5b-1484_advanced diagnostics for fieldbus

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Advanced Diagnostics for

Foundation Fieldbus

Advanced Diagnostics for

Foundation FieldbusChris Williams

Eastman Chemical Company

South Carolina Operations

PresentersPresenters

Chris Williams

Bernd Scheussler

IntroductionIntroduction

Improved fieldbus operations with advanceddiagnostics at Eastman Chemical Company

The Challenge of fitting 21st century technology in a20th century plant

Implementing a Foundation Fieldbus topology based

on FISCO in a chemical processing facility. Fieldbus Commissioning procedures – from manual

to automated

Design ChallengeDesign Challenge

Plant was originally put in to service in the1970’s

Over the past four years converted the BPCS over toDeltaV

Now the plant was undergoing an expansion toincrease production capacity.

Another plant at our site was recently brought onlinewith the majority of the instrumentation running onFoundation Fieldbus.

Foundation Fieldbus has already proven its worth.

The Power of Foundation Fieldbus

Foundation Fieldbus Implementation

BPCS with Host card

Power Conditioner

Route Trunk withTerminators

Hang Instruments

Mini-fast connectors

Spurs not run in conduit

Spur to Trunk junction point visible from instruments

Do not want to have to gas check area

Needs to work in classified areasClass I Division 2 and Class I Division 1

Survive in corrosive environment over time

Can handle long trunk runs in a distributedenvironment

Maintenance Requirements

Engineering Requirements

Standard full power FFB?

Non-Incendive?

FNICO – Fieldbus Non-Incendive COncept?

Entity Instrinsically Safe?

FISCO – Fieldbus Instrinsically Safe COncept?

Which Foundation Fieldbus Model to use?

Intrinsically Safe FFB seemed to be the only solutionto meet all of the design requirements.

Where to install the I.S. barrier?

FFB instrumentation requires at least 9 Vdc tooperate. I.S. has limited voltage available.

I.S. is distance limited due to power limitations. Will itbe long enough?

Design SolutionDesign Solution

SOLUTION! FISCO based on P+F FieldConnexProduct Line.

Implement using a High-Power Trunk with Barrierslocated in the field.

Trunk operates at 30 Vdc and can deliver as much as

500 mA. Field-barriers separate the high-power trunk and the

FISCO rated field instruments.

Uniform installation Barriers are near field instrumentation

Long trunk lines with little loss

Maintenance can work on instruments live. Only the trunk has to be installed via classic

methods.

Instruments need either FISCO or Entity I.S.rating.

FISCO provided

FieldConnex Power Conditioners and Hub

HD2-FBPS-1.500 conditionerprovides 30 Vdc at up to 500 mA DCto trunk from a 24Vdc supply.

Can be swapped out hot with out

powering down the hub..

Hub Mother board is passive andredundancy is an option.

Compact.

Model RD0-FB-Ex4 DIN rail mounted in NEMA 4Xenclosure

Can be mounted in Class I Division 2 areas

Provides short-circuit protection for spurs

Limits power to spurs (FISCO and Entity compatible)

FieldConnex Field Barrier

Basic Layout for FISCO FieldBarrier with HPT

Mounts directly on power conditioner motherboard

No extra wiring needed to connect to segments

Monitors each segment for signal quality

Enables remote diagnostics

Added Bonus! P+F’s Advanced Diagnostic Module

Physical InstallationPhysical Installation

H1 Fieldbus Card

HD2-FPS Segment Power

Supply High Power Trunk to Field

ADM – AdvancedDiagnostic Module

RS-485 to Ethernetadapter for remoteconnection

Field BarrierInstallation

High-PowerTrunk routed inconduit

Only spurs have

min-fastconnectors

Field Instrumentationhave FISCO approval.

Spur cables are keptshort. Typ. < 30 feet

Routed in small cabletrays separate from all

non-I.S. circuits.

Segment CommissioningSegment Commissioning

First couple of segments commissioned used oldmethod.

Physical walk down of trunk

Check terminations

Resistance and capacitance checks

Power up and voltage checks at each junction

Sweep segment with oscilloscope

Connect instruments and commission

Re-sweep segment with oscilloscope.

Gotcha MomentGotcha Moment

Double checked segment using P+F ADM.

Segment had passed physical checkout but ADMfound a problem!

ADM provideddetailed information

about the segmentand the problem

Diagnostic pointedstraight to the

problem. A terminator was not

enabled on the last

junction on the trunk

Taking the DiveTaking the Dive

The ADM confirmed the readings we took manuallyand found problems we missed.

Next section we brought online had 8 segments.

Checked all 8 with the ADM only.

ADM found an under-terminated segment and one

with polarity reversed.

Even with a trip to fix the errors, all 8 were checkedout in 20 minutes!

Taking the DiveTaking the Dive

Next we attached and commissioned 40 instrumentsas a group.

We used ADM to validate each segment withinstruments.

With the information at hand, confidence in the network

was high. Segments 1500 feet long came online as easily as

segments that were right next to the control cabinet.

Commissioning ReportsCommissioning Reports

The Great UhOh!The Great UhOh!

What happens when an entire segment suddenlystops working?!?

Case in point, segment with 8 instruments that werecommissioned and controlling the process.

Suddenly all instruments stop communicating with

the BPCSA few moments later, they all come back

Several minutes later, they all stop talking again

ADM was alarming every time the event occurred.

The Great UhOh!The Great UhOh!

SCOPE SWEEP to the rescue!

The backup link master was periodically…well….

Business Results AchievedBusiness Results Achieved

By using FISCO we reduced checkout and startuptime

Field technicians were more confident in thenetworks. Not quick to blame them anymore

ADM is constantly monitoring the segments looking

for potential problems Great tool for working with instrument vendors when

looking for gremlins.

SummarySummary

Foundation Fieldbus installation based on FISCO andutilizing ADM

Faster Installation, Commissioning, andTroubleshooting

Constant monitoring

Where To Get More InformationWhere To Get More Information

Other training sessions

– Automated Fieldbus Segment Commissioning

Session 7-1441

– Fieldbus Predictive Maintenance with AMS SuiteSession 5B-1474

www.controlglobal.com/articles/2009/FieldbusDiagnostic0905.html?page=full

Visit us at the P+F booth in the exhibitions hall

www.pepperl-fuchs.com

More on Advanced DiagnosticsMore on Advanced Diagnostics

Past Commissioning ProceduresPast Commissioning Procedures

FF AG 181 Engineering Guidelines:

– Manually checkout cable

– Manually checkout network/segment

Tools necessary: – Volt meter

– Digital storage oscilloscope

– Capacitance meter

– Inductance meter

– Other handheld testers

– Pencil and notepad

What were the Problems?What were the Problems?

Manual procedures

Very time consuming

Very labor intense

Requires skilled workforce

Can introduce errors

– Connect/disconnect wiring

Can delay start-up

Not efficient

Very expensive $$$

Automated Commissioning ToolsAutomated Commissioning Tools

Advanced Diagnostic Module:

A single tool forcommissioning, operation, and troubleshooting

Integrated into AMS 9.0 and higher! Integrated into AMS 9.0 and higher!

S Ti d M D iS Ti d M D i

Saves Time and Money DuringCommissioningSaves Time and Money DuringCommissioning

ADM commissioning wizard significantly reduces FF segmentcheckout and commissioning time by 80%;

The simple to use commissioning wizard: generates baseline reports,which enables confirmation of proper construction/installation to

reduce project risk

Ensures compliance with AG181 and IEC 61158-2

Monitoring Increases Plant Up-TimeMonitoring Increases Plant Up-Time

– Monitors continuous operation

– Notifies when deviations occur

– Enables proactive plant up keep – Keeps the plant up and running

Accelerated TroubleshootingAccelerated Troubleshooting

– Actionable information guides to potential sources of faults

– ADM provides expert knowledge and advice

– For anyone working with fieldbus

– Accessible from remote for consultation with fieldbus experts

Physical Layer Diagnostics: FeaturesPhysical Layer Diagnostics: Features

Features of the Diagnostic Module

– User-configurable warning and alarm levels for long-term

diagnostics

– Alarming with time stamping

– History/trending for all measured values stored in the diagnostic

module

– DCS system integration via OPC

– AMS integration via Ethernet

– Automated commissioning for easy warning and alarm level

definition

– Documentation tool, file or print out

– Diagnostic wizard to isolate cause of deviation or errors

– Built-in Fieldbus oscilloscope

CommissioningCommissioning

PrintPrint

““Save asSave as …”…”

e.g. pdfe.g. pdf--filefile

Export the completeExport the complete

ReportReport

Commissioning Report – Page 1Commissioning Report – Page 1

CommissioningCommissioningNo two segments are identical.

Every segment needs to be evaluated Individually, so alarmvalues can be set, based on the segments conditions

IEC 61158 Fieldbus Specifications

ADM Calculated Alert Limits

ADM Measured FF Data

Online monitoringOnline monitoring

Displays measurement values

– Issues warnings and alarms – Highlights violations with color coding:

Good value

Maintenance required

Out of specification

The segment is still operating with good performance

Online Monitoring – Global AlarmingOnline Monitoring – Global Alarming

Monitoring the physical layer ensures error freeoperation of the process

During operation the Advanced Diagnostic Module:Monitors changing PL conditions, notifies whendeviations occur and alerts operators before thesegment fails

Diagnostic MenuDiagnostic Menu

ADM delivers actionableinformation for quick

resolution1 Active messages

2 Actionable information withsolution guideance based

on expert knowledge3 History with timestamps

When the failure…

… occured

… disappeared – Export function for external

analysis and storage

Built-in Fieldbus Oscilloscope

Troubleshooting ToolsTroubleshooting Tools

Physical Layer Diagnostics: FuturePhysical Layer Diagnostics: Future

The key advantage of a physical layer monitoring tool isthe ability to identify potential fieldbus segment

degradations and enable maintenance action before asystem malfunction or related process alarm occurs

Industry trend is toward automated “Expert Tool”

Tools must include solutions guidance (i.e. intelligent

scope) Allow for remote access

Wizard driven – user friendly

Easy to integrate into PAM systems

Where To Get More InformationWhere To Get More Information

Other training sessions

– Automated Fieldbus Segment Commissioning

Session 7-1441 – Fieldbus Predictive Maintenance with AMS Suite

Session 5B-1474

www.controlglobal.com/articles/2009/FieldbusDiagno

stic0905.html?page=full

Visit us at the P+F booth in the exhibitions hall

www.pepperl-fuchs.com

5b-1484_advanced diagnostics for fieldbus

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