Fieldbus Foundation Seminar Mumbai – 16 Oct · PDF file · 2014-11-13Fieldbus...

11 Successful Implementation & Improved Operation

Fieldbus Foundation Seminar Mumbai – 16th Oct 2014

Enhancing Usability Through Physical Layer Diagnostics

Arasu Thanigai


FF Usability

What is Usability

Usability is all about how easy, effective and pleasant the features are for a human to use

Simplicity, logical, orderly processes that are well defined and organized steps to use the digital network

The objective is to make FF easier than conventional instrumentations.


FF Usability


FF Usability - Simplicity

Iphone

Simple Apps usability and vendor participation Adaptability

Blackberry

The iPhone did not introduce anything particularly new or exciting to the mobile industry upon its release.


FF Usability

Interoperability

Automated Device replacement

Backwards compatibility

PV Interchangeability

Device Templates

Managing Diagnostics


FF Usability – HOST Profile Registration


FF Usability – New ITK 6.2+ profile

New ITK 6 profile improves device commissioning

Improves Maintenance activities

Improves self monitoring and diagnostics of field devices ( diagnostics alerts)

Device replacement

Supports new EDDL features ( integrating data from multiple blocks, multiple views, mode control etc)


FF Usability – Physical Layer Diagnostics

End users require actionable diagnostics information from physical layer

Expert systems advices

Components level diagnostics

Relevant tools to help the plant during installation / operation / maintenance

Integrating the physical layer diagnostics into the AMS.


DeviceCoupler(Zone1 – Exd)

Fiel

d D

evic

es

Fiel

d D

evic

es

Fiel

d D

evic

es

TerminatorSurgeProtec.

SurgeProtect.

Fiel

d D

evic

es FieldbusProcessInterfaces

Fieldbus Physical layer

PowerSupplies

– Types and Causes of faults– Components with a view on availability– Assessment of risk of failure

DeviceCoupler(Zone2 – ExiC)

DeviceCoupler(Zone1 – Exia)


Corrosion

10


Hazardous safety rules not followed

– Ground faults– Fieldbus and power

cables tied together


Poor cable installation


Poor cable installations– Cable gland not tight– Seal missing


Poor Device Instalation


Poor maintenance


Typical locations and Fieldbus issues



Diagnostics Tools

Integrated single tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need


Diagnostics Tools

Handheld tools


Advanced Diagnostic Options

A single tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need

Handheld

Portable

Integrated version


Fieldbus Diagnostic Handheld

Display interface for stand-alone operation Multi-language support Intrinsically safe fieldbus interface (Ex ia)

FISCO, Entity, DART Operation in Zone 1/Div. 1 Focused on practical application Operating modes for novice and expert users With expert system advice Data backup and documentation on PC


Suitability check for existing cable


Failure margin check

Communications check


Device coupler short-circuit check


Oscilloscope

Built into the FDH-1 Many trigger conditions selectable Operation on the display or via software Trigger output for external oscilloscope


Intuitive Handling

One-button, quick check with NAMUR signals (NE 107)

Recording and storage for32 segments with 32 devices each

Data backup on laptop/PC

Multi language support: ENG+GER


Expert system on board

Interprets raw physical layer measurements Translates into possible causes Suggests corrective action NAMUR NE 107 status


Handheld Power

Power modes for every situation: segment power, intrinsically safe USB port internal rechargeable battery:

power for an entire work day

Selectable power modes


Mobile Diagnostic Module– Portable module for 1 segment, mainly for

field usage– Powered via USB or bulk power– Nearly identical to the Power Hub

Diagnostic Module

USB interface

Bulk PowerFieldbus interface


Diagnostic Manager Software

User interface in the control room:– Display of values – Warnings with actionable information– Color coding for easy recognition

Value-add:– Automated commissioning procedures

and documentation– Live segment monitoring with alarms– Expert troubleshooting tools

Embedded expert-knowledge


One Plant Asset Management – Includes fieldbus now as asset– Customary look and feel– Reduces required training – Reduces potential for errors

Open Architecture Integration:– AMS Suite– PRM– FieldCare – FieldMate– PACTware– OPC Interface

Asset Management Integration


Example ADM and DCS integration

Diagnostics atDCS Station

Rel

ay c

onta

ctop

tiona

l)

RS485

Industrial Switch

Ethernet or FF H1

Address switches



Operatorstation

Rel

ay c

onta

ctop

tiona

l)

RS485

EthernetVnetIP

AMS


Operatorstation

Rel

ay c

onta

ctop

tiona

l)

RS485

Ethernet


VnetIP

AMS


The Solution

Operatorstation

Rel

ay c

onta

ctop

tiona

l)

RS485

EthernetEthernet (optional)

AMS


Example


Cabinet Control via Diagnostic Gateway

– Inputs for monitoring the control cabinet• Namur sensors / Frequency input (6x)• Analog input for temperature (2x)• Humidity sensor on board

– Power outputs (240 V, 2x)– On/Off controller – Configurable via Foundation

Fieldbus H1– Fan is not working– Door not closed– Water ingress


Diagnostic Device Couplers

Measures in the field:– Measures fieldbus signal conditions at the spur level– Reports changes all the way to Plant Asset

Management– Feeds the expert system

– Better advice – better knowledge – focused plant upkeep – fewer trips to the field


Diagnostic Segment Protector

Improved and innovative spur fault protection: – Progressive spur short-circuit protection– Jabber protection – cuts off devices talking too much– Maintenance work causing contact bounce or short-circuits– Reliable containment of gradual overload conditions– Protects operations from manual intervention and device

failure– Loose wire strands– Bad installations causing multiple devices to talk at the same

time– Water ingress with ground faults or corrosion


Water Ingress


Water Ingress Sensor

Monitoring the inside of the enclosure– Placed inside the enclosure of choice– Connects in parallel to the fieldbus segment– Sends alarm all the way to plant asset management– Know what the housing looks like on the inside


Older way of Commissioning– Always on the critical path– Manual, step-by-step procedure– Labor intensive– Requires

• Screw driver• Check sheet• Pencil• Multimeter• Oscilloscope

– Connect one device at a time– Disconnect after testing

Test Report


Simple Commissioning Steps with ADM– Verify address setting– Wire up devices in the right location– Check shielding– Activate communication– Use automated work procedures

• Testing • Documentation

– All devices at once– Wiring remains undisturbed Commissioning Wizard

Test Report


Commissioning Wizard

With Expert System Support– Takes snapshot– Identifies wiring errors– Ensures compliance with

AG181 and IEC 61158-2– Recommends limits for ADM messages– Stores limits in non-volatile memory

Automatic Tag ReadoutCreates baseline report:

– Snapshot of all measurements – Complete documentation

Saves significant (almost 80%) of pre-commissioning time


Online monitoring as per NAMUR

ADM increases the number of detectable faults– Displays measurement values – Issues warnings and alarms– Highlights violations with color coding:

Good valueMaintenance required

Out of specification

The segment is still operating with good performance


Diagnostic Menu

ADM delivers actionable information for fast fault finding

1 Active messages2 Actionable information with

solution guideance based on expert knowledge

3 History with timestampsWhen the failure…

… occured… disappeared

– Export function for external analysis and storage

11

222

33


Spurs

Field Instruments

Basic Principles: Typical Topology

Segment Protectors

Trunk

Surge Protector

Terminator

Plant Asset Management

Diagnostic Gateway


Poor Wiring


Poor Wiring


Practical Example of Frequencey disturbance

In this example the frequency of noise was approx. 150Hz

7 ms


Not a good device location

FF Device Moved away from Drive


Surge Protection



Diagnostic in Surge Protector

Condition-based replacement– Monitors strike severity and count – Reports end of functional reserve to AMS– Instead of repetitive scheduled maintenance– Surely protects you from the next strike

At Junction box Trunk input At junction box Spur output

At Power supply output at Control room


Diagnostic Surge Protection On Device Coupler


Diagnostic Surge Protection On IS Device Coupler


Surge Protection at PowerHub


Integrated Diagnostic


Summary

– Advanced Diagnostics tools and components for physical layer have reduced physical layer commissiong time and provide online monitoring and reporting system that brings savings at CAPEX and OPEX

– Most problems at early bus installations were due to poor installation. However, simple, user-friendly, Fieldbus testers are now available, allowing the installation crew to easily check the wiring, and the device commissioning crew to check network operation, spotting any problems early

– Many contractors and Technicians are trained and are skilled in Fieldbus installation and commissioning, and have the test equipment and in-house procedures to ensure reliable operation

– USABILITY of Foundation Fieldbus physical is greatly improved


Thank you

03.11.2014 60

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