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Achieving Target Control Performance Using Fieldbus Devices Achieving Target Control Performance...
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Transcript of Achieving Target Control Performance Using Fieldbus Devices Achieving Target Control Performance...
Achieving Target Control Achieving Target Control Performance UsingPerformance Using
Fieldbus Fieldbus DevicesDevices
[File Name or Event]Emerson Confidential27-Jun-01, Slide 2
PresentersPresenters
• Terry Blevins
• Marcos Peluso
• Dan Christensen
[File Name or Event]Emerson Confidential27-Jun-01, Slide 3
IntroductionIntroductionIntroductionIntroduction
• Overview – FF Block• Applications that May be Addressed
– Single loop feedback control– Feedforward control– Cascade control– Interlock, Input selection, Flow integration, Calculations and characterization
• Control Performance– Variation if Block Execution Time– Impact of Device Response Time and Slot Time– What determine Macrocycle– Example – Single Loop
• Splitting Control Between Fieldbus and the Control System– Impact on delay on loop response, guidelines– Future – Assigning blocks to execute in DeltaV H1 card– Future – Viewing Execution Schedule
• Summary• References
[File Name or Event]Emerson Confidential27-Jun-01, Slide 4
FF Function BlocksFF Function BlocksFF Function BlocksFF Function Blocks
• 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
Function Blocks Addressed by FF Interoperability Function Blocks Addressed by FF Interoperability Testing, v4.5Testing, v4.5
[File Name or Event]Emerson Confidential27-Jun-01, Slide 5
Applications that may be addressed Applications that may be addressed using FF function block capabilityusing FF function block capability
Applications that may be addressed Applications that may be addressed using FF function block capabilityusing FF function block capability
• 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
[File Name or Event]Emerson Confidential27-Jun-01, Slide 6
Example: Single LoopExample: Single LoopExample: Single LoopExample: Single Loop
FC 101
FT 101
Feed
Feed Tank
[File Name or Event]Emerson Confidential27-Jun-01, Slide 7
Single Loop - FieldbusSingle Loop - FieldbusSingle Loop - FieldbusSingle Loop - Fieldbus
[File Name or Event]Emerson Confidential27-Jun-01, Slide 8
Example: Interlock Based on Status of Example: Interlock Based on Status of Blocking ValveBlocking Valve
Example: Interlock Based on Status of Example: Interlock Based on Status of Blocking ValveBlocking Valve
FC 151
FT 151 Reactor 1 Feed
ZT 150
[File Name or Event]Emerson Confidential27-Jun-01, Slide 9
Interlock Example: Use of Discrete Interlock Example: Use of Discrete Input From Upstream On-Off ValveInput From Upstream On-Off ValveInterlock Example: Use of Discrete Interlock Example: Use of Discrete Input From Upstream On-Off ValveInput From Upstream On-Off Valve
[File Name or Event]Emerson Confidential27-Jun-01, Slide 10
Example: Selection of Redundant Example: Selection of Redundant MeasurementMeasurement
Example: Selection of Redundant Example: Selection of Redundant MeasurementMeasurement
Static Mixer
AC 302
AT 301
Reactor 1
Feed A
Feed B
AT 302
AY 302
[File Name or Event]Emerson Confidential27-Jun-01, Slide 11
Automatic Input Selection for Automatic Input Selection for Redundant Measurements Redundant Measurements
Automatic Input Selection for Automatic Input Selection for Redundant Measurements Redundant Measurements
[File Name or Event]Emerson Confidential27-Jun-01, Slide 12
Example: Cascade ControlExample: Cascade ControlExample: Cascade ControlExample: Cascade Control
TC 202
TT 202
TT 201
TC 201
RSP
Reactor 1
Coolant
Discharge
[File Name or Event]Emerson Confidential27-Jun-01, Slide 13
Cascades Loop - FieldbusCascades Loop - FieldbusCascades Loop - FieldbusCascades Loop - Fieldbus
[File Name or Event]Emerson Confidential27-Jun-01, Slide 14
Arithmetic Block May be used to Arithmetic Block May be used to address a Variety of Calculationsaddress a Variety of CalculationsArithmetic Block May be used to Arithmetic Block May be used to address a Variety of Calculationsaddress a Variety of Calculations
• Flow Compensation – Linear
• Flow Compensation – Square root
• Flow Compensation – Approximate
• BTU Flow
• Multiply and Divide
• Average of inputs
• Sum of inputs
• Fourth order polynomial
• Simple HTG compensate level
[File Name or Event]Emerson Confidential27-Jun-01, Slide 15
Example: Calculation and Integration Example: Calculation and Integration of Mass Flowof Mass Flow
Example: Calculation and Integration Example: Calculation and Integration of Mass Flowof Mass Flow
FY 3-4
FT 3-4
PT 3-4
TT 3-4
FY 3-4
Process Steam
Pressure & TemperatureCompensation
Totalized Mass Flow
[File Name or Event]Emerson Confidential27-Jun-01, Slide 16
Example: Arithmetic and Integrator Example: Arithmetic and Integrator Function BlocksFunction Blocks
Example: Arithmetic and Integrator Example: Arithmetic and Integrator Function BlocksFunction Blocks
[File Name or Event]Emerson Confidential27-Jun-01, Slide 17
TE 801A
Distillate Receiver
Column
Distillate
Bottoms
Steam
Feed
TE 801B
TE 801C
TE 801D
TE 801E
Fieldbus enables Multi-sensor ApplicationsFieldbus enables Multi-sensor ApplicationsFieldbus enables Multi-sensor ApplicationsFieldbus enables Multi-sensor Applications
TT 801
Distillation
[File Name or Event]Emerson Confidential27-Jun-01, Slide 18
Multi-sensor Applications (Cont)Multi-sensor Applications (Cont)Multi-sensor Applications (Cont)Multi-sensor Applications (Cont)
• Chemical Reactors
Cooling Fluid In
Cooling Fluid Out
TE 901A-H
TT 901
Process Out
Process In
[File Name or Event]Emerson Confidential27-Jun-01, Slide 19
Example: Multiple Analog Input BlockExample: Multiple Analog Input BlockExample: Multiple Analog Input BlockExample: Multiple Analog Input Block
Supports a Supports a Maximum of 8 Inputs Maximum of 8 Inputs From a Fieldbus From a Fieldbus DeviceDevice
[File Name or Event]Emerson Confidential27-Jun-01, Slide 20
Other Function Blocks Are Defined by Other Function Blocks Are Defined by FF and Supported by Some DevicesFF and Supported by Some Devices
Other Function Blocks Are Defined by Other Function Blocks Are Defined by FF and Supported by Some DevicesFF and Supported by Some Devices
Blocks not included in device testing/registration ITK v4.5 , v5.0
• DC – Device Control (motor control)• OS – Output Splitter (split range control)• LL – Lead Lag (dynamic compensation of feedforward)• DT – Deadtime (dynamic compensation of feedforward)• SPG – Setpoint Ramp Generator (Program setpoint change)• AAL – Analog Alarm (alarming based on calculated value)• CS– Control Selector (override control for constraint handling)• B/G – Bias Gain (coordination of multiple loops)• RA – Ratio (blending to specified feed ratio)
[File Name or Event]Emerson Confidential27-Jun-01, Slide 21
Control Performance Using FieldbusControl Performance Using FieldbusControl Performance Using FieldbusControl Performance Using Fieldbus
The control performance that may be achieved is dependent on many factors:
• Function block execution, maximum response time for compel data and slot time ( dependent of the device technology/design – specific to manufacturer)
• Whether control is done in the field or in the control system (customer decision)
• Scheduling of block execution and communications on the FF segment (dependent of control system design)
[File Name or Event]Emerson Confidential27-Jun-01, Slide 22
AI Function Block Execution TimeAI Function Block Execution TimeAI Function Block Execution TimeAI Function Block Execution Time
AI Function Block Execution Time (Based on 22 manufacturers)
0-50msec
51-100msec
101-150msec
151-200msec
[File Name or Event]Emerson Confidential27-Jun-01, Slide 23
AO Function Block Execution TimeAO Function Block Execution TimeAO Function Block Execution TimeAO Function Block Execution Time
AO Function Block Execution Time (Based on 13 manufacturers)
0-50msec
51-100msec
101-150msec
151-200msec
[File Name or Event]Emerson Confidential27-Jun-01, Slide 24
PID Function Block Execution TimePID Function Block Execution TimePID Function Block Execution TimePID Function Block Execution Time
PID Function Block Execution Time (Based on 16 manufacturers)
0-50msec
51-100msec
101-150msec
151-200msec
[File Name or Event]Emerson Confidential27-Jun-01, Slide 25
DI Function Block Execution TimeDI Function Block Execution TimeDI Function Block Execution TimeDI Function Block Execution Time
DI Function Block Execution Time (Based on 9 Manufacturers)
0-25msec
26-50msec
51-75msec
76-100msec
101-125msec
[File Name or Event]Emerson Confidential27-Jun-01, Slide 26
DO Function Block Execution TimeDO Function Block Execution TimeDO Function Block Execution TimeDO Function Block Execution Time
DO Function Block Execution Time (Based on 10 Manufacturers)
0-25msec
26-50msec
51-75msec
76-100msec
101-125msec
[File Name or Event]Emerson Confidential27-Jun-01, Slide 27
Calculation Block Execution TimesCalculation Block Execution TimesCalculation Block Execution TimesCalculation Block Execution Times
Execution Time of Blocks Used in Calculations
0 0.5 1 1.5 2 2.5
0-25msec
51-75msec
101-125msec
Number of Manufacturers
CHAR
ARITH
INTG
ISEL
[File Name or Event]Emerson Confidential27-Jun-01, Slide 28
Third Generation Devices Offer Significant Third Generation Devices Offer Significant Improvement if Block Execution TimeImprovement if Block Execution Time
Third Generation Devices Offer Significant Third Generation Devices Offer Significant Improvement if Block Execution TimeImprovement if Block Execution Time
Example*:
Second Generation Third Generation Improvement
AI = 30ms AI = 20ms 33%
PID = 45ms PID = 25ms 44%
* Execution times based on Rosemount 3051
[File Name or Event]Emerson Confidential27-Jun-01, Slide 29
Variation in Device Response Time of Variation in Device Response Time of Different Fieldbus DevicesDifferent Fieldbus Devices
Variation in Device Response Time of Variation in Device Response Time of Different Fieldbus DevicesDifferent Fieldbus Devices
Maximum Response Delay Time (Based on 29 Manufacturers)
0-5msec
6-10msec
11-15msec
16-20msec
[File Name or Event]Emerson Confidential27-Jun-01, Slide 30
Typical Slot Time for Different DevicesTypical Slot Time for Different DevicesTypical Slot Time for Different DevicesTypical Slot Time for Different Devices
Slot Time (Based on 29 Manufacturers)
<1.1msec
1.1-1.5msec
1.6-2.1msec
[File Name or Event]Emerson Confidential27-Jun-01, Slide 31
Control Execution is Scheduled Control Execution is Scheduled Based on the Segment MacrocycleBased on the Segment Macrocycle
Control Execution is Scheduled Control Execution is Scheduled Based on the Segment MacrocycleBased on the Segment Macrocycle
A Macrocycle is determined by:
- Function Block Execution times.- Transmission time of the cyclic messages.
-Gaps between messages determined by the Network parameters.
-Time reserved for acyclic messages
[File Name or Event]Emerson Confidential27-Jun-01, Slide 32
MacrocycleMacrocycleMacrocycleMacrocycle
• Function Block execution time depends on the type of block and on the hardware and software design.
• In the time calculation, only blocks that must be executed consecutively are considered.
• Block Execution Time = 30+45+45+80 = 200 ms
• *Note that the AI in the flow device is executed in parallel.
Cascade Control Example
AI=30 PID=45
AI=30 PID=45
AO=80
TT
FT
FCV
[File Name or Event]Emerson Confidential27-Jun-01, Slide 33
Scheduled Control ExecutionScheduled Control ExecutionScheduled Control ExecutionScheduled Control Execution
0 250
ms
AI PID AO
CD CDDATA
DATA
Macro Cycle
Macro Cycle Macro CycleMacro CycleMacro Cycle
2.3 ms 5.4 ms
Bus Traffic
[File Name or Event]Emerson Confidential27-Jun-01, Slide 34
MacrocycleMacrocycleMacrocycleMacrocycle
Some manufactures may by default assume conservative constant values for MRD and SLT. The user may change these values.
FB FB
CDDATA
MID
(MRD+2xSLT)
MID
SLT - Slot timeMRD - Maximum Response DelayMID - Minimum Inter PDU Delay
DATADATA
[File Name or Event]Emerson Confidential27-Jun-01, Slide 35
Network ParametersNetwork ParametersNetwork ParametersNetwork Parameters
• Network Parameters establish how the network operates.
• The LAS must be set with the larger parameter values of the devices participating in the Network.
SLT = 10MRD= 3MID = 12
SLT = 8MRD= 3MID = 10
SLT = 4MRD= 4MID = 8
SLT = 5MRD= 4MID = 8
LAS BackupLAS
LinkSettings
104
12
[File Name or Event]Emerson Confidential27-Jun-01, Slide 36
Impact of Network Parameters on Maximum Impact of Network Parameters on Maximum Number of Communications/SecondNumber of Communications/Second
Impact of Network Parameters on Maximum Impact of Network Parameters on Maximum Number of Communications/SecondNumber of Communications/Second
8 ms
DATACD CD
2.3 41 5.4 3.1
49.50ms
20 / sIdeal Max.SLT= 16
MRD=10MID= 12
DATACD CD
2.3 6.14 5.4 3.1
58 / s
Ideal Max.SLT= 8MRD=3MID=12
17 ms
DATACD CD
2.3 5.4
SLT= 1MRD=1MID= 1
125 / sIdeal Max.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 37
Minimum Execution Time With Only Minimum Execution Time With Only One(1) Control Loop on an H1 SegmentOne(1) Control Loop on an H1 Segment
Minimum Execution Time With Only Minimum Execution Time With Only One(1) Control Loop on an H1 SegmentOne(1) Control Loop on an H1 Segment
AI PID XFR XFRAO
20ms 25ms 30ms 60ms 30ms
Macrocycle = 165 ms
Assumptions: 3rd Generation Transmitter, AI&PID executed in Transmitter, Second generation Valve executes AO
[File Name or Event]Emerson Confidential27-Jun-01, Slide 38
Executing PID in the Valve Reduces the Number of Executing PID in the Valve Reduces the Number of Communications But Increases Loop Execution TimeCommunications But Increases Loop Execution Time
Executing PID in the Valve Reduces the Number of Executing PID in the Valve Reduces the Number of Communications But Increases Loop Execution TimeCommunications But Increases Loop Execution Time
AI XFR PID
20ms 30ms 120ms 60ms
Macrocycle = 230 ms
Assumptions: 3rd Generation Transmitter, AI executed in Transmitter, Second generation Valve executes AO&PID
AO
[File Name or Event]Emerson Confidential27-Jun-01, Slide 39
Minimum Execution Time With Only Two(2) Minimum Execution Time With Only Two(2) Control Loop on an H1 SegmentControl Loop on an H1 Segment
Minimum Execution Time With Only Two(2) Minimum Execution Time With Only Two(2) Control Loop on an H1 SegmentControl Loop on an H1 Segment
AI PID XFR XFRAO
20ms 25ms 30ms 30ms 60ms 30ms 55ms
Macrocycle = 250 ms
Assumptions: 3rd Generation Transmitter, AI&PID executed in Transmitter, Second generation Valve executes AO, 50ms for every 125ms of the execution schedule (for display update)
AI PID XFR XFRAO
ACYCLIC
[File Name or Event]Emerson Confidential27-Jun-01, Slide 41
Impact of Splitting Control Between Impact of Splitting Control Between Fieldbus and Control SystemFieldbus and Control System
Impact of Splitting Control Between Impact of Splitting Control Between Fieldbus and Control SystemFieldbus and Control System
• Execution in the control system is typically not synchronized with function block execution on fieldbus segments.
• Lack of synchronization introduces a variable delay into the control loop as great as the segment macrocycle e.g. 1/2 sec loop may have up to 1/2 sec variable delay.
• Added delay will increase variability in the control loop.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 42
PID executed in the Control System PID executed in the Control System PID executed in the Control System PID executed in the Control System
0 250
AI AO
CD CDDATA
DATA0 250
PID
Minimum Delay
Max Delay
Macrocycle
0 250
PID
0 250
AI AO
CD CDDATA
DATA
Macrocycle
0 250
PID
0 250
PID
[File Name or Event]Emerson Confidential27-Jun-01, Slide 43
Recommendation on Splitting Control Recommendation on Splitting Control Between Fieldbus and Control SystemBetween Fieldbus and Control SystemRecommendation on Splitting Control Recommendation on Splitting Control Between Fieldbus and Control SystemBetween Fieldbus and Control System
• Oversampling of the fieldbus measurement to compensate for lack of synchronization i.e. setting macrocycle faster than control execution is often not practical if the loop execution is fast
• Conclusion: Execute control loops in Fieldbus for better performance.
• If target execution is ½ sec or faster, then limit the number of control loops to no more than two(2) per segment.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 44
Execution of Function Block in H1 CardExecution of Function Block in H1 CardExecution of Function Block in H1 CardExecution of Function Block in H1 Card
• Capability is targeted of v9.x release of DeltaV
• Will allow synchronization of block execution on the H1 card with those on the segment i.e. the H1 card acts as a FF device with function blocks.
• Block execution time on H1 cards is significantly less and will allow a shorter macrocycle or more to be done within a given macrocycle.
[File Name or Event]Emerson Confidential27-Jun-01, Slide 45
Auto-Assigned Execution to H1 Auto-Assigned Execution to H1 – Module Property– Module Property
Auto-Assigned Execution to H1 Auto-Assigned Execution to H1 – Module Property– Module Property
[File Name or Event]Emerson Confidential27-Jun-01, Slide 46
PID Execution in The ControllerPID Execution in The ControllerPID Execution in The ControllerPID Execution in The Controller
[File Name or Event]Emerson Confidential27-Jun-01, Slide 47
PID Assigned to Execute in H1 CardPID Assigned to Execute in H1 CardPID Assigned to Execute in H1 CardPID Assigned to Execute in H1 Card
[File Name or Event]Emerson Confidential27-Jun-01, Slide 48
PID Assigned to Execute in the DevicePID Assigned to Execute in the DevicePID Assigned to Execute in the DevicePID Assigned to Execute in the Device
[File Name or Event]Emerson Confidential27-Jun-01, Slide 49
Viewing Execution ScheduleViewing Execution ScheduleViewing Execution ScheduleViewing Execution Schedule
[File Name or Event]Emerson Confidential27-Jun-01, Slide 50
Schedule – PID in ControllerSchedule – PID in ControllerSchedule – PID in ControllerSchedule – PID in Controller
[File Name or Event]Emerson Confidential27-Jun-01, Slide 51
Schedule – PID in H1 CardSchedule – PID in H1 CardSchedule – PID in H1 CardSchedule – PID in H1 Card
Parameter show when cursor is over item
[File Name or Event]Emerson Confidential27-Jun-01, Slide 52
Schedule – PID in FF TransmitterSchedule – PID in FF TransmitterSchedule – PID in FF TransmitterSchedule – PID in FF Transmitter
[File Name or Event]Emerson Confidential27-Jun-01, Slide 53
[File Name or Event]Emerson Confidential27-Jun-01, Slide 54
Schedule – Showing Execution Divided Schedule – Showing Execution Divided Between Controller, H1 and FF DeviceBetween Controller, H1 and FF Device
Schedule – Showing Execution Divided Schedule – Showing Execution Divided Between Controller, H1 and FF DeviceBetween Controller, H1 and FF Device
[File Name or Event]Emerson Confidential27-Jun-01, Slide 55
SummarySummarySummarySummary
• A variety of control applications may be implemented using the function block capability of FF devices.
• The performance of fast process control loops may be influenced by block execution times and number of loops implemented on a segment.
• Control may be split between the DeltaV Control and FF devices for slower processes.
• Future DeltaV releases are targeted to support assignment of function blocks to execute in the H1 card. This new capability will allow a variety of applications to be addressed with no impact on control performance.
• Please direct questions or comments on this presentation to Terry Blevins ([email protected]) or Marcos Peluso ( [email protected] ).
[File Name or Event]Emerson Confidential27-Jun-01, Slide 56
Where To Get More InformationWhere To Get More InformationWhere To Get More InformationWhere To Get More Information• “Reliability and Performance of Fieldbus installations (Tutorial)”,
Marcos Peluso, Terry Blevins, ISA2002.
• “Application of High Speed Ethernet With Fieldbus Foundation Devices (Tutorial)”, Marcos Peluso, Terry Blevins, ISA2001
• “Advanced Functionality and Diagnostics of Fieldbus Devices (Tutorial)”, Marcos Peluso, Terry Blevins, ISA2000
• “Rules of thumb for applying Fieldbus (Tutorial)”, Marcos Peluso, Terry Blevins, ISA1999.
• “Installation and Checkout of Foundation Fieldbus Installations (Tutorial)”, Marcos Peluso, Terry Blevins, Jim Cameron, Duane Toavs, ISA1998.
• “Planning and Engineering Design for Foundation Fieldbus Installations (Tutorial)”, Marcos Peluso, Terry Blevins, ISA1997
• “Application Solutions Using Fieldbus Devices (Tutorial)”’ Marcos Peluso, Terry Blevins, ISA1996.
• “How Fieldbus May Influence Your Next Project (Tutorial)”, Marcos Peluso, Terry Blevins, Tom Kinney, ISA1995.