5B-1484_Advanced Diagnostics for Fieldbus
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Transcript of 5B-1484_Advanced Diagnostics for Fieldbus
7/31/2019 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
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PresentersPresenters
Chris Williams
Bernd Scheussler
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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
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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.
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Design ChallengeDesign Challenge
The Power of Foundation Fieldbus
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Design ChallengeDesign Challenge
Foundation Fieldbus Implementation
BPCS with Host card
Power Conditioner
Route Trunk withTerminators
Hang Instruments
TT
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Design ChallengeDesign Challenge
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
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Design ChallengeDesign Challenge
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?
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Design ChallengeDesign Challenge
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?
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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.
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Design SolutionDesign Solution
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
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Design SolutionDesign Solution
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.
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Design SolutionDesign Solution
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
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Design SolutionDesign Solution
Basic Layout for FISCO FieldBarrier with HPT
FISCO
HPT
T T
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Design SolutionDesign Solution
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
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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
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Physical InstallationPhysical Installation
Field BarrierInstallation
High-PowerTrunk routed inconduit
Only spurs have
min-fastconnectors
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Physical InstallationPhysical Installation
Field Instrumentationhave FISCO approval.
Spur cables are keptshort. Typ. < 30 feet
Routed in small cabletrays separate from all
non-I.S. circuits.
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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.
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Gotcha MomentGotcha Moment
Double checked segment using P+F ADM.
Segment had passed physical checkout but ADMfound a problem!
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Gotcha MomentGotcha Moment
ADM provideddetailed information
about the segmentand the problem
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Gotcha MomentGotcha Moment
Diagnostic pointedstraight to the
problem. A terminator was not
enabled on the last
junction on the trunk
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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!
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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.
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Commissioning ReportsCommissioning Reports
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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.
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The Great UhOh!The Great UhOh!
SCOPE SWEEP to the rescue!
The backup link master was periodically…well….
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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.
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SummarySummary
Foundation Fieldbus installation based on FISCO andutilizing ADM
Faster Installation, Commissioning, andTroubleshooting
Constant monitoring
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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
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More on Advanced DiagnosticsMore on Advanced Diagnostics
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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
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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 $$$
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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
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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
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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
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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
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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
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CommissioningCommissioning
PrintPrint
““Save asSave as …”…”
e.g. pdfe.g. pdf--filefile
Export the completeExport the complete
ReportReport
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Commissioning Report – Page 1Commissioning Report – Page 1
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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
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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
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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
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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
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Built-in Fieldbus Oscilloscope
Troubleshooting ToolsTroubleshooting Tools
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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
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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