Shivaji Day Process Automation, ABB - · PDF fileShivaji Day Process Automation, ABB AB B ......

DCS and Fieldbus Foundation

Shivaji Day

Process Automation, ABB

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© 1994 – 2011 Fieldbus Foundation 3 © ABB

July 17, 2012 | 3

FOUNDATION Fieldbus HSE - Server Integration

- HSE is the “Open Common” interface for access to the server

- All H1 and HSE data are available on the server

- Application packages give information for the MIS (Management Information System)

- Servers provide the platform for application packages (e.g. HMI, configuration, diagnosis, ...)

FOUNDATION Fieldbus HSE - Subsystem Integration

- Communication between control level and Linking Device H1 (field level)

- Quick data exchange, High Performance Control Backbone (100 Mbit/s)

- Standard Ethernet accessories and cables

- Redundant HSE devices and interfaces

- Standard „Function Blocks“ plus flexible „Function Blocks“

FOUNDATION Fieldbus H1 – Device Integration

- Communication and power supply via one 2-wire cable

- Transmission rate fixed 31.25 kbit/s

- Installation in Zone 1 (Intrinsic Safety EEx i)

- “Function Blocks“ run in the field devices

- Supports control functions in the field device, device-to-device communication,

LAS Backup, time stamp

P L

P L

P L

P L

APPLICATION

PACKAGES

MIS

IEC 61158

Foundation Fieldbus Specification

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| 4

H1/HSE

PHYSICAL LAYER 1

2

3

4

5

6

7

USER LAYER

COMMUNICATION

STACK

H1 HSE

H1 PHY @ 31.25 kbit/s

H1 DLL

1

2

3

4

5

6

7

USER LAYER

TCP/UDP

Ethernet/IEEE 802

IP

1

2

3

4

5

6

7

USER LAYER

FMS FDA FMS

TRANSPORT LAYER

SESSION LAYER

PRESENTATION LAYER

APPLICATION LAYER

PHYSICAL LAYER

DATA LINK LAYER

NETWORK LAYER

1

2

3

4

5

6

7

OSI Model

Fully integrated Foundation Fieldbus architecture

FAS

Ethernet/IEEE 802

@ 100 Mbit/s

ISO/OSI Layer Model for Foundation

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July 17, 2012 | 5

Ethernet / IEEE 802 / FO

FOUNDATION Fieldbus HSE

OPC

Server

Ethernet TCP/IP

IEC 61158-2

Engineer

FOUNDATION Fieldbus H1

Linking

Device

PS

Operate

Engineer

Control

Field

Foundation Fieldbus Network

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| 6

100 Mbit/s

FF HSE

HSE

Remote IOs

Field Devices

FF-H1

P

L

Plant

P

L

P

L

FF-H1

Linking

Device

Gateway

Other Networks

OPC

Server Operate

Engineer

Control

Field

HSE Controller

OPC

Server

HSE - High Speed Ethernet Topology

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July 17, 2012 | 7

232 subscribers per link

T R R R

FO

Seg. 4

32 subscr.

Seg. 2

32 subscr.

Seg. 3 Segment 1

32 subscribers, incl. repeater

FOUNDATION H1

FOUNDATION HSE

Operate

Engineer Control

Field

Linking

Device

T

OPC

Server

Ethernet TCP/IP

T

PS

In applications the number of subscribers per H1 link is limited to < approx.12 by: - too high data refresh times (cycle times)

- energy requirement of the subscribers

- set-up in Ex area (IS)

- max. 12 per segment is a recommendation of Fieldbus Foundation

Subscribers – Foundation Fieldbus-H1

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July 17, 2012 | 8

FOUNDATION HSE

Operate

Engineer Control OPC

Server

Ethernet TCP/IP

For the use

of passive T-junctions

in the Ex (Haz.) area:

8 H1 field devices

acc. to FISCO

Field

Us 12,6 VDC

Is 100mA

[EEx ia]

Linking

Device

T

LT 1.000 m

LS

30 m

Ltotal = LT+ ( LS) 1.000 m

T T 4-fold

IEC 61158-2: FF-H1

Transmission rate fixed 31.25 KBit/s

max. segment length for copper cable Type A

Non-Ex Area: 1.900 m

Ex Area: 1.000 m

Caution !

Segment length (H1 cable)

considerably reduced by

…the voltage drop

…the limited supply current

…the cable diameter

…the number of H1 Slaves

FOUNDATION H1

T

PS

Line Lengths, Transmission Rate – FF-H1 [Ex (Haz.) Area]

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July 17, 2012 | 9

FieldBarrier*)

LS

12

0 m

Ltotal = LT+ ( LS) 1.900 m

LT 1.900 m

Field

EEx e

EEx ia

For the use of the

FieldBarrier in the Ex area:

16 H1 field devices

acc. to FISCO

IEC 61158-2: FF-H1

Transmission rate fixed 31.25 KBit/s

max. segment length for copper cable Type A

Non-Ex Area: 1.900 m

Ex Area: 1.000 m (with FieldBarrier 1.900 m)

Us 28 VDC

Is 500 mA

Linking

Device

FOUNDATION H1

FOUNDATION HSE

Operate

Engineer Control OPC

Server

Ethernet TCP/IP

*) max. four FiedBerrier per segment

T

PS

Line Lengths, Transmission Rate – FF-H1 [Ex (Haz.) Area]

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July 17, 2012 | 11

Operate Engineer

Control

Field

Ethernet / IEEE 802 / FO

FOUNDATION Fieldbus HSE

Linking

Device

OPC

Server

Ethernet TCP/IP

EDD / CF-Files: For display and

configuration of FF device parameters

IEC 61158-2

FOUNDATION Fieldbus H1

EDD – Electronic Device Description, CF – Capability File

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© 1994 – 2011 Fieldbus Foundation 12

Foundation Fieldbus

with 800xA

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800xA – DCS with integrated FF

High availability means

redundancy at all levels:

System servers and

workplaces

Controllers

Communication

interfaces

Remote I/O

Linking devices

Media/cable redundancy

Linking

Device

Drives

AC800M

RLM01

Remote IO

PROFIBUS DP

PROFIBUS PA devices

FF HSE

FF H1 devices

Linking

Device

OPC Server FF

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Foundation Fieldbus redundancy

Redundant

Linking device

FF HSE

HSE / H1

Linking

Device Multi Barrier Multi Barrier

Redundant FF

OPC servers

FF H1

FF H1

Ethernet TPC/IP

Redundant

Communication

to Controllers

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FF Device Integration FF is an integrated architecture for

distribution of control applications

Two different fieldbus networks supported:

H1 Link with 31.25 kbit/s

HSE Subnet with 100 Mbit/s

Controller connection to HSE via CI860 (optionally redundant)

LD 800HSE: gateway between H1 and HSE (optionally redundant)

Asset Optimization and Process Portal application connected via OPC Server FF

Device Integration Library comprises FF field devices and its aspects for easy Drag´n Drop configuration

H1 Devices

4x H1 Links

Fieldbus Builder FF

AC 800M

CI860

LD 800HSE

HSE Subnet

OPC Server FF

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Fieldbus Builder Foundation Fieldbus

Fieldbus Builder FF performs the

configuration and commissioning of FF

network and application

Management of FOUNDATION Fieldbus for

entire FF network with HSE subnets and

H1 Links

Configuration and loading of OPC Server FF

Engineering tasks

Application configuration

Automatic schedule generation

Device parameterization

Commissioning

Diagnostics

Incremental Download also for complete HSE subnets

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FF Device Integration Library (1)

Library contents:

FF Block Library with FF standard

blocks and device specific blocks

HSE Device Library with ABB

Linking Device LD 800HSE

H1 Device Library with ABB FF field

devices

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FF Device Integration Library (2)

Asset monitoring

Asset tree viewer

Asset reporter

Asset alarms / notification

Maintenance management

(CMMS connectivity)

Faceplates

Device documentation

access

The devices offer all aspects required for field device management

Latest Device List at

www.abb.com/controlsystems

-> System 800xA -> Device Management

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../../../../../../../Documents and Settings/mowendla/Local Settings/Temp/notesFFF692/FFDevices.pdf


FF Faceplates

Header: display of process tag and its description

Indicator bar: display of function block status (MODE_BLK.Actual)

Faceplate element: display and operation of process values and parameters

Process value (Pv)

Output value (Out)

Simulate value (Sim)

Parameters

Operator bar: operation buttons for switching the block mode (MODE_BLK.Target)

Different faceplates for

Analog input (AI) and output (AO)

Discrete input (DI) and output (DO)

PID control (PID)

FF Faceplates comply the IndustrialIT standards

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FF System Structure

AC 800M

FF HSE Link

FF H1 Links

Pub/Sub Pub/Sub HSE

Linking Device

FF HSE Link

FF H1 Links

Pub/Sub

Fieldbus Builder FF

Pub/Sub

Pub/Sub

Pub/Sub

Pub/Sub Pub/Sub

Pub/Sub Pub/Sub

FF HSE Link

LD 800HSE

800xA Workplace

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FF HSE application

H1 link A

OUT AI PID

BK_CAL IN

OUT

IN

H1 link B

OUT AI

PID BK_CAL IN

OUT IN

CAS_ IN

CAS_IN AO

BK_CAL OUT

BK_CAL OUT

FF HSE Link

FF H1 Link FF H1 Link

Pub/Sub Pub/Sub Pub/Sub

Pub/Sub

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FF Parameter Displays

Display and operation of block parameter

All parameters listed

Predefined tabs for the main parameter groups

Device and Block dependent

Adaptation via block library for all instances

Import/export capabilities

Tabs with structured

parameters

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FF Network Components

Device 1

Device 2

Device n

Spur Blocks

Power Supply

Power

Conditioner

H1 Link

HSE Subnet

Redundant Linking Devices

Two LD 800HSE build up a redundant Linking Device

Module redundancy

HSE interface redundancy

H1 interface redundancy

Power Supply

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Foundation Fieldbus Basic Layout

Max. 4000 devices per connectivity server

(application dependent)

Max. 30 Linking Devices

per HSE subnet

Max. 16 field

devices per H1

Link (application

dependent)

40 signals per second per H1 link

between H1 and HSE

CI860 1000 signals overall

Max. 6 (12) CI860

at CEX Bus

• max 1000 for analog input

• max 500 for analog output

• max 500 for discrete input

• max 250 for discrete output

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FF Installation - References

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• Client The Reliance Group, is India's largest private sector enterprise, with businesses in the

energy and materials value chain. Group's annual revenues are in excess of US$ 58 billion. The flagship company,Reliance Industries Ltd., is a Fortune Global 500 company and is the largest private sector company in India.

The Group's activities span exploration and production of oil and gas, petroleum refining and marketing, petrochemicals (polyester, fibre intermediates, plastics and chemicals), textiles, retail, infotel and special economic zones.

• Application • Automation of Butene Plant.

• Site • Reliance Industries Ltd.,Hazira

• Scope The ABB Scope of supply includes 2 set of redundant controllers,around 1600 I/Os,

Redundant set of Aspect cum Connectivity Server, 1 Engineering Station, 4 operator workplace, 1 IM server and 1Web Server.

The System has FF solution with 300 FF devices connected to System

HART communication with Field Devices ( Around 450 Devices)

Performance of PST for 18 Emerson DVC ( for the 1st time on 800xA Platform)

Asset Optimization,Alarm Management & Information Management system

Remote Connectivity of Plant Data through CPM Smart Client

In Operation • Oct- 2011

Reliance Industries Ltd,India Butene Plant

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• Client Jindal Steel West(JSW) Limited, are Specialized manufacturer and supplier of Steel

Products.

JSW group with turnover of 7 BUSD has diversified interests in Steel, Energy, Minerals and mining, Aluminium, Infrastructure and logistics, Cement and Information Technology.

• Application • Complete automation of Sinter Plant.

• .

• Site • JSW Steel Ltd, Thoranagallu

• Scope JSW Steel Ltd chose ABB System 800xA as DCS package for the Sinter Plant

Automation.

The ABB Scope of supply includes 2 controllers, around 8,000 I/Os, 7 operator workplace, Redundant aspect & connectivity servers, 400 devices on Profibus and 80 devices on FF.

• In Operation • June- 2006.

JSW,India Sinter Plant

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References for Foundation Fieldbus installation

1 Tata Steel, Jamshedpur Sinter Plant#3 5000 IO on Profibus, 7OS Mar-05

80 FF H1 devices

2 Reliance Patalganga Conitnuous Polymerisation Plant - 7 4500 IO, 1ES/OS+5OS, FF, IM Mar-06

150 FFH1 devices

3 Reliance Hazira Conitnuous Polymerisation Plant - 10 4400 IO, 1ES/OS+5OS, FF, IM April-06

275 FFH1 devices

4 Reliance Hazira Conitnuous Polymerisation Plant - 11 6600 IO, 1ES/OS+5OS, FF, IM June-06

50 FFH1 devices

5 JSW, Bellary Sinter Plant #1 5000 IO on Profibus, 7OS Aug-06

80 FF H1 devices

6 JSPL, Raigarh Sinter Plant 5000 IO on Profibus, 7OS Sep-06

80 FF H1 devices

7 JSPL, Raigarh Coke Oven 800 IO 2OS Mar-06

250 FF H1 devices

8 Tata Steel, Jamshedpur Sinter Plant#4 5000 IO on Profibus, 7OS March-08

80 FF H1 devices

9 JSW, Bellary Sinter Plant #2 5000 IO on Profibus, 7OS Aug-09

80 FF H1 devices

10 JSW, Bellary Sinter Plant #4 5000 IO on Profibus, 7OS Dec-11

80 FF H1 devices

11 Reliance Hazira Butene Plant 1600 IO on Profibus, 5OS Oct-11

300 FF H1 devices


THANKS

Shivaji Day Process Automation, ABB - · PDF fileShivaji Day Process Automation, ABB AB B ......

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