fieldbus tutorial part 8 - fieldbus function blocks

Foundation Function Blocks

[File Name or Event]Emerson Confidential27-Jun-01, Slide 2

Agenda

Standard Blocks

Block Examples


Applications are modeled using function blocks which may be distributed between field devices.

FF function block application process is consistent with IEC 61804 Process Industry Function block

Function block execution may be synchronized through system management - based on each device having a common sense of time.

USER LAYER

PHYSICAL LAYER

COMMUNICATIONSTACK

Function Block Application Process


Mode and Status, foundation of distributing control

Engineering Unit Value + STATUS attributes of input and output parameters

Target and Actual attributes of Mode parameter

BLOCK_ERR Parameter


Mode

Possible modes:


Mode

TARGET, ACTUAL, PERMITTED

TARGET is the desired mode

ACTUAL is the actual mode.

PERMITTED are the permitted mode

You can not use a non permitted mode

If the resource block is out of service, all blocks go to Out of Service

If the Transducer Block is in OOS, the status will be Bad, Out of Service


BASIC FF FUNCTION BLOCKS

Discrete Input

Discrete Output

Analog input

Analog Output

PID, PI, I Controller

P, PD Controller

Control Selector

Manual Loader

Bias/Gain Station

Ratio Station


ADVANCED FF FUNCTION BLOCKS

Pulse Input

Complex Analog Output

Complex Discrete Output

Step Output PID

Device Control

Setpoint Ramp Generator

Splitter

Input Selector

Signal Characterizer

Lead Lag

Deadtime

Arithmetic

Calculate

Integrator(Totalizer)

Timer

Analog Alarm

Discrete Alarm

Analog Human Interface

Discrete Human Interface


New Block Subclass - Flexible

Flexible (MIO) - Part 4

Multiple Analog Input - 8 Channels

Multiple Analog Output - 8 Channels

Multiple Discrete Input - 8 Channels

Multiple Discrete Output - 8 Channels

Flexible (61131) - Part 5

Application-specific Blocks

Flexible Function Block For Devices that

are Complex or have high I/O Count


Function Blocks Addressed by FF Interoperability Testing, v4.5

AI – Analog Input

AO – Analog Output

PID – PID Control

DI – Discrete Input

DO – Discrete Output

ISEL – Input Selector

ARITH– Arithmetic

SC – Signal Characterizer

INT – Integrator

MAI – Multiple Analog Input

MAO – Multiple Analog Output

MDI – Multiple Discrete Input

MDO – Multiple Discrete Output


Example - Emerson 3051

Resource

Block

Analog Input

Block (Press)

Analog Input

Block (Temp)

Transducer

Block(Sensor)

Diagnostic

Block

LCD

Block

PID

Arithmetic

Input Selector

Integrator

Signal

Characterization

Typical Fieldbus Tx

3051S - Standard

+

3051S - Optional


FF function block capability may be used to address many applications

Single loop feedback control

Feedforward control

Cascade control

Interlock based on a discrete input

Input selection when redundant measurements are available

Flow integration

Calculations and signal characterization


Control in the field

Fieldbus

AI1

Fieldbus

AI3

AI2

PID1

AI4

PID3

AO1

PID2 AO2

M

FT

FIC

FCV

LT LIC

TT

TCV TIC

PT


Engineering Monitoring and Control Applications Using Function Blocks


Easy control strategy configuration

TT100

TIC100

FT101

FIC101 FCV101

CASCADE CONTROL

CAS

ININ

SP



Temperature

TransmitterFlow

Transmitter

TT100

TIC100

FT101

FIC101 FCV101

OUT

OUT OUT

OUT

BCKCAL_OUT

Positioner.

IN IN

CAS-IN CAS-IN

BCKCAL_OUT BCKCAL_INBCKCAL_IN



Temperature

TransmitterFlow

Transmitter

TIC100

FT101

FIC101

FCV101

AI

PID

AI

PID AO

OUT

OUT OUT

OUT

BCKCAL_OUT

Positioner.

TT100

TT100.OUT

IN IN

CAS-IN CAS-IN

BCKCAL_OUT BCKCAL_INBCKCAL_IN


Single Loop PID Control Configuration


AI

PIDBCKCAL_IN

BCKCAL_OUT

CAS_IN

IN OUT

FF_VAL

TRK_VAL

TRK_IN_D

AOOUT

OUTCAS_IN

BCKCAL_OUT

Transducer Scale:

10 to 210 in H20

OUT Scale:

0 to 15 ft

PV Scale:

0 to 15 ft

OUT Scale:

0 to 100 %(Default)

Kp=1, Tr=10min

Direct Acting

PV Scale:

0 to 100 %(Default)

Transducer Scale:

0 to 180 0 rpm

Fail Safe Value=0

TAG: LT108

TAG: LIC108

TAG: SC108

Control loop Configuration


Analog Input Block

TRANSDUCER

SCALE

OUTPUT

SCALE

Alarms

LOW/LOW-LOW

HIGH/HIGH-HIGH

OUTTRANSDUCER

Sensor

Type

Trim

Characterization

Diagnostics

100 % = 100

FILTER25 % 25 %

FUNCTION

Direct

Indirect

Square root

100 % = 100

50 in H2O

STATUS

• Good

50 in H2O

• Good

• Hi Alarm

0 % = 0 0 % = 0

dp measurement


Calibration in Fieldbus

Calibration - checking against a standard source - is done in the Transducer Block

Wet leg compensation - Elevation and Suppression - should be done at the Analog Input Block.


TRANSDUCER BLOCKS PROVIDE DEVICE SPECIFIC INFORMATION


Impact of sample rate

Transducer

Updates

(free running)

AI

Updates

(Depends on

Macrocycle)

Transducer

Block

Analog

Input

Block

Macro Cycle


Transducer Block Filtering

Use the Transducer Block Filter to compensate for differences between transducer and Analog Input execution rates

Transducer

Block

Analog

Input

Block


Example: Single Loop

FC

101

FT

101Feed

Feed Tank


Single Loop - Fieldbus


Example: Interlock Based on Status of Blocking Valve

FC

151

FT

151 Reactor 1 Feed

ZT

150


Interlock Example: Use of Discrete Input From Upstream On-Off Valve


Example: Selection of Redundant Measurement

Static Mixer

AC

302

AT

301

Reactor 1

Feed A

Feed B

AT

302

AY

302


Automatic Input Selection for Redundant Measurements


Example: Cascade Control

TC

202

TT

202

TT

201

TC

201

RSP

Reactor 1

Coolant

Discharge


Cascades Loop - Fieldbus


Flow Compensation – Linear

Flow Compensation – Squareroot

Flow Compensation – Approximate

BTU Flow

Multiply and Divide

Average of inputs

Sum of inputs

Fourth order polynomial

Simple HTG compensate level

Arithmetic Block May be used to address a Variety of Calculations


Example: Calculation and Integration of Mass Flow

FY

3-4

FT

3-4

PT

3-4TT

3-4

FY

3-4

Process Steam

Pressure & Temperature

CompensationTotalized

Mass Flow


Example: Arithmetic and Integrator Function Blocks


TE

801A

Distillate Receiver

Column

Distillate

Bottoms

Steam

Feed

TE

801B

TE

801C

TE

801D

TE

801E

Fieldbus enables Multi-sensor Applications

TT

801

Distillation


Multi-sensor Applications (Cont)

Chemical Reactors

Cooling

Fluid In

Cooling

Fluid Out

TE 901A-H

TT

901

Process Out

Process In


Example: Multiple Analog Input Block Supports a Maximum of 8 Inputs From a Fieldbus Device


CV-101A/O

NOTES

BRIGHTENGINEERING

1 UNLESS OTHERWISE NOTED ALL INSTR.ON THIS DRAWINGCARRY AN AREADESIGNATION OF878, THAT IS FI-1 IS878FI-1.

GOODMANUFACTURING

IP102

FIELD LOCATION

FIC102

FRC103

161

LIC101

4

AI103

19 20 21 22 23 24 25

MOTOR CONTROL

26

INTERLOCKS

26 LIME FEEDERS WILL TRIP OFF IF GREENLIQUOR FLOW IS LOW

REV DESCRIPTION

0 OWNER REVIEW

20

19

FT102

2

6

CONTROLROOM

Example Application

AC106

8

FY104

AT103

21

4

AT107A

LT101

1

AT107B

9

TT105

HS107

7

AT106

From Recovery Area

Condutivity

9

AIC107

Re-BurnedLime

LT108

PurchasedLime

LT112

17

Green Liquor Storage

IP104A

IP104B

Heater Cooler

15LT111

SC111

16

SC112

SC108

DT109

12

FT110

13

14

11

SC110

TT104

3

5

8

10

18

3 1 5

TIC104

6 7

TIC105

10

LIC108

11 12

DIC109

FY110

14 13

FIC110

17

HIC112

18 15

LI111

24

25

23

22

FAL102

26

To Slaker #2Slaker #1


Control Applications May Be Distributed

Fieldbus Segment #2

FT102 SC111 AT103 AT107B AT107AIP102 AT106LT101

Causticizing Process

Green Liq Flowcv

Lime Grn Ratio

Caust. Efficiency Control

Cond.Meas. Select


Indicator

Re-BurnedLime

AI

LT111

LI

111

LT

111


Analog Input Block

TRANSDUCER

RANGE

OUTPUT

RANGEAlarms

HI, HI_HI

LO, LO_LO

OUTTRANSDUCER

Sensor

Type

Trim

Characterization

Diagnostics

100 %

FILTER

100 %

0 %0 %

SIMULATE

(VALUE +STATUS)

AUTO

MANUAL

MANUAL

VALUE

CONVERT

SQ. ROOT

LOW_CUT

L_TYPE

MODE

XD_SCALE OUT_SCALE

PV

PV_FTIME

Measurement

UNITUNIT

FIELD_VAL


Tim e (Sec)

63% of Ch an geP V

FIELD_VAL

P V_FTIME

OUT (Mode in Au to)

OUT (Mode in Man )

Analog Input Function Block


Indicator Configuration


PurchasedLime

Hand Indicator Controller

AI AOML

LT112 HIC112 SC112

HIC

112LT

112

SC

112


CAS_INHI/LO

LIMIT

CONVERTPV_SCALE

XD_SCALETRANSDUCER

MODE

OUT

SIMULATE

Manual

Value

CAS

AUTO

I/O OPTIONS

SP

CONVERTPV_SCALE

XD_SCALE

BCKCAL_OUT

Readback

PV

SP RATE

LIMIT

MANUAL

Analog Output Block


Time (Sec)

SP

1 Secon d

OUT (Mode in Man )

OUT (Mode in Cas )

SP _RATE_UP

1 Secon d

SP_RATE_DOWN

OUT (Mode in Au to)

Analog Output Function Block


IN FILTEROUTPUT

OUT_HI_LIM

OUT_LO_LIM

OUT

BCKCAL_IN

ALARM

HI / LO

TRK_IN_D

TRK_VAL

Manual Loader Function Block

PV_FTIME


Hand Indicator Controller Configuration


Single Loop PID Control

AI PID AO

LIC

108

LT

108

SC

108

LT108 LIC108 SC108


PID Function Block

PID

CALCULATIONOUT

MANUAL

MANUAL

VALUE

CAS_IN

IN

SP

FF_VALUE

TRK_IN_D

TRK_VAL

FF_GAIN

MODE

+

BCKCAL_IN

BCKCAL_OUT

KP,TR,TD

OUT_HI_LIM

OUT_LO_LIM

PV_SCALE

OUT_SCALE

FF_GAIN

C

AC,A

ALARMHI / LO

DEV

SP PV


AI

PIDBCKCAL_IN

BCKCAL_OUT

CAS_IN

IN OUT

FF_VAL

TRK_VAL

TRK_IN_D

AOOUT

OUTCAS_IN

BCKCAL_OUT

Transducer Scale:

10 to 210 in H20

OUT Scale:

0 to 15 ft

PV Scale:

0 to 15 ft

OUT Scale:

0 to 100 %(Default)

Kp=1, Tr=10min

Direct Acting

PV Scale:

0 to 100 %(Default)

Transducer Scale:

0 to 180 0 rpm

Fail Safe Value=0

TAG: LT108

TAG: LIC108

TAG: SC108

Control loop Configuration


Single Loop PID Control Configuration


AI PID

AI PID

CSEL AO

<

Override Control

FY

110

SC

110

FIC

110

DIC

109

FT

110DT

109

DT109 DIC109

FIC110

FY110 SC110

FT110


Control Selector Block

SEL_1

SELECTORSEL_TYPE

high, medium

or low

OUTPUTOUT_HI_LIM

OUT_LO_LIM

OUT

BCKCAL_IN

SEL_1

SEL_1

SELECTORSEL_TYPE

BCKCAL_OUT1

BCKCAL_OUT1

BCKCAL_OUT1


Override Control Configuration


AI PID

AI

PID SPLT

AO

AO

Cascade Control, Split Range Control

TIC

105

IP

104A

TT

105

IP

104B TT

104

FY

104

TIC

104

COOLERHEATER

TT105TIC105

TT104

TIC104 FY104 IP104A

IP104B


ValvePosition(% of Span)

Split Range Output (FY104)

TIC104 Output (% of Span)1000

0

100

Cooling (IP104B)

Heating (IP104A)


CAS_INHI/LO

LIMIT

MODE

OUT_1

BCKCAL_OUT

SP RATE

LIMIT

CALCULATE

OUTPUT

OUT_2

BALANCE

OUTPUT

BALANCE

OUTPUT

BCKCAL_IN_1

BCKCAL_IN_2

SHED MODE

Splitter Block

TABLE


SP

0 100

0

100

0

100

0

100

100

100

0

0

OUT_1

OUT_2

LOCK_VAL “h olds”

LOCK_VAL “is zero”

OUT_ARRAY

0 100 0 100

IN_ARRAY

0 100 0 100

OUT_ARRAY

100 0 0 100

IN_ARRAY

0 40 35 100

OUT_ARRAY

0 100 0 100

IN_ARRAY

0 40 35 100

Splitter Block


Cascade Control, Split Range Control Configuration


AI ISEL PID

AI

AI

PID RATIO

AI

AO

CV-102A/O

Conductivity

Ratio and Cascade

PID AOAI LL

FIC

102

AT

107B

AT

107AAT

106

AT

103

IP

102FT

102

SC

103 HS

107

AIC

107

AC

106FRC

103

AY

103

AT107A

AT107B HS107 AIC107 AIC106 FRC103 SC103

IP102FIC102FT102

AT106

AY103AT103


Lime/GL Ratio

Lime/Green Liquor Vs Causticizing Efficiency

Causticizing Efficiency


BALANCE

OUTPUTOUTX

MANUAL

VALUE

AUTO

MANUAL

MODE

DYNAMIIC

COMPENSATION

FOLLOW

IN

LAG_TIME

LEAD_TIME

GAIN

Lead Lag Function Block


Tim e (Se c)

IN

OUT (FOLLOW On ), Au to

OUT (FOLLOW Off), Au to

2.0 Le ad/Lag

1.0

0.50 Le ad/Lag

LAG_TIME

63% of Ch an ge

De ltOu t

De ltIn

GAIN =De ltOu t

De ltIn

Lead-Lag Function Block


Ratio and Cascade Configuration


AI PID SPLT AI PID AO

From Recovery Area

Green Liquor Storage

B/G

B/GAI PID AO

Throughput Coordination

LIC

101

LT

101FT

102

IP

102

FIC

102

LT101 LIC101 LY101

LY101A

FT102 FIC102 IP102


Throughput Coordination Configuration


Control For Motors

OUTPUT

FAL102 RunContact

Start

Stop

AI AALM

DI DEVC DO

FAL

102

FT

102

26

SC

111

25

FAL102FT102


Control For Motors Configuration


Example - Control Execution

AI

PID

AI

PID AO CAS

IN

IN

SP

Product

Steam

TT100

TIC100

FT101

FIC101 FCV101

TIC100.OUT


16 ~ 20 mA

I (mA)

Iq1

I (mA)

Iq2

Iq3

I (mA)

Total Current = Iq1 + Iq2 + Iq3 + ……... Iqn

Link Active Scheduler

Token

Token

Token

Scheduling By System Management – see Communication


AI

PID

AI

PID AO CAS

IN

IN

SP

280oF

Product

Steam

TT100

TIC100

FT101

FIC101 FCV101

279oF

355lb/s


AI

PID

AI

PID AO CAS

IN

IN

SP

280oF

Product

Steam

TT100

TIC100

FT101

FIC101 FCV101

279oF

357lb/s

355lb/s55%


Data sequence

Cyclic Acyclic

TT

FCV

FT

Block Execution

TIC100.OUT

PID

FIC101.OUT

AI

PID

macro-cycle

355 lb/s

Good, Cascade

AI

55 %

Good, Cascade

TIC100.OUT

PID

FIC101.OUT

AI

PID

macro-cycle

356 lb/s

Good, Cascade

AI

56 %

Good, Cascade


AI

PID

AI

PID AO CAS

IN

IN

SP

280oF

Product

Steam

TT100

TIC100

FT101

FIC101 FCV101

279oF

357lb/s

355lb/s55%


Data sequence

Cyclic Acyclic

TT

FCV

FT

Block Execution

TIC100.OUT

PID

FIC101.OUT

AI

PID

macro-cycle

355 lb/s

Good, Cascade

AI

55 %

Good, Cascade

TIC100.OUT

PID

FIC101.OUT

AI

PID

macro-cycle

356 lb/s

Good, Cascade

AI

56 %

Good, Cascade


AI

PID

AI

PID AO CAS

IN

IN

SP

280oF

Product

Steam

TT100

TIC100

FT101

FIC101 FCV101

55%355 lb/s


Data sequence

Cyclic Acyclic

TT

FCV

FT

Block Execution

PID

AI

PID

macro-cycle

355 lb/s

Good, Cascade

AI

55 %

Good, CascadeAO

355 lb/s

Good, Cascade PID

AI

PID

macro-cycle

355 lb/s

Good, Cascade

AI

55 %

Good, CascadeAO

355 lb/s

Good, Cascade


Backup LAS

AO

AI

PID

AI

PID

Fieldbus

ADVANCED

CONTROLOPTIMIZATION

LAS

PS

LAS


An installation with Fieldbus:Control in the Controller

PS CH1

PS

F

TM

1 - Transmitter 2 - Valve

3 - Cable

4 – Fieldbus

Power Supply

5 – H1 Card6 - Backplane

7 - Controller

8 – Controller

Power Supply


An installation with Fieldbus:Control in the Field

PS CH1

PS

1 - Transmitter 2 - Valve

3 - Cable

4 – Fieldbus

Power Supply


Reliability Analysis

Control in the DCS

1. Transmitter

2. Valve

3. Cable

4. Fieldbus Power Supply

5. H1 Card

6. Backplane

7. Controller

8. Controller Power Supply

Control in the Field

1. Transmitter

2. Valve

3. Cable

4. Fieldbus Power Supply

MTBF = X MTBF = 1.833X


Comp Flow Information to

PID

Use the Compensated DP Flow Calc in the ARTH Block For Much tighter Control

Increase Accuracy

Easy Configuration

Execution time = 20 ms

In

In

In

ARTHM

OutARTHM

FT-100

PT-100

TT-100

FT-100

PT-100

TT-100Comp

FlowIn


Measure Tank Level without Capillary Systems by using the ARTH Block

In

In

In

ARTHM

Out

PTB-100

PTT-100

Level In

PTT-100

PTB-100

Increased Accuracy



Use the Input Selector Block to Average or Select Stacked Transmitters

First Good

Maximum Value

Minimum Value

Average

Execution time = 20ms

Input

Selector

In

In

In

In

In

In

In

In

Out

IS


Use the Signal Characterizer to Define up to a 20 Point Input/Output Relationship

20 Point Strapping Table

Execution Time = 20 ms

In

In

SGCROut

Out


Use the SGCR to correct for Changing Flow Coefficients

In

In

SGCROut

Out

Reyn

old

s N

um

ber

Flo

w E

rro

r

Flow in Gal/hr.

Flow without Correction

Flow Corrected with SGCR Block

Coefficient correction

set for 4000 Gal/hr.

Increased Accuracy


Output out

of AI Block


Use the Integrator Block to Totalize Flows and Ratio Control Totalizer

Range 0-SP or SP-0

Set Point Pre Trip

Set Point Trip

Integrate Two Flows

Flow 1

Flow 2

Flow 1*(Mix Ratio)-Flow 2 = 0

Maintain Mix Quality

Execution Time = 20 ms

In

In

INT Out

Pre Trip OutIn

In

In

IN_1

IN_2

Rev_Flow1

Rev_Flow2

Reset_IN

Trip Out


Use the Integrator Block to Totalize Flows and trip a Discrete Output

Use Integrator Block

output to Fine Tune

Loading

Flow 1

Flow 2

FT 100 FCV 100

FT 101

FCV 101

In

In

INTOut

Pre Trip OutIn

In

In

IN_1

IN_2

Rev_Flow1

Rev_Flow2

Reset_IN

Trip Out

FCV 100

FCV 101

Total

Flow 1

Flow 2

Set Point

Pre Trip

Trip

To

tal


Output Splitter

STEAMCOLD

WATE

R

AI

PID

SPL

AO AO

IN

O1

O2

BK

BK1

CAS

_IN

O1O2

BK2


Control Selector

PIDLTSEL

FT

PID

PID

S2

O

BK1

BK2

BK

S1 Max

Min

First Good,

MiddleS3

BK3


Advanced Flow compensation Function Block

Calculates mass flow for different types of gases and liquids based on Pressure and Temperature variations.

p

t

Mass

flow

Δp


Multiple Analog Input Block Supports 8 Inputs


Temperature Monitoring and Data Acquisition

Example:

8 independently configurable channels

– RTDs and Thermocouples

Multi

Sensor

8 Temperature

Sensors

Dis

till

ati

on

Co

lum

n

FOUNDATION fieldbus

H1 Segment,

2-wire


Control

Room

T/C Wire (8 x $1.00/ft) =

$8.00/ft

Transmitter Wire

(1 x $0.30/ft)=

$0.30/ft

T/C Wire

DCS or

PLC

I/O

Multi

Sensor

Control

RoomH1 Card

Value Proposition

Multi-Sensor vs. Sensors Wired Direct:


Discrete Input / OutputWith Logic Capability

Com Input Output

SW1 SW2

FOUNDATION Fieldbus

H1 Segment,

2-wire


848L Logic Controller for Fieldbus

Multiplexer for discrete inputs

– 8 inputs / 4 outputs

Field hardened

Basic Logic Blocks

Logic Function Blocks

Foundation Fieldbus H1

24 Wires

2 Wires

Control room

18

1 8

Logic

Timer

Timer

Logic


Multiple Analog Input Block Supports 8 Inputs


Fieldbus enables Multi-sensor applications

Chemical Reactors

Process In

Process Out

Catalyst Tube

Cooling

Fluid In

Cooling

Fluid Out

Up to 24

wires !

Fielbus H1 - two wires


Multi-sensor application

Distillation Columns

M1

M2

M3

M4

M5

M6

Naptha

Crude Oil

Kerosene

Light Gas Oil

Heavy Gas Oil

Butane and Lighter Gas

Straight Run

Gasoline

Straight Run Residue

Fielbus H1 - two wires


Application-

Specific

Algorithm

e.g., IEC 61131

Ladder Logic

Structured Text

Function Blocks

FFB is a “Wrapper” for an Application-specific Algorithm

Flexible Function Block

Inputs Outputs


Flexible Function Block Capability in HSE Devices

IEC 61131


PLC

FFB

FFB

Dry Contacts Opto sensors

Pressure Switches

Push Buttons

On-Off Valves

Motion ControlDrives

Lights/Displays

Typical Applications

Sequence of EventsCoordinated Drives (Roll Handling)

Thermocouples

RTDs

HMI

PLC

Multiplexer

Supervisory Data AcquisitionI/O Subsystem Interface

FFB

100 Mbit/s Switch

Gateway

DeviceNet

Profibus

Interbus S

World Fip

ControlNet

FFB



Batch Controller

Typical Applications

Burner ManagementBatch Sequencing

HMI100 Mbit/s Switch

Linking

Device

Linking

Device

H1

Networks

Gateway

DeviceNet

Profibus

Interbus S

World Fip

ControlNet

FFB

FFB

FFB

AI, AO, PID, FFB



Summary - Fieldbus Foundation Solution

Both Continuous and Discrete Requirements Are Met By FF Function Block Set Capability

fieldbus tutorial part 8 - fieldbus function blocks

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