Honeywell FTE Training Course

FTE Sales Presentation*
What is “process control”?
What is Fault Tolerant Ethernet (FTE)?
How does FTE work?
How is FTE implemented?
Example: heating water
“Actuators” regulate amount of something used in the process
Examples: fuel control valve, damper actuator
A “controller” continually reads data from a transmitter and calculates actuator adjustments to maintain a property value.
PROCESS
output
input
controller
actuator
transmitter
Read the Process Value (PV)
Calculate
Gov’t regulations- safety, emissions, etc.
Security: must have access restrictions/controls.
PROCESS
output
input
Characteristics of real process plants
The process shown below is very simple, and the controller shown below is very simple.
In a real plant, many properties of the product are measured:
Temperature, pressure, viscosity, size, weight, color, etc.
…and many properties of the process equipment are measured:
Fuel consumption, up/down time, corrosion, wear, etc.
PROCESS
output
input
controller
actuator
transmitter
Paper mill: a series of processes that transform trees into paper.
Makes many different products (toilet paper to computer paper).
Must control each process plus interactions between processes.
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Paper mill: a series of processes that transform trees into paper.
Makes many different products (toilet paper to computer paper).
Must control each process plus interactions between processes.
10’s-100’s of field devices / process; 1000’s of control loops total
Can’t control the plant with 1000’s of simple controllers!
X
How does FTE work?
What is a “Distributed Control System (DCS)”?
A DCS is an integrated set of modules with distributed functions.
Multi-loop controllers (10’s-100’s) that connect to field devices
Via direct Input/Output modules and industrial buses
Multi-loop
Controller
Supervisory coordinating controllers
Operator
Stations
Supervisory
Controller
Servers for system data management
System
Server
Operator
Stations
Supervisory
Controller
Control network for intercommunication
Control network for intercommunication
A DCS, throughout the whole system, must provide:
Performance: control must be faster than the process.
Determinism: control must always take the same time.
Fault tolerance: redundancy; must fail to a known state.
Security: must have access restrictions/controls.
Remote
Server
A DCS is designed, sold, maintained as a system, including:
System capacity and performance specifications
System configuration, simulation, and management
Alarms and status of the entire system
System releases (with on-line installation)
System maintenance and support (including 3rd party equipment)
Remote
Server
Remote
Server
Mfr sells a complete system of integrated components.
Mfr sells some components; an SI acquires others and engineers the system.
Mfr supports the system.
On-line repair/ maintenance is the norm.
Off-line repair/ maintenance is the norm.
System management built-in.
Users expect to evolve/upgrade/expand a system over 10/20/30 years.
System is a one-off project (like a house). Upgrades / expansions are new projects.
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Controllers designed by Honeywell
Proprietary 5 Mbps control networks
Interfaces/gateways required to non-Honeywell equipment
Near performance limits
How does FTE work?
>10x performance, + determinism, security, fault tolerance
Reduce cost of communication infrastructure and support
Reduce cost of connection to PCs and IT networks
Ethernet preferred
Industry bus protocols migrating to Ethernet
FF H1 FF HSE
No suitable fault tolerance approach
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Analogous to TPS LCN/UCN and PlantScape ControlNet.
Remote
Server
FTE is the control network of Experion PKS.
Dedicated to the control mission
Fault-tolerant
Deterministic
Secure
Not an IT network, but leverages IT technology to lower cost of:
FTE network infrastructure
Maintenance and support
3 Cisco switches qualified for R200
100/1000 Mbps; single and multi-mode optical fiber up to 70 km
Security and determinism functions required for control mission
Preferred supplier by many customers
.
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An FTE network has redundant switches and cables.
Topology: 2 parallel trees joined at the top to form one network.
An FTE node connects to both trees.
An Ethernet node (non-FTE) connects to either tree.
Switches
1 communication path between Ethernet nodes
Switches
2 communication paths between an FTE node and an Ethernet node
Switches
Switches
4 communication paths between FTE nodes
A - A
A - B
B - B
B - A
How does FTE work?
How Does FTE Work? –FTE path status
Each FTE node continually issues short diagnostic messages to test each path to every other node, and builds a status table.
Below is a node’s status table. The first 2 nodes are FTE nodes, and the last 4 nodes are singly-connected Ethernet nodes.
A bad link displays as “SILENT”.
If the B cable to the FTE-GUS node fails, A>B and B>B SILENT.
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User Mode
Operational Details
For Microsoft applications an intermediate driver is inserted between layers of NDIS (Network Driver Interface Standard)
The TCP stack and its connection to the OS are unaffected.
The FTE software has the ability to intercept, analyze, and redirect messages
The location of this driver in the Kernel while still using standard calls is what gives FTE its openness and performance.
User Interface
FTE nodes:
There are four possible paths between two FTE Nodes
Sequence numbered messages are periodically sent from both ports to exercise all four paths
The status of the four paths is sent back in the next “test message” transmission
Loopback (shown in red) is also checked to diagnose the inter-switch link.
From this data the best possible path from Node 1 to Node 2 is determined and used.
Link carrier status can also be checked for rapid detection (hardware dependent).
6
FTE
Ethernet nodes:
Operational Details
There are two possible paths between an FTE and a non-FTE Node
The best viable path is chosen (using the data derived from the test messages)
No test messages are required from the non-FTE nodes.
Singly attached nodes can receive and use test message data to determine LAN health.
If the inter-switch link is bad, multicast messages are sent via both ports to maximize the connectivity to singly attached nodes
FTE
Station
CDA = Control Data Access
DSA = Distributed Systems Architecture
This diagram shows levels of the plant automation system (level 0 – field devices – is not shown).
FTE is the Experion PKS network for the control and operation levels (1 and 2 ).
FTE
Control
How Does FTE Work? – Security and Determinism
Firewall hides/secures Level 2 and Level 1-- Only L2 PKS Servers are visible
PKS server on L3 consolidates and makes available L2 data / alarms for applications via DSA
Firewall hides all but servers
PKS Server
How Does FTE Work? – Security and Determinism
Firewall hides/secures Level 2 and Level 1-- Only L2 PKS Servers are visible
PKS server on L3 consolidates and makes available L2 data / alarms for applications via DSA
FTE switches provide:
Port Filtering between L2 and L1 to allow only CDA and FTE messages for control
L2 bandwidth allocation to ensure that L2 supervisory traffic is not disrupted
L1 bandwidth allocation to ensure that L1 control is not disrupted
Broadcast, Multicast, Unicast storm suppression to maximize FTE network availability
L1: Restricted to CDA and FTE Traffic Only
Firewall hides all but servers
L1 & L2: Bandwidth Allocation
L2: CDA Traffic Prioritized High
PKS Server
How does FTE work?
An FTE network interconnects clusters of nodes.
A cluster is a group of nodes with high intercommunication, typically associated with the same process unit.
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FTE
Redundant
Servers
Experion
Stations
Application
Control
Environment
Confidential and Proprietary
Basic FTE Configurations
A minimum FTE network is one pair of cluster switches; larger networks could have several cluster switch pairs connected to backbone switches.
UNIT #1
Firewall
Cabling: CAT5 STP copper; single and multi-mode fiber optic.
Cisco switches: 24/48 STP ports + 2 GBIC ports; 10 GBIC ports.
Switches are expandable up to 436 ports; can mix switch types
GBICs: plug-in converters for 0.5 / 10 / 70 km fiber optic
FTE software and dual Network Interfaces per PC node
Cluster
Switches
Ethernet
FTE
FTE
Ethernet
FTE
FTE
Backbone
Switches
Media
Converters
FTE network:
Up to 99 of those can be C200 controllers
up to 511 Ethernet nodes (singly-connected)
Firewall/router: required to connect to other networks
FTE network is a separate IP subnet
Private IP addresses; only servers are visible externally
Cable: shielded twisted pair (STP) or fiber optic recommended for best noise immunity and performance
Required for CE Mark
Authorization, authentication, encryption, activity logging, intrusion detection, virus protection
Firewall engineering, configuration, testing and management
Remote Network Administration
Systems (servers, workstations)
Network (switches, routers, firewalls, etc.)
Honeywell network experts can do it all-- for FTE and for all networks in the plant.
1st
Systems (PlantScape, TPS, PHD, any type of PC)
Applications on PCs (are they running/responding)
Network and System Performance Management
Proactive tracking of system, server, network performance
Work load Characterization & Capacity Planning
Procurement and support of PCs and network equipment
.
Honeywell network experts can do it all-- for FTE and for all networks in the plant.
1st
Dedicated to the control mission
Fault-tolerant
Deterministic
Secure
Not an IT network, but leverages IT technology to lower cost of:
FTE network infrastructure
Maintenance and support
2950G-24
2950G-48
3550-12G
3550-24-FX
2955C-12
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Honeywell FTE Training Course

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Transcript of Honeywell FTE Training Course