commissioning simplified - fieldbus...opc server hart hart device library hart multiplexer connect...
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Commissioning SimplifiedARASU THANGAI – PEPPERL+FUCHS
Fieldbus Infrastructure
Commissioning Benefits
• Commissioning - Device integration• Commissioning - Physical layer
Commissioning Benefits
• Commissioning - Device integration
Device Integration
Continuous Productivity Improvements• Integrated system environment• Freedom of choice• Information availability• Fieldbus solutions to meet all plant requirements
Plug and produceDevice Integration
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Easier - Real Number Engineering Unit
No range mismatchUnit downloaded when device is replaced
Transmitter PositionerFF FF
BUSFF
CTRL
CPU
CPU
CPUDigital
Digital
DigitalDigital
TransmitterRange0-800 kPa
SystemRange0-400 kPa
8 mAProcess200 kPa
Reading100 kPa...alarms and tripsnot working
AIA/D
D/A 4-20 mA
AOD/A
A/D4-20 mA
RangeRange
Range mismatch
Range exceed (more than100%)
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Lower Cost & Faster
Traditional: 2 hours / device for 2 technicians
(Calibration)Attach deviceVerify 4-20 mA signal
» five pointsVerify link to control strategyCheck device parameters with handheld
Foundation fieldbus: 25 minutes / device for 1 technician (Remote)
Attach deviceDrag-and-drop commissioning wizardCompare configuration faster on computer
•Devices are auto-recognized•Devices are auto-addressed•Devices identify themselves
Plug-n-Play
Only FF has automatic addressing
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Fieldbus Maintenance Made Easy:Device Commissioning Wizard
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Fieldbus Maintenance Made Easy:Protective Decommission
Removing device in an orderly fashion
“Safely remove hardware”Temporary removal
To remove for calibration etc. with intention to put back into same place soon after
Permanent removalTo remove for replacement etc.
Control-in-the-field does not mean just “simple” PID
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Easier FF Device Commissioning and ReplacementCommission or replace device without
touching the softwareSystem automatically logs process in
background
Automatic configuration reconciliation with device database
Automatic configuration download
View details in historian and log
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Faster Project StartupExpress and Batch DownloadReduced commissioning time
•Initiate multiple downloads at the same time•Runs unattended•At pre-commissioning need not run as a background communication to real-time control
Intelligent Devices via Fieldbus is a MustProcess Industries worldwide require
fieldbus based systems because of cost reduction
Reduction of wiring and cabinet costsLess system and instrumentation hardwareReduced commissioning time
Intelligent devices enable Asset Optimization
Increase of maintenance effectivenessImproves process availabilityEnhances productivity
Aventis says: Fieldbus technology saves costs and enables innovative applications. Future plant will be equipped with fieldbus
Incorporating intelligent devices via fieldbus integration streamlines work processes, improves process and product quality, maximizes plant availabilityintegrates fieldbus seamlessly
Exploiting new levels of field device informationMaking device resident information available to the right people at the right time
Device Management lowers costs over life cycle in design, implementation, operation and maintenance
Device Management
Expectations on Fieldbus Technology• Industry proven and
reliable• High system availability
through redundancy concepts
• Intrinsically safe solutions• Seamlessly integrated
into control system • Access to device internal
data• Openness for all device
manufacturers• Easy to use
Optimization Engineering Operations
ControllerDiagnosisMaintenanceCalibration
ConfigurationParameterizationCommissioning
OperationDisplayAlarm signals
Process variablesTime synchronizationStatus
07
Field Devices
Fieldbus and Field Device Configuration• Integrated fieldbus
management tools and comprehensive Device Libraries for– Configuration of function
block applications– Device parameterization
with graphical user interfaces
– Online and offline configuration
• All devices accessible from a central workplace
• Early plausibility checks ensure proper and fast configuration
Fieldbus and Change History
Maintenance Event & Work Order History
Calibration Changes
Operator Changes
Configuration Changes
Process Event & Alarm History
Audit List
Intelligent Devices Enable Asset OptimizationOK!Oops!BAD!
• Scheduled monitoring of asset health status• Smart condition reporting• Notification of key personnel independent of their location• Generation of fault reports and submission to CMMS
Device Management
Device Management HART Fieldbus Builder PROFIBUS/HARTBasic HART DTM / HART DTM BuilderOPC Server HARTHART Device LibraryHART Multiplexer Connect
Device Management FOUNDATION Fieldbus
Fieldbus Builder FOUNDATION FieldbusOPC Server FOUNDATION Fieldbus FOUNDATION Fieldbus Device Library
Object Types
800xA
System
Commissioning Benefits
• Commissioning - Physical layer
Physical Layer Commissioning Guidelines
• IEC 61158-2 – Physical Layer standard
• AG 181 (Rev-3.2.1) – System Engineering Guidelines
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
User Benefit : Design guidelines
The physical layer – alive and well?
Proper terminationWater ingressGround faultsLoose wiring Faulty devices
The physical layer – alive and well?Proper terminationWater ingressGround faultsLoose wiring Faulty devicesUnstable communicationShort circuitsBulk power failure…
Typical locations and Fieldbus issues
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Advanced Commissioning for physical layerIntegrated single tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Advanced Commissioning for physical layerA portable tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Commissioning Tools expectations
User interface in the control room:
Display of values Warnings with actionable informationColor coding for easy recognition
Value-add:Automated commissioning procedures and documentationLive segment monitoring with alarmsExpert troubleshooting tools
Embedded expert-knowledge
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Commissioning Tools Expectaions
Design Verification tools: design of the physical layer
Verify against original design Automated checkout procedures
Longer plant uptime Know before you act Actionable information in clear text
TroubleshootMonitorCommission
Cas
h Fl
ow
Plan and purchase
Install and commission Operate and maintain
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Commissioning in the pastAlways on the critical pathManual, step-by-step procedureLabor intensiveRequires
» Screw driver» Check sheet» Pencil» Multimeter» Oscilloscope
Connect one device at a timeDisconnect after testing
Test Report
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Commissioning nowVerify address settingWire up devices in the right locationCheck shieldingActivate communicationUse automated work procedures
» Testing » Documentation
All devices at onceWiring remains undisturbed
Commissioning Wizard
Test Report
Cable
Type A Type B
Cable structure Twisted wire pair, shielded
One or more twisted wire pairs, complete shielding
Conductor cross-section (nominal) 0,8 mm² (AWG 18) 0,32 mm² (AWG 22)
Loop resistor (direct current) 44 Ω/km 112 Ω/km
Wave resistance at 31.25kHz (direct current) 100 Ω ± 20% 100 Ω ± 30%
Wave attenuation at 39kHz 3 dB/km 5dB/km
Capacitive asymmetry 2 nF/km 2nF/km
Group runtime distortion (7.9 … 39 kHZ) 1.7 µs 1.7us
Covering level of the shield 90 % 10%
Max. extent of the network for non IS applications 1900 m 1200 m
Max. extent of the network for IS applications (e.gusing FISCO power supplies)
Suitability check for existing cable
Failure margin checkCommunications check
Device coupler short-circuit check
Surge Protector health check
Water Ingress
38
Water Ingress in Junction Box
39
Water Ingress in Junction Box
40
Water Ingress information at DCS level
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Commissioning based on StandardsSimple to useEliminates manual test procedures Ensures compliance with AG181 and IEC 61158-2Creates baseline report:
» Snapshot of all measurements » Complete documentation
Recommends warning and alarm limits for the ADMStores limits in non-volatile memoryReduces pre-commissioning time by up to estimted 80%
Commissioning saves time and money
A few mouse clicks conduct automatic testing Reports on the actual installation with all devices connectedAutomatic setting of warning and alarm limits
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Online monitoring
Advanced Commissioning tools increases the number of detectable faults
Monitors continuous operation Notifies when deviations occur Enables proactive plant up keep Keeps the plant up and running
The Advanced Commissioning Tools helps to:Monitor the health condition of the physical layer Detect changing conditionsReport limit violations with time stampsAlert operators before the segment fails
FCG Thai Seminar | 19 Nov 2015 at Pattaya, Thailand
Online monitoring – Continuous health check – Inline with NAMUR
Commissioning Tools increase the number of detectable faults
Displays measurement values Issues warnings and alarmsHighlights violations with color coding:
Good value
Maintenance requiredOut of specification
Fault Finding is Easier
•Commissioning Tools delivers actionable information to minimize the time spent for fault finding
1 Active messages2 Actionable information with solution guideance based on
expert knowledge3 History with timestamps
When the failure…… occured… disappeared
Export function for external analysis and storage
Bad cable impedance
Loose wire
Troubleshooting is easier
•Advanced Diagnostics Tools provide expert tools for fast fault finding
Simplifies testingCaptures intermittent problemsPinpoints the issue Guides to potential solutionsIs accessible from remote for
consultation with fieldbus experts.
Simplified commissiong leads CAPEX and OPEX savings
Rapid commissioning: Accelarates loop checkLonger operation: Warns before failureFaster troubleshooting: Assists with actionable information
Conclusion- DeviceFoundation Fieldbus Simplifies device commissioning and saves time. Device integaration into the control system environment made fool proof.
Fieldbus devices transmit measurements are unaltered.
For most Fieldbus transmitters there is no need to set a range. Avoids Rang mismatch, the reading for controls and alarms in the system will be correct. Therefore, traditional five point loop test can be replaced by a simple plausibility check thus speeding up project completion
Fieldbus devices have no error due to analog signal calibration (4-20 mA) differences between transmitter output and DCS input, saving time on re-calibration
Conclusion- DeviceFoundation Fieldbus address assignment is automatic and error free. Some systems have wizards to guide the technician, even commission the devices without using software, thus demystifying Fieldbus commissioning
The configuration for all Fieldbus devices is maintained in a database and can be downloaded remotely in a single click saving time as compared to checking devices one by one, parameter by parameter, with a handheld field communicator and maintaining documentation separately.
Conclusion – Physical Layer
Advanced Diagnostics tools for for physical layer reduced physical layer commissiong time and provided online monitoring and reporting system that saves CAPEX and OPEXMost 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 earlyMany 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
QUESTIONS?