MULTAQA 2007MULTAQA 2007

CONTROL IN THE FIELD: CAPABILITIES, CONTROL IN THE FIELD: CAPABILITIES, LIMITATIONS & POTENTIAL APPLICATIONSLIMITATIONS & POTENTIAL APPLICATIONS

PO Box – 20753Al Khobar 31952, Saudi ArabiaTel No: 00966 3 891 95 94Fax No: 00966 3 891 16 56Email: inquiries@daresd.com

By Shibi EmmanuelHead of Department, I & C Engineering

Industrial Division, Dar Al Riyadh

Foundation Fieldbus and Foundation Fieldbus and Control in the FieldControl in the FieldThis presentation focuses on CIF capabilities, This presentation focuses on CIF capabilities,

limitations and applications:limitations and applications:

Introductory review of CIF and how it works.Introductory review of CIF and how it works.

Applications Overview of CIF in the Process Applications Overview of CIF in the Process industry.industry.

Limitations and how they can be addressed.Limitations and how they can be addressed.

Summary of RecommendationsSummary of Recommendations

Control in the Field: DefinedControl in the Field: Defined

Control System Network

Processor I/O Sub system

HSE

H1

Processor Linking DevicePID

AIAOPID

AO

AI

Traditional DCS: FF based Control System:

Control in the Field (CIF) : Control within H1 devices, typically on the same segment.

FOUNDATION FIELDBUS TECHNOLOGY

Processing

power in field devices

Standard

Communication

interface

Less cables, H/W

Better diagnostics

Single Loop Integrity

Inter-operability

Derived Benefits:1) Lower

Capex/Opex2) Safety3) Ease of Scale up 4) Faster Start up5) etc

Foundation Fieldbus leverages inherent capacities to deliver many benefits:

Control in the Field: An FF Capability

Use of Control in the Field further enhances benefits in an FF installation. How?

FF H1: Control Oriented featuresFF H1: Control Oriented features

FF provides interoperable, assignable Function blocksFF provides interoperable, assignable Function blocks

FF provides for deterministic transfer of real time data betweenFF provides for deterministic transfer of real time data betweendevices at the same time allows for queued and event based devices at the same time allows for queued and event based communications.communications.

Users can choose the device for FB execution, multiple blocks caUsers can choose the device for FB execution, multiple blocks can n execute in parallel in different devices at the same time.execute in parallel in different devices at the same time.

Users can choose the degree of redundancy, network topology, Users can choose the degree of redundancy, network topology, segment parameters like Macrocycle period etc, depending controsegment parameters like Macrocycle period etc, depending control l loop requirements.loop requirements.

Robust control with signals transmitted with associated signal qRobust control with signals transmitted with associated signal quality uality status.status.

CIF: Building BlocksCIF: Building Blocks

Ten Function Blocks for basic controlTen Function Blocks for basic control

–– AI, AO, DI, DOAI, AO, DI, DO–– PID, PDPID, PD–– BG(BiasBG(Bias & Gain)& Gain)–– RA(RatioRA(Ratio))–– ML(ManualML(Manual Loader)Loader)–– CS(ControlCS(Control Selector)Selector)

CIF: Building Blocks CIF: Building Blocks (..Cont)(..Cont)

Eleven Advanced Function BlocksEleven Advanced Function Blocks

–– AA: Analog AlarmAA: Analog Alarm–– TMR: TimerTMR: Timer–– AR: ArithmeticAR: Arithmetic–– IS: Input SelectorIS: Input Selector–– SPG: SPG: SetpointSetpoint Ramp GeneratorRamp Generator–– INT: IntegratorINT: Integrator–– DT: Dead TimeDT: Dead Time–– LL: Lead/LagLL: Lead/Lag–– SC: Signal CharacterizerSC: Signal Characterizer–– OS: Output SplitterOS: Output Splitter–– DC: Device ControlDC: Device Control

CIF: Building Blocks CIF: Building Blocks (..Cont)(..Cont)

Multi I/O Blocks & Flexible Function BlocksMulti I/O Blocks & Flexible Function Blocks

–– Multi I/O BlocksMulti I/O BlocksMultiple Analog Input, Analog Output, Digital Multiple Analog Input, Analog Output, Digital Input and Digital Output.Input and Digital Output.

–– Flexible Function BlocksFlexible Function BlocksMulti I/O Blocks +allows user defined functionality Multi I/O Blocks +allows user defined functionality specified in any of the IEC 61131specified in any of the IEC 61131--3 languages3 languages

Vendor defined blocks/ Custom designed Vendor defined blocks/ Custom designed blocksblocks

CIF: Analog Input BlockCIF: Analog Input BlockAnalog Measurement

OUT_D

OUT

CIF: PID Function BlockCIF: PID Function Block

CIF: Applications OverviewCIF: Applications Overview

Example by Control Loop Example by Control Loop TypesTypes–– Single Loop PIDSingle Loop PID–– PID with Feed ForwardPID with Feed Forward–– PID with Cascade PID with Cascade

(Master/Slave loop)(Master/Slave loop)–– PID with OverridePID with Override–– Split Range ControlSplit Range Control–– Pressure, Temperature Pressure, Temperature

Flow compensationFlow compensation–– Ratio ControlRatio Control–– Signal CharacterizationSignal Characterization–– Basic InterlocksBasic Interlocks

Examples within a Examples within a processprocess–– Pressure/Flow controlPressure/Flow control–– Level/ Temperature Level/ Temperature

controls with Flow as controls with Flow as slave loopslave loop

–– MultiMulti--valve valve flow/pressure controlsflow/pressure controls

–– Gas flow measurementGas flow measurement–– Blending controlsBlending controls–– Calculations of Volume Calculations of Volume –– Inlet /Outlet valve Inlet /Outlet valve

interlocksinterlocks

CIF: Single Loop PIDCIF: Single Loop PID

TT-01TT-02

TCV-01

TIC-01

STEAM IN

CONDENSATE OUT

PRODUCT IN

PRODUCT OUT

CIF: Single Loop PIDCIF: Single Loop PID

PIDCAS_IN

IN

FF_VAL

BKCAL_OUT

OUT

BKCAL_IN

AOCAS_IN

BKCAL_OUT

OUT

AI OUT

TransmitterControl Valve

CIF: Cascaded PID with FeedCIF: Cascaded PID with Feed--forward Control forward Control

PID(TIC-01)

CAS_IN

IN

FF_VAL

BKCAL_OUT

OUT

BKCAL_INAI(TT-01)

OUT

CIF: Cascaded PID with feedCIF: Cascaded PID with feed--forward controlforward control

PID(FIC-03)

CAS_IN

IN

FF_VAL

BKCAL_OUT

OUT

BKCAL_IN

AOCAS_IN

BKCAL_OUT

OUT

AI(FT-03)

OUT

AI(TT-02)

OUT

CIF: Main PointsCIF: Main Points

CIF is suitable for most single loops, recommended to be the CIF is suitable for most single loops, recommended to be the default option. Typically gives better loop performance and default option. Typically gives better loop performance and higher overall reliability.higher overall reliability.

CIF can be also implemented for cascaded /CIF can be also implemented for cascaded /feedforwardfeedforward/ / Ratio / other types too.Ratio / other types too.

Process is indifferent whether control is in the field or in theProcess is indifferent whether control is in the field or in theControl system.Control system.

There are limits to the number of blocks available in a device, There are limits to the number of blocks available in a device, type of blocks available, time required to execute loop type of blocks available, time required to execute loop (macrocycle), etc. Design to be within these limits.(macrocycle), etc. Design to be within these limits.

CIF: Advantages & LimitationsCIF: Advantages & Limitations

AdvantagesAdvantages

–– Single loop integrity: Higher overall reliability.Single loop integrity: Higher overall reliability.–– Better Performance( Better Performance( egeg: faster : faster macrocyclesmacrocycles, synchronized , synchronized

execution) possible than with FFexecution) possible than with FF--CIH.CIH.–– Frees up control processor for other tasks.Frees up control processor for other tasks.–– Advantages are maximized for new plants / complete upgradesAdvantages are maximized for new plants / complete upgrades

LimitationsLimitations

–– Not for very fast loops : Not for very fast loops : typically for loop execution rate >= 200ms.typically for loop execution rate >= 200ms.

–– No Auto Tune, advanced control, complex logic.No Auto Tune, advanced control, complex logic.–– No sequence logic, Discrete I/O intensive applications.No sequence logic, Discrete I/O intensive applications.–– Not preferred for multiNot preferred for multi--segment loops.segment loops.

CIF: Typical client concernsCIF: Typical client concerns

Performance Performance

ReliabilityReliability

Device AvailabilityDevice Availability

Expertise within design, construction, Expertise within design, construction, maintenance.maintenance.

CIF: Concerns: ReliabilityCIF: Concerns: Reliability

Physical Integrity IssuesPhysical Integrity IssuesFailure of a bus segment can result in inaccessibility of all deFailure of a bus segment can result in inaccessibility of all devices on vices on that segment.that segment.

Failure of individual devices can disrupt controlFailure of individual devices can disrupt control

Failure of Link Active Scheduler, power supply and failure of H1Failure of Link Active Scheduler, power supply and failure of H1 cards cards can result in inaccessibility of all the devices on the segment.can result in inaccessibility of all the devices on the segment.

Good wiring practices, use surge protectors & short circuit proGood wiring practices, use surge protectors & short circuit protection.tection.

Function Blocks can be configured to set control to safe state Function Blocks can be configured to set control to safe state on on detection of bad input values to the block.detection of bad input values to the block.

FF easily supports other redundancy options like redundant devices and redundant H1 segments.

Use redundant H1 cards, redundant power supplies & back up Use redundant H1 cards, redundant power supplies & back up link active scheduler.link active scheduler.

CIF: Concerns: ReliabilityCIF: Concerns: Reliability

Compatibility between devices and Compatibility between devices and between hosts and devicesbetween hosts and devices

-- All devices and Hosts to be FF certified.All devices and Hosts to be FF certified.-- Host Vendors also conduct additional FF compatibility and Host Vendors also conduct additional FF compatibility and functional tests.functional tests.

Availability of Devices: Flow, Level, Availability of Devices: Flow, Level, Pressure, Temperature Pressure, Temperature

ABB Automation Products GmbHABB Automation Products GmbH 44 44 88

Anderson Instrument Co.Anderson Instrument Co. 11 11 22

Dandong Top Electronic Instrument Co., Ltd.Dandong Top Electronic Instrument Co., Ltd. 11 11 22

Emerson Process ManagementEmerson Process Management 55 44 11 33 1313

EndressEndress + Hauser+ Hauser 66 44 22 44 1616

EnrafEnraf Terminal AutomationTerminal Automation 22 22

Foxboro (and FoxboroFoxboro (and Foxboro--EckardtEckardt)) 22 11 1010 33 1616

GE SensingGE Sensing 22 22

Honeywell Industrial Automation & ControlHoneywell Industrial Automation & Control 1010 33 1313

KROHNE KROHNE MesstechnikMesstechnik 33 33

MagnetrolMagnetrol 33 33

OhmartOhmart / VEGA/ VEGA 55 11 66

Other 12 ManufacturersOther 12 Manufacturers 33 22 22 55 1212

Oval CorporationOval Corporation 22 22

PR ElectronicsPR Electronics 22 22

Ronan EngineeringRonan Engineering 11 11 22

Siemens AGSiemens AG 11 11 22

Smar International Co.Smar International Co. 33 11 44

VEGA VEGA GrieshaberGrieshaber KGKG 44 11 55

WIKA Alexander WIKA Alexander WiegandWiegand GmbH & Co. KGGmbH & Co. KG 11 11 22

Yokogawa Electric CorporationYokogawa Electric Corporation 55 44 22 1111

Grand TotalGrand Total 3434 2727 4141 2626 128128

Manufacturer NameManufacturer Name FlowFlow LevelLevel PressurePressure TemperatureTemperature TotalTotal

Availability of Devices: Final Control ElementsAvailability of Devices: Final Control Elements

ABB Automation Products GmbHABB Automation Products GmbH 11 11

AUMAAUMA 11 11

BiffiBiffi 22 22

Dresser Valve DivisionDresser Valve Division 22 22

Emerson Process ManagementEmerson Process Management 33 33

Flowserve CorporationFlowserve Corporation 11 11 11 33

Foxboro (and FoxboroFoxboro (and Foxboro--EckardtEckardt)) 22 22

Harold Beck & Sons, Inc.Harold Beck & Sons, Inc. 11 11

KOSO America Inc.KOSO America Inc. 11 11

L. Bernard S. A.L. Bernard S. A. 11 11

Metso AutomationMetso Automation 11 11

RotorkRotork Controls LtdControls Ltd 11 11

SAMSON AGSAMSON AG 11 11

Siemens AGSiemens AG 11 11

Smar International Co.Smar International Co. 11 11

SpiraxSpirax SarcoSarco S.R.L.S.R.L. 11 11

TopWorxTopWorx, Inc., Inc. 11 11

Tyco Valves & ControlsTyco Valves & Controls 11 11 22

WestlockWestlock ControlsControls 11 11 22

Yamatake CorporationYamatake Corporation 22 22

Yokogawa Electric CorporationYokogawa Electric Corporation 22 22

Grand TotalGrand Total 77 44 2121 3232

ManufacturerManufacturer Electric ActuatorElectric Actuator PositionerPositioner DiscreteDiscrete PositionerPositioner PneumaticPneumatic TotalTotal

Availability of Instruments: OthersAvailability of Instruments: Others

ManufacturerManufacturerConduct Conduct

ivityivity DensityDensityGas Gas

DetectorDetectorParticle Particle CountCount pHpH OxygenOxygen

Grand Grand TotalTotal

ABB Automation Products GmbHABB Automation Products GmbH 11 11

Berthold Technologies GmbH & Co. KGBerthold Technologies GmbH & Co. KG 11 11

ChemtracChemtrac Systems, Inc.Systems, Inc. 11 11

DraegerDraeger Safety Safety AG&CoAG&Co. . KGaAKGaA 11 11

Emerson Process ManagementEmerson Process Management 44 22 11 77

EndressEndress + Hauser+ Hauser 11 11 11 11 44

HachHach CompanyCompany 33 11 11 55

Knick Knick ElektronischeElektronische MessgerateMessgerate GmbH & GmbH & Co.KGCo.KG 22 22 11 55

MettlerMettler--Toledo GmbHToledo GmbH 22 22 11 55

OhmartOhmart / VEGA/ VEGA 11 11

Ronan EngineeringRonan Engineering 11 11

Smar International Co.Smar International Co. 11 11

Yokogawa Electric CorporationYokogawa Electric Corporation 22 11 22 55

Grand TotalGrand Total 1212 55 11 11 1010 77 3838

Typical Design Sequence without FF, CIFTypical Design Sequence without FF, CIF

Design Sequence with FF, CIFDesign Sequence with FF, CIF

CIF: Design IssuesCIF: Design Issues

Implementation of FF and CIF in particular requires additional Implementation of FF and CIF in particular requires additional steps which can be accommodated into current design steps which can be accommodated into current design methodology.methodology.

Design Engineers need thorough knowledge of FF Design Engineers need thorough knowledge of FF architecture, capabilities and limitations as well as the procesarchitecture, capabilities and limitations as well as the process s control requirements.control requirements.

Use of CIF requires Design Engineers to synthesize Use of CIF requires Design Engineers to synthesize information from multiple points of view:information from multiple points of view:–– process controlprocess control–– Layout of Instruments in the fieldLayout of Instruments in the field–– Criticality and safetyCriticality and safety–– Capabilities and Limitations of an FF SegmentCapabilities and Limitations of an FF Segment

CIF: Design IssuesCIF: Design Issues

FF specification document is required early in the detailed desiFF specification document is required early in the detailed design to specify gn to specify the FF philosophy to be used in the project.the FF philosophy to be used in the project.

–– Specify criteria to categorize loops in terms of safety, criticaSpecify criteria to categorize loops in terms of safety, criticality, speed of execution lity, speed of execution requiredrequired

–– Specify segment loading, device selection allowed for each categSpecify segment loading, device selection allowed for each category of loopsory of loops–– Foundation Fieldbus publications on Foundation Fieldbus publications on ““System Engineering GuidelinesSystem Engineering Guidelines”” are available.are available.

Detail Design should take into consideration the following:Detail Design should take into consideration the following:

–– Number of and types of Function blocks available.Number of and types of Function blocks available.–– Assignment of devices to each segment.Assignment of devices to each segment.–– Trunk and spur cable length limits.Trunk and spur cable length limits.–– Voltage drop.Voltage drop.–– Redundancy requirements.Redundancy requirements.

Tools are available to ease the design process.Tools are available to ease the design process.

RERE--CAP: CONTROL IN THE FIELD: CAP: CONTROL IN THE FIELD: CAPABILITIES, LIMITATIONS & POTENTIAL CAPABILITIES, LIMITATIONS & POTENTIAL

APPLICATIONSAPPLICATIONS

-- Brief overview of FFBrief overview of FF--CIFCIF-- Applications overviewApplications overview-- Advantages & LimitationsAdvantages & Limitations-- Concerns and how they can be Concerns and how they can be

addressed.addressed.

Control in the Field: SummaryControl in the Field: Summary

CIF is recommended default option for new and upgrade CIF is recommended default option for new and upgrade projects and in many cases is the best option.projects and in many cases is the best option.

Performance, Reliability and other concerns about use of CIF Performance, Reliability and other concerns about use of CIF can be addressed effectively.can be addressed effectively.

Engineers and constructors need to be knowledgeable of CIF Engineers and constructors need to be knowledgeable of CIF benefits and limitations.benefits and limitations.

Design with CIF introduces new activities at Preliminary and Design with CIF introduces new activities at Preliminary and Detailed design, use of design tools helps.Detailed design, use of design tools helps.

CONTROL IN THE FIELD: CAPABILITIES, CONTROL IN THE FIELD: CAPABILITIES, LIMITATIONS & POTENTIAL APPLICATIONSLIMITATIONS & POTENTIAL APPLICATIONS

Questions?Questions?

MULTAQA 2007MULTAQA 2007Control in the Field: FF Capabilities, Control in the Field: FF Capabilities,

Limitations, ApplicationsLimitations, Applications

PO Box – 20753Al Khobar 31952, Saudi ArabiaTel No: 00966 3 891 95 94Fax No: 00966 3 891 16 56Email: inquiries@daresd.com

Shibi Emmanueleshibi@daresd.com

Thank You