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Fault Tolerant Ethernet (FTE) The communication network of Experion PKS


TOPICS

Honeywell Process Solutions are based on “process control”.

What is “process control”?

What is a “Distributed Control System (DCS)”?

What is Fault Tolerant Ethernet (FTE)?

How does FTE work?

How is FTE implemented?



A “process” transforms material from input to output.– Example: heating water

“Field instruments” measure properties of materials/processes– Examples: flow, pressure, temperature, level transmitters

“Actuators” regulate amount of something used in the process– Examples: fuel control valve, damper actuator

A “controller” continually reads data from a transmitter and calculates actuator adjustments to maintain a property value.

PROCESS outputinput

controller

actuator

transmitter


Requirements of “process control”

Performance: must be faster than the process.

Determinism: must always take the same time.– Read the Process Value (PV) – Calculate – Move the actuator

Fault tolerance: redundancy; must fail to a known state.– Gov’t regulations- safety, emissions, etc.

Security: must have access restrictions/controls.

PROCESS outputinput

“control loop”controller

actuator

transmitter


Characteristics of real process plants

The process shown below is very simple, and the controller shown below is very simple.

In a real plant, many properties of the product are measured: – Temperature, pressure, viscosity, size, weight, color, etc.

…and many properties of the process equipment are measured:– Fuel consumption, up/down time, corrosion, wear, etc.

PROCESS outputinput

controller

actuator

transmitter

“control loop”



Paper mill: a series of processes that transform trees into paper.– Makes many different products (toilet paper to computer paper).– Must control each process plus interactions between processes.

10’s-100’s of field devices / process; 1000’s of control loops total



Paper mill: a series of processes that transform trees into paper.– Makes many different products (toilet paper to computer paper).– Must control each process plus interactions between processes.

10’s-100’s of field devices / process; 1000’s of control loops total

Can’t control the plant with 1000’s of simple controllers!

X


TOPICS





How does FTE work?




Multi-loopController

Direct I/O Module

A DCS is an integrated set of modules with distributed functions. – Multi-loop controllers (10’s-100’s) that connect to field devices

• Via direct Input/Output modules and industrial buses



SupervisoryController


Direct I/O Module

A DCS is an integrated set of modules with distributed functions. – Multi-loop controllers (10’s-100’s) that connect to field devices– Supervisory coordinating controllers



OperatorStations


Engineering Station


Direct I/O Module

A DCS is an integrated set of modules with distributed functions. – Multi-loop controllers (10’s-100’s) that connect to field devices– Supervisory coordinating controllers – Multi-loop operator stations and engineering stations



SystemServer

OperatorStations


Engineering Station


Direct I/O Module

A DCS is an integrated set of modules with distributed functions. – Multi-loop controllers (10’s-100’s) that connect to field devices– Supervisory coordinating controllers – Multi-loop operator stations and engineering stations– Servers for system data management



SystemServer

OperatorStations


Engineering Station


Direct I/O Module

A DCS is an integrated set of modules with distributed functions. – Multi-loop controllers (10’s-100’s) that connect to field devices– Supervisory coordinating controllers – Multi-loop operator stations and engineering stations– Servers for system data management– Control network for intercommunication

Control Network



RemoteServer

Remote Users SystemServer

OperatorStations


Engineering Station

www


Direct I/O Module

Other Industrial Devices

[to production management equipment]

A DCS is an integrated set of modules with distributed functions. – Multi-loop controllers (10’s-100’s) that connect to field devices– Supervisory coordinating controllers – Multi-loop operator stations and engineering stations– Servers for system data management– Control network for intercommunication+ External connections

Control Network



RemoteServer


OperatorStations


Engineering Station

www


Direct I/O Module



A DCS, throughout the whole system, must provide:– Performance: control must be faster than the process. – Determinism: control must always take the same time.– Fault tolerance: redundancy; must fail to a known state.– Security: must have access restrictions/controls.

Control Network



RemoteServer


OperatorStations


Engineering Station

www


Direct I/O Module



A DCS is designed, sold, maintained as a system, including: – System capacity and performance specifications– System configuration, simulation, and management– Alarms and status of the entire system– System releases (with on-line installation)– System maintenance and support (including 3rd party equipment)

• Performance• Determinism• Fault tolerance• Security

Control Network


How is a DCS different from a PLC system?

RemoteServer


OperatorStations


Engineering Station

www


Direct I/O Module



Mfr sells a complete system of integrated components.

Mfr sells some components; an SI acquires others and engineers the system.

Mfr supports the system. Mfr supports the components and the SI.

On-line repair/ maintenance is the norm. Off-line repair/ maintenance is the norm.

System management built-in. System management designed per project.

Users expect to evolve/upgrade/expand a system over 10/20/30 years.

System is a one-off project (like a house). Upgrades / expansions are new projects.

DCS PLC system


Control Network


Honeywell DCS Evolution

RemoteServer


OperatorStations


Engineering Station

www


Direct I/O Module



Honeywell DCS architecture before Experion PKS – Controllers designed by Honeywell– Servers and stations had become PC-based – Proprietary 5 Mbps control networks

• Interfaces/gateways required to non-Honeywell equipment• Near performance limits


Control Network


TOPICS





How does FTE work?



Why FTE?

Needed a next generation control network for Experion PKS– >10x performance, + determinism, security, fault tolerance– Reduce cost of communication infrastructure and support– Reduce cost of connection to PCs and IT networks

Ethernet preferred+ Industry trend to “industrial Ethernet”+ Industry bus protocols migrating to Ethernet

• FF H1 FF HSE• Profibus ProfiNet• DeviceNet/ControlNet Ethernet/IP• Modbus Modbus/TCP• Etc.

– Ethernet equipment perceived as not “industrial” enough– No suitable fault tolerance approach

FTE provides the required fault tolerance, using Cisco switches to provide determinism and security.


Experion PKS

RemoteServer


OperatorStations


Engineering Station

www


Direct I/O Module



FTE is the control network of Experion PKS.– Analogous to TPS LCN/UCN and PlantScape ControlNet.


FTE


.



Dedicated to the control mission– Fault-tolerant– Fast performance– Deterministic – Secure

Not an IT network, but leverages IT technology to lower cost of:– FTE network infrastructure– Connection to IT networks– Connection to 3rd party Ethernet devices– Maintenance and support

3 Cisco switches qualified for R200– 100/1000 Mbps; single and multi-mode optical fiber up to 70 km– Security and determinism functions required for control mission– Preferred supplier by many customers


What is FTE?

An FTE network has redundant switches and cables.– Topology: 2 parallel trees joined at the top to form one network.

– An FTE node connects to both trees.

– An Ethernet node (non-FTE) connects to either tree.

Switches

A tree B tree

EthernetFTEFTE

EthernetFTEFTE


An FTE network has redundant switches and cables. – 1 communication path between Ethernet nodes

What is FTE? – With Ethernet nodes

Switches

A tree B tree

EthernetFTEFTE

EthernetFTEFTE


What is FTE? – With FTE & Ethernet nodes

An FTE network has redundant switches and cables. – 1 communication path between Ethernet nodes– 2 communication paths between an FTE node and an Ethernet node

Switches

A tree B tree

EthernetFTEFTE

EthernetFTEFTE


What is FTE? – With FTE & Ethernet nodes

An FTE network has redundant switches and cables. – 1 communication path between Ethernet nodes– 2 communication paths between an FTE node and an Ethernet node

Switches

A tree B tree

EthernetFTEFTE

EthernetFTEFTE


What is FTE? – With FTE nodes

An FTE network has redundant switches and cables. – 1 communication path between Ethernet nodes– 2 communication paths between an FTE node and an Ethernet node– 4 communication paths between FTE nodes

A - A

Switches

A tree B tree

EthernetFTEFTE

EthernetFTEFTE




A - B

Switches

A tree B tree

EthernetFTEFTE

EthernetFTEFTE




B - B

Switches

A tree B tree

EthernetFTEFTE

EthernetFTEFTE




B - A

Switches

A tree B tree

EthernetFTEFTE

EthernetFTEFTE


TOPICS





How does FTE work?



How Does FTE Work? –FTE path status

Each FTE node continually issues short diagnostic messages to test each path to every other node, and builds a status table.

Below is a node’s status table. The first 2 nodes are FTE nodes, and the last 4 nodes are singly-connected Ethernet nodes. – A bad link displays as “SILENT”.

• If the B cable to the FTE-GUS node fails, A>B and B>B SILENT. • If the crossover cable fails, A>B and B>A SILENT on all nodes.


Station

CDA = Control Data AccessDSA = Distributed Systems Architecture

How Does FTE Work? – Security and Determinism

This diagram shows levels of the plant automation system (level 0 – field devices – is not shown).

FTE is the Experion PKS network for the control and operation levels (1 and 2 ).

FT

E

ControlLevel 1

OperationLevel 2

Plant Automation System Levels

PKS Server

Station Station Station

ACE PKS Server


ACE

ManagementLevel 3

Station PKS ServerDomain

Controller APC PHD Server

Switch A Switch B

Layer 3 Switch


Station


FT

E

ControlLevel 1

OperationLevel 2


PKS Server


ACE PKS Server


ACE

ManagementLevel 3



Switch A Switch B

Layer 3 Switch


Firewall hides/secures Level 2 and Level 1-- Only L2 PKS Servers are visible

PKS server on L3 consolidates and makes available L2 data / alarms for applications via DSA

Firewall hides all but servers


Station


FT

E

ControlLevel 1

OperationLevel 2


PKS Server


ACE PKS Server


ACE

ManagementLevel 3



Switch A Switch B

Layer 3 Switch


Firewall hides/secures Level 2 and Level 1-- Only L2 PKS Servers are visible

PKS server on L3 consolidates and makes available L2 data / alarms for applications via DSA

FTE switches provide:

Port Filtering between L2 and L1 to allow only CDA and FTE messages for control

L2 bandwidth allocation to ensure that L2 supervisory traffic is not disrupted

L1 bandwidth allocation to ensure that L1 control is not disrupted

Broadcast, Multicast, Unicast storm suppression to maximize FTE network availability

L1: Restricted to CDA and FTE Traffic Only

Firewall hides all but servers

L1 & L2: Bandwidth Allocation

L1 & L2: Broadcast, Multicast, Unicast Storm Suppression

L2: CDA Traffic Prioritized High


TOPICS





How does FTE work?



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Basic FTE Configurations

An FTE network interconnects clusters of nodes. – A cluster is a group of nodes with high intercommunication,

typically associated with the same process unit.

FTE

RedundantServers

ExperionStations

ApplicationControl

Environment Engineering Tools

FTE

FTE

FTE

FTE

FTE

C200

FTE

FTE

FTE


UNIT #4CLUSTE

R

UNIT #3CLUSTE

R

UNIT #1CLUSTER

UNIT #2CLUSTER

History,Advanced

Control

BackboneSwitches

ClusterSwitches

To Plant Information Network (PIN)Firewall

Basic FTE Configurations

A minimum FTE network is one pair of cluster switches; larger networks could have several cluster switch pairs connected to backbone switches.


How Is FTE Implemented?

Cabling: CAT5 STP copper; single and multi-mode fiber optic.

Cisco switches: 24/48 STP ports + 2 GBIC ports; 10 GBIC ports.– Switches are expandable up to 436 ports; can mix switch types– GBICs: plug-in converters for 0.5 / 10 / 70 km fiber optic

FTE software and dual Network Interfaces per PC node

ClusterSwitches

Typically CAT5 STP, but often fiber optic, single or multi-mode-1000 Mbps- up to 70km

Typically CAT5 STP- 100 Mbps- up to 100m

EthernetFTEFTE

EthernetFTEFTE

BackboneSwitches

MediaConverters

Dual NIC card

Software

GBICs


Main Configuration Rules

Switches: 24/48 ports, expandable up to 432 ports

FTE network: • up to 200 FTE nodes (dual-connected)

• Up to 99 of those can be C200 controllers

+ up to 511 Ethernet nodes (singly-connected)

Firewall/router: required to connect to other networks– FTE network is a separate IP subnet– Private IP addresses; only servers are visible externally

Cable: shielded twisted pair (STP) or fiber optic recommended for best noise immunity and performance – Required for CE Mark


Honeywell network experts can do it all-- for FTE and for all networks in the plant.

Honeywell Network Services

Planning, design, installation, integration– Cabling, testing, training, documentation– Special needs, e.g., video surveillance

Network security assessment, engineering, management – Authorization, authentication, encryption, activity logging,

intrusion detection, virus protection– Firewall engineering, configuration, testing and management

Remote Network Administration – Systems (servers, workstations)– Network (switches, routers, firewalls, etc.)

1st


1st

.

Honeywell Network Services

Remote Monitoring 24/7– Networks (Switches, Routers, VPNs, Firewalls)– Systems (PlantScape, TPS, PHD, any type of PC)– Applications on PCs (are they running/responding)

Network and System Performance Management– Proactive tracking of system, server, network performance– Work load Characterization & Capacity Planning

Procurement and support of PCs and network equipment

Honeywell network experts can do it all-- for FTE and for all networks in the plant.


.

Fault Tolerant Ethernet (FTE)-----


Dedicated to the control mission– Fault-tolerant– Fast response– Deterministic – Secure

Not an IT network, but leverages IT technology to lower cost of:– FTE network infrastructure– Connection to IT networks– Connection to 3rd party Ethernet devices– Maintenance and support


Cisco products in FTE

Products being qualified for R200– 2950G-24– 2950G-48– 3550-12G– GigaStack GBIC– 1000BASE-T GBIC– 1000BASE-SX GBIC– 1000BASE-LX GBIC– 1000BASE-ZX GBIC

Potential additional products for qualification or certification– 3550-24-FX– 2955C-12– Other 2950 models with Enhanced Image

Thank You!

.

Date post:	13-Dec-2015
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