Vietnam FF Seminar20th Apr 2011
1
Arasu ThanigaiBusiness Development Manager
Pepperl+Fuchs - Singapore
ON BEHALF OF FUNDATION FIELDBUS
Commissioning Benefits
Vietnam FF Seminar20th Apr 2011
Device CouplerZone2
Device Coupler / FieldBarrier
Zone1Fi
eld
Dev
ices
Fiel
d D
evic
es
Fiel
d D
evic
es
Device Coupler TerminatorSurgeProtec.
SurgeProtect.
Fiel
d D
evic
es FieldbusProcess
Interfaces
Fieldbus Infrastructure
PowerSupplies
Vietnam FF Seminar20th Apr 2011
Commissioning Benefits
• Commissioning - Device integration• Commissioning - Physical layer
Vietnam FF Seminar20th Apr 2011
Device Integration
Continuous Productivity Improvements• Integrated system environment• Freedom of choice• Information availability• Fieldbus solutions to meet all plant requirements
– Plug and produce– Device Integration
Vietnam FF Seminar20th Apr 2011
Easier Easier -- Real Number Engineering UnitReal Number Engineering Unit
• No range mismatch• Unit downloaded when device is replaced
Transmitter PositionerFF FF
BUSFF
CTRL
CPU
CPU
CPUDigital
Digital
DigitalDigital
TransmitterRange
0-800 kPa
SystemRange
0-400 kPa
8 mAProcess200 kPa
Reading100 kPa
...alarms and tripsnot working
AIA/D
D/A 4-20 mA
AOD/A
A/D4-20 mA
RangeRange
Range mismatch
Range exceed (more
than100%)
Vietnam FF Seminar20th Apr 2011
Lower Cost & FasterLower Cost & Faster
• Traditional: 2 hours / device for 2 technicians
• (Calibration)– Attach device– Verify 4-20 mA signal
• five points– Verify link to control strategy– Check device parameters with
handheld
• Foundation fieldbus: 25 minutes / device for 1 technician (Remote)– Attach device– Drag-and-drop
commissioning wizard– Compare configuration
faster on computer
•Devices are auto-recognized•Devices are auto-addressed•Devices identify themselves
Plug-n-Play
Only FF has automatic addressing
Vietnam FF Seminar20th Apr 2011
Fieldbus Maintenance Made Easy:Fieldbus Maintenance Made Easy:Device Commissioning WizardDevice Commissioning Wizard
Vietnam FF Seminar20th Apr 2011
Fieldbus Maintenance Made Easy:Fieldbus Maintenance Made Easy:Protective DecommissionProtective Decommission
• Removing device in an orderly fashion– “Safely remove
hardware”• Temporary removal
– To remove for calibration etc. with intention to put back into same place soon after
• Permanent removal– To remove for
replacement etc.
Control-in-the-field does not mean just
“simple” PID
Vietnam FF Seminar20th Apr 2011
Easier FF Device Commissioning and Easier FF Device Commissioning and ReplacementReplacement
• Commission or replace device without touching the software
• System automatically logs process in background
Automatic configuration reconciliation with device database
Automatic configuration
download
View details in historian and
log
Vietnam FF Seminar20th Apr 2011
Faster Project StartupFaster Project StartupExpress and Batch DownloadExpress and Batch Download
• Reduced commissioning time
•Initiate multiple downloads at the same time•Runs unattended•At pre-commissioning need not run as a background communication to real-time control
Vietnam FF Seminar20th Apr 2011
Intelligent Devices via Fieldbus is a Must• Process Industries worldwide require
fieldbus based systems because of cost reduction– Reduction of wiring and cabinet costs– Less system and instrumentation hardware– Reduced commissioning time
• Intelligent devices enable Asset Optimization– Increase of maintenance effectiveness– Improves process availability– Enhances productivityAventis says: Fieldbus technology
saves costs and enables innovative applications. Future plant will be
equipped with fieldbus
Vietnam FF Seminar20th Apr 2011
Incorporating intelligent devices via fieldbus integration streamlines work processes, improves process and product quality, maximizes plant availabilityintegrates fieldbus seamlessly
Exploiting new levels of field device informationMaking device resident information available to the right people at the right time
Device Management lowers costs over life cycle in design, implementation, operation and maintenance
Device Management
Vietnam FF Seminar20th Apr 2011
Expectations on Fieldbus Technology• Industry proven and
reliable• High system availability
through redundancy concepts
• Intrinsically safe solutions• Seamlessly integrated
into control system • Access to device internal
data• Openness for all device
manufacturers• Easy to use
Optimization Engineering Operations
ControllerDiagnosisMaintenanceCalibration
ConfigurationParameterizationCommissioning
OperationDisplayAlarm signals
Process variablesTime synchronizationStatus
07
Field Devices
Vietnam FF Seminar20th Apr 2011
Fieldbus and Field Device Configuration• Integrated fieldbus
management tools and comprehensive Device Libraries for– Configuration of function
block applications– Device parameterization
with graphical user interfaces
– Online and offline configuration
• All devices accessible from a central workplace
• Early plausibility checks ensure proper and fast configuration
Vietnam FF Seminar20th Apr 2011
Fieldbus and Change History
Maintenance Event & Work Order History
Calibration Changes
Operator Changes
Configuration Changes
Process Event & Alarm History
Audit List
Vietnam FF Seminar20th Apr 2011
Intelligent Devices Enable Asset OptimizationOK!Oops!BAD!
• Scheduled monitoring of asset health status• Smart condition reporting• Notification of key personnel independent of their location• Generation of fault reports and submission to CMMS
Vietnam FF Seminar20th Apr 2011
Device ManagementDevice Management HART
– Fieldbus Builder PROFIBUS/HART
– Basic HART DTM / HART DTM Builder
– OPC Server HART– HART Device Library– HART Multiplexer Connect
Device Management FOUNDATION Fieldbus– Fieldbus Builder FOUNDATION
Fieldbus– OPC Server FOUNDATION
Fieldbus – FOUNDATION Fieldbus Device
Library
Object Types
800xA
SystemDevice Library
Wizard
Vietnam FF Seminar20th Apr 2011
The physical layer – alive and well?
– Proper termination– Water ingress– Ground faults
Vietnam FF Seminar20th Apr 2011
The physical layer – alive and well?
– Proper termination– Water ingress– Ground faults– Loose wiring– Faulty devices
Vietnam FF Seminar20th Apr 2011
The physical layer – alive and well?
– Proper termination– Water ingress– Ground faults– Loose wiring– Faulty devices– Unstable communication– Short circuits– Bulk power failure– …
Vietnam FF Seminar20th Apr 2011
Diagnostics in process automation today
DCS with intelligent hosts■ Asset management and diagnostics■ Proactive plant upkeep
Fieldbus infrastructure■ Simplistic tools■ Reactive maintenance
Field instrumentation■ Asset management and diagnostics■ Proactive plant upkeep
Vietnam FF Seminar20th Apr 2011
Online monitoring of the physical layer
Time
Equipment Health100%
Minimum device health FAILURE
Time to respond
Warning level
Monitoring the physical layer protects you from unwanted shutdowns!
Vietnam FF Seminar20th Apr 2011
Advanced Commissioning for physical layer
•Integrated single tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need
Vietnam FF Seminar20th Apr 2011
Advanced Commissioning for physical layer
•A portable tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need
Vietnam FF Seminar20th Apr 2011
Commissioning Tools expectations
•User interface in the control room:– Display of values– Warnings with actionable information– Color coding for easy recognition
•Value-add:– Automated commissioning
procedures and documentation– Live segment monitoring with alarms– Expert troubleshooting tools
•Embedded expert-knowledge
Vietnam FF Seminar20th Apr 2011
Commissioning Tools Expectaions
■ Design Verification tools: design of the physical layer
■ Verify against original design■ Automated checkout procedures
■ Longer plant uptime■ Know before you act■ Actionable information in clear text
TroubleshootMonitorCommission
Cas
h Fl
ow
Plan and purchase
Install and commission Operate and maintain
Vietnam FF Seminar20th Apr 2011
Commissioning in the past
– Always on the critical path– Manual, step-by-step procedure– Labor intensive– Requires
• Screw driver• Check sheet• Pencil• Multimeter• Oscilloscope
– Connect one device at a time– Disconnect after testing
Test ReportTest Report
Vietnam FF Seminar20th Apr 2011
Commissioning now
– Verify address setting– Wire up devices in the right location– Check shielding– Activate communication– Use automated work procedures
• Testing• Documentation
– All devices at once– Wiring remains undisturbed
Commissioning Wizard
Test Report
Test Reportx
Vietnam FF Seminar20th Apr 2011
Commissioning based on Standards
– Simple to use– Eliminates manual test procedures – Ensures compliance with
AG181 and IEC 61158-2– Creates baseline report:
• Snapshot of all measurements • Complete documentation
– Recommends warning and alarm limits for the ADM– Stores limits in non-volatile memory– Reduces pre-commissioning
time by up to 80%
Vietnam FF Seminar20th Apr 2011
Automated Commissioning Saves Time
• Case Study with cost comparison for pre-commissioning: – 4…20 mA– Fieldbus– Fieldbus with Advanced Diagnostics
4 hoursMean time to repair (MTTR) a fault
8 hoursHours per work day 12Instruments per segment100Number of segments1,200Number of instruments
Case Study – Specifications
Pre-commissioning is defined as work steps taken to install and validate the hardware configuration and the physical layer.
Source: Fieldbus Testing with Online Physical Layer DiagnosticsTechnical White Paper available from Pepperl+Fuchs Part No: 198636
Vietnam FF Seminar20th Apr 2011
Automated Commissioning Saves Time
06 ½ days6 daysTotal Time
Not required1 Trunk, 12 Spurs
12 loopsUnits
Not required4 h MTTR4 h MTTRTime/Unit
Construction failures (1%):
02 days12½ daysTotal Time
Not required100 segments1200 loopsUnits
Not required10 min5 minTime/Unit
Constructional checks:
Fieldbus with Advanced
Diagnostics
Fieldbus without
diagnostics4-20 mAModelTask 1 of 2
Vietnam FF Seminar20th Apr 2011
Automated Commissioning Saves Time
2.6 days U21.5 days U46.5 days UTotals
8 h =1 day
4 h =½ day
24 h =3 days
Total Time
1.5% = 2 segments
0.5% = 1 segment
0.5% =6 loops
Units
4h MTTR4h MTTR4h MTTRTime/Unit
Pre/commissioning failure:
1.6 days12½ days25 daysTotal Time
100 segments100 segments1200 loopsUnits
8 min60 min10 minTime/Unit
Pre/commissioning instrument checks:
Fieldbus with Advanced
Diagnostics
Fieldbus without diagnostics
4-20 mAModelTasks 2 of 2
Vietnam FF Seminar20th Apr 2011
Commissioning saves time and money
– A few mouse clicks conduct automatic testing
– Reports on the actual installation with all devicesconnected
– Automatic setting of warning and alarm limits
Vietnam FF Seminar20th Apr 2011
Online monitoring
• Advanced Commissioning tools increases the number of detectable faults
– Monitors continuous operation – Notifies when deviations occur – Enables proactive plant up keep – Keeps the plant up and running
• The Advanced Commissioning Tools helps to:– Monitor the health condition of the physical layer – Detect changing conditions– Report limit violations with time stamps– Alert operators before the segment fails
Vietnam FF Seminar20th Apr 2011
Online monitoring – Continuous health check
•Commissioning Tools increase the number of detectable faults
– Displays measurement values– Issues warnings and alarms– Highlights violations with color coding:
Good valueMaintenance required
Out of specification
Vietnam FF Seminar20th Apr 2011
Fault Finding is Easier
•Commissioning Tools delivers actionable information to minimize the time spent for fault finding
1 Active messages2 Actionable information with solution guideance based on
expert knowledge3 History with timestamps
When the failure…… occured… disappeared
– Export function for external analysis and storage
Vietnam FF Seminar20th Apr 2011
Bad cable impedanceBad cable impedance
Loose wireLoose wire
Troubleshooting is easier•Advanced Diagnostics Tools provide expert tools for fast fault finding
– Simplifies testing– Captures intermittent problems– Pinpoints the issue – Guides to potential solutions– Is accessible from remote for consultation with fieldbus experts.
Vietnam FF Seminar20th Apr 2011
Simplified commissiong leads CAPEX and OPEX savings
– Rapid commissioning: Accelarates loop check
– Longer operation: Warns before failure
– Faster troubleshooting: Assists with actionableinformation
Vietnam FF Seminar20th Apr 2011
Conclusion- Device
– Foundation Fieldbus Simplifies device commissioning and saves time. Device integaration into the control system environment made fool proof.
– Fieldbus devices transmit measurements are unaltered.
– For most Fieldbus transmitters there is no need to set a range. Avoids Rang mismatch, the reading for controls and alarms in the system will be correct. Therefore, traditional five point loop test can be replaced by a simple plausibility check thus speeding up project completion
– Fieldbus devices have no error due to analog signal calibration (4-20 mA) differences between transmitter output and DCS input, saving time on re-
calibration
– Foundation Fieldbus address assignment is automatic and error free. Some systems have wizards to guide the technician, even commission the devices without using software, thus demystifying Fieldbus commissioning
Vietnam FF Seminar20th Apr 2011
Conclusion- Device– The configuration for all Fieldbus devices is maintained in a database and
can be downloaded remotely in a single click saving time as compared to checking devices one by one, parameter by parameter, with a handheld field communicator and maintaining documentation separately.
Vietnam FF Seminar20th Apr 2011
Conclusion – Physical Layer
– Advanced Diagnostics tools for for physical layer reduced physical layer commissiong time and provided online monitoring and reporting system that saves CAPEX and OPEX
– Most problems at early bus installations were due to poor installation. However, simple, user-friendly, Fieldbus testers are now available, allowing the installation crew to easily check the wiring, and the device commissioning crew to check network operation, spotting any problems early
– Many contractors and Technicians are trained and are skilled in Fieldbus installation and commissioning, and have the test equipment and in-house procedures to ensure reliable operation
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