  • Need to Change Documentation
  • Need Tools to Help!

RB NMIB TB AI PID SMIB ISel Arith

  • Lots of Benefits, but…
  • Lots of Responsibilities too!
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SLIDE 19

ISA–The Instrumentation, Systems, and Automation Society

20 Simplifying the Complexity of Engineering a Process with FF

Changing Documentation?

  • P&ID Drawings
  • Loop Drawings
  • SAMA or Control

Strategy Drawings

  • Data Sheets
  • System Drawings
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SLIDE 20

ISA–The Instrumentation, Systems, and Automation Society

21 Simplifying the Complexity of Engineering a Process with FF

Changing Doc’n - P&ID Drawings

  • Not much change
  • ISA S5.1
  • Dotted line with

circles to represent the multi-drop signal line.

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SLIDE 21

ISA–The Instrumentation, Systems, and Automation Society

22 Simplifying the Complexity of Engineering a Process with FF

Changing Doc’n - P&ID Drawings

UE 101 FV 101-1

Thinner

ZE 215

Thick Stuff 0-100 OHM

TE 222 DV 101-1 TI 101-1 FI 101-2 ZI 215 TI 222 101-1 FY UT 101 Density Mass Volume Temp Volume Mass B B B B B DY 101-1 UT 201 Temp Viscosity FIC 101-1 101-1 DIC

Fieldbus with PID in the

host

From Fieldbus User Network, Gary Addison, Equistar Chemicals LP

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SLIDE 22

ISA–The Instrumentation, Systems, and Automation Society

23 Simplifying the Complexity of Engineering a Process with FF

Changing Doc’n - P&ID Drawings

UE 101 FV 101-1

Thinner

ZE 215

Thick Stuff 0-100 OHM

TE 222 DV 101-1 TI 101-1 FI 101-2 ZI 215 TI 222 101-1 FCY UT 101 Density Mass Volume Temp Volume Mass B B B B B DCY 101-1 UT 201 Temp Viscosity FI DI 101-1 101-1

Fieldbus with PID in the

field devices

From Fieldbus User Network, Gary Addison, Equistar Chemicals LP

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SLIDE 23

ISA–The Instrumentation, Systems, and Automation Society

24 Simplifying the Complexity of Engineering a Process with FF

Changing Doc’n – Loop Drawings

  • Conventional…
  • Devices…
  • through marshalling…
  • to controller termination
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SLIDE 24

ISA–The Instrumentation, Systems, and Automation Society

25 Simplifying the Complexity of Engineering a Process with FF

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
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SLIDE 25

ISA–The Instrumentation, Systems, and Automation Society

26 Simplifying the Complexity of Engineering a Process with FF

Changing Doc’n – Loop Drawings

Devices 24vdc Power Power Conditioners

Terminators & Expanders

Lengths

From Fieldbus User Network, Bud Szoke, Keyspan Energy Canada

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SLIDE 26

ISA–The Instrumentation, Systems, and Automation Society

27 Simplifying the Complexity of Engineering a Process with FF

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)
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SLIDE 27

ISA–The Instrumentation, Systems, and Automation Society

28 Simplifying the Complexity of Engineering a Process with FF

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
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SLIDE 28

ISA–The Instrumentation, Systems, and Automation Society

29 Simplifying the Complexity of Engineering a Process with FF

Changing Doc’n – System Drawings

  • Part of DCS
  • All nodes of all networks
  • Op stations
  • Application Stations
  • Printers, Servers
  • Controllers
  • I/O Chasses
  • Interfaces
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ISA–The Instrumentation, Systems, and Automation Society

30 Simplifying the Complexity of Engineering a Process with FF

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?

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ISA–The Instrumentation, Systems, and Automation Society

31 Simplifying the Complexity of Engineering a Process with FF

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?

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SLIDE 31

ISA–The Instrumentation, Systems, and Automation Society

32 Simplifying the Complexity of Engineering a Process with FF

The “Physical” Tree

  • Microsoft Explorer

Familiarity

  • Start at Interface Module.
  • Links are Subordinate to

FIMs

  • Devices are Subordinate

to Links.

  • Blocks are Subordinate to

Devices.

  • Parameters are

Subordinate to Blocks. Interface Module Trans- ducer Function blocks Link Interfaces Devices

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ISA–The Instrumentation, Systems, and Automation Society

33 Simplifying the Complexity of Engineering a Process with FF

  • Microsoft Explorer

Familiarity

  • Start at Interface Module.
  • Links are Subordinate to

FIMs

  • Devices are Subordinate

to Links.

  • Blocks are Subordinate to

Devices.

  • Parameters are

Subordinate to Blocks.

The “Physical” Tree

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ISA–The Instrumentation, Systems, and Automation Society

34 Simplifying the Complexity of Engineering a Process with FF

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 Control Module Function Blocks

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ISA–The Instrumentation, Systems, and Automation Society

35 Simplifying the Complexity of Engineering a Process with FF

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.

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SLIDE 35

ISA–The Instrumentation, Systems, and Automation Society

36 Simplifying the Complexity of Engineering a Process with FF

Device Object Instantiation

  • Create an instance
  • f a device model

that corresponds to a device being delivered.

  • Drag and drop onto

appropriate link.

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SLIDE 36

ISA–The Instrumentation, Systems, and Automation Society

37 Simplifying the Complexity of Engineering a Process with FF

Device Commissioning

  • Place the available device on the link.
  • Find the device on the Physical tree.
  • PD_TAG
  • Address
  • Unique Device ID
  • Match it up with pre-configured device.
  • Commission it (loads it).
  • Start up device & blocks
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SLIDE 37

ISA–The Instrumentation, Systems, and Automation Society

38 Simplifying the Complexity of Engineering a Process with FF

Device & Block Monitoring

  • Monitor the Physical

Tree for link, device, and block status

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SLIDE 38

ISA–The Instrumentation, Systems, and Automation Society

39 Simplifying the Complexity of Engineering a Process with FF

Device & Block Monitoring

  • Monitor the Physical

Tree for link, device, and block status

  • Monitor the Strategy

Tree for control strategy and block status.

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SLIDE 39

ISA–The Instrumentation, Systems, and Automation Society

40 Simplifying the Complexity of Engineering a Process with FF

Device & 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.

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SLIDE 40

ISA–The Instrumentation, Systems, and Automation Society

41 Simplifying the Complexity of Engineering a Process with FF

Exception Reporting

  • Process Alarms detected by device fully

integrated with DCS/PAS process alarms.

  • Device Alarms detected by device fully

integrated with device hardware and I/O alarms.

  • Device Alarms detected by interface fully

integrated with device hardware and I/O alarms.

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SLIDE 41

ISA–The Instrumentation, Systems, and Automation Society

42 Simplifying the Complexity of Engineering a Process with FF

Maintenance Data Access

  • Reports from

database of devices

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SLIDE 42

ISA–The Instrumentation, Systems, and Automation Society

43 Simplifying the Complexity of Engineering a Process with FF

Maintenance Data Access

  • Reports from

database of devices

  • Bad & Uncertain

values

  • Propagation and

reaction

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SLIDE 43

ISA–The Instrumentation, Systems, and Automation Society

44 Simplifying the Complexity of Engineering a Process with FF

Maintenance Data Access

  • Reports from

database of devices

  • Bad & Uncertain

values

  • Propagation and

reaction

  • Events recorded on

change

  • Integrated with

conventional

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SLIDE 44

ISA–The Instrumentation, Systems, and Automation Society

45 Simplifying the Complexity of Engineering a Process with FF

Maintenance Data Access

  • Reports from

database of devices

  • Bad & Uncertain

values

  • Propagation and

reaction

  • Events recorded on

change

  • Integrated with

conventional

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SLIDE 45

ISA–The Instrumentation, Systems, and Automation Society

46 Simplifying the Complexity of Engineering a Process with FF

Device Replacement

  • Replacing Similar Devices
  • Decommission Old
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SLIDE 46

ISA–The Instrumentation, Systems, and Automation Society

47 Simplifying the Complexity of Engineering a Process with FF

Device Replacement

  • Replacing Similar Devices
  • Decommission Old
  • Commission New
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SLIDE 47

ISA–The Instrumentation, Systems, and Automation Society

48 Simplifying the Complexity of Engineering a Process with FF

Device Replacement

  • Replacing Similar Devices
  • Decommission Old

Save image

  • Commission New
  • Reclaim parameter values
  • Note Differences

Replace: Reconcile Differences

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SLIDE 48

ISA–The Instrumentation, Systems, and Automation Society

49 Simplifying the Complexity of Engineering a Process with FF

Simplifying Engineering with FF

 What is FF Technology?  What Needs to be Engineered?  What Documentation Needs to be

Changed?

 Making it Bearable with Tools

F F

DCS PAS

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SLIDE 49

ISA–The Instrumentation, Systems, and Automation Society

50 Simplifying the Complexity of Engineering a Process with FF

Summarizing…

  • FF Technology…
  • …Is Complex
  • …Is “Cultural” Change
  • …Requires Advanced Tools
  • Tools are Growing in Strength
  • Goal is Engineeringless Interoperability (ELI)

Simplifying the Complexity of Engineering a Process with FOUNDATION™ Fieldbus

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SLIDE 50

ISA–The Instrumentation, Systems, and Automation Society

51 Simplifying the Complexity of Engineering a Process with FF

Simplifying the Complexity of Engineering a Process with FOUNDATION™ Fieldbus William R. Hodson, P.E.

Honeywell Industrial Control

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SLIDE 51