foundation fieldbus usability from field device perspective · foundation fieldbus usability from...

Hemal DesaiEndress+Hauser India Pvt. Ltd

16th October 2014Automation 2014 Mumbai

Foundation Fieldbus Usability from field Device Perspective

2 © 2014 by Fieldbus Foundation

Digital Revolution has come this far..

900+ Registered products

20,000 Systems Installed

10 Control systems

Digital

Interoperable

Vendor neutral

Automation focused

500 members/affiliates

20,00,000 devices in service


Key Deliverables – Foundation Fieldbus Promise

• Scalable, Automation Infrastructure – Future proof• Function Block Based Architecture - Interoperability• Multi drop, Multi-variable - CAPEX• Reduced Footprint - CAPEX• Data Integrity - Quality• Control in the Field - Single Loop Integrity - OPEX• Interrupt Driven Alerts – Optimized traffic• Isochronous Communication – Optimized traffic• Device Level Time Stamping – Traceability, SOE• Approved for use in Safety Instrumented Systems• Rigorous Test and Registration Program - Interoperability


Vendors Continually Work Meet End User Requirements Over the Years

FISCO


Example 1 - Interoperability Testing

• 3rd Party compliance testing executed by the Fieldbus Foundation Field Devices Fieldbus Power Suppliers/Conditioners Couplers Cable Hosts

• First registered product 1998• Interoperability Test Kit (ITK) is only one of many tools

used for product registration


Host & Device Interoperability testing

ITK Test Kit

Device Testing Host Testing

ITK Interface


Interoperability Testing at Vendors®

FOUNDATION

Triangle of Testing

Fieldbus

DCS Systems VendorsDevice Vendor


Fieldbus testing Lab at Endress+Hauser


Example – Interoperability Testing at Vendor

Process Management

Process controlPlant Asset Management

(PAM)

Vendor

Field Devices

ABB• Composer• Fieldbus Builder• Control Builder

Endress+Hauser• FieldCare

Emerson• AMS• FC 375

Honeywell• Control Builder• Experion PKS• Asset Manager

Invensys• IA Series

Metso• FieldCare• FF Explorer

PACTware• PACTware

Siemens• PCS7/PDM• Step7

Yokogawa• PRM, Fieldmate

“Device Integration into Automation Architectures”

ABB• Symphony• AC800M• AC800F/ Freelance

Endress+Hauser• ControlCare

Emerson• Delta V

Honeywell• PlantScape• Experion PKS

Invensys• IA Series

Metso Automation

• compactDNA

Rockwell• Control Logix• PLC5, SLC 500, FFLD

Schneider• Premium

Siemens• S7, PCS7

Yokogawa• Centum CS3000


Example – Interoperability Testing at Host End


New Usability Initiative

• What is the Usability Initiative?• To make Foundation Fieldbus as simple to use as 4-20 ma.

• Takes Interoperability & Ease of Use one step further.

• Objectives• Backward compatibility• Device Templates• Automated Device Replacement• PV Interchangeability


Backwards Compatibility

• Device Replacement with different version• Maintain minimum level of functionality• Operate new instrument of old DD• Future proofing technique

• The Backwards Compatibility specification and testing is available today under ITK6.1+


Device Templates

• A standard template will achieve basic configuration for a given application – Basic configuration

• Configure devices to specific application• Devices come with pre defines set of values from

manufacturer.• Device may support multiple templates• User may decide to make additional configuration

changes. - Advanced configuration.• Local help available within the device• Specifications available today and can be used for

testing under ITK 6.2+ & Host Test Kit 3.


Automated Device Replacement

• Replacement of a existing device with a new device.• Automatic configuration of new device without manual

intervention.• Plug & Play like solution• No re engineering, Host configuration or changing any

element of the H1 network except the instrument.• Will reduce integration risk


PV Interchangeability

• Addresses the “3 am Sunday Device Replacement Scenario”

• Replacement device gives a PV to get process up & running until Monday morning.

• Ideally should provide a PV without available DD• Similar to replacing a 4-20 ma device. Decouple PV from

DD• Easier to handle the 4-20 ma. No ranging or calibration

required.


Example 2 – Implementation of FF-912 Field Diagnostic Profile

• The technical specification which describes the implementation of the NE 107 into Foundation Fieldbus Endress+Hauser was part of the specialist team which defined the FF 912

Failure

Function

Check

Out

of

Specification

Maintenance

Required


Current Diagnostic Information from Devices

Electronics FailureSensor FailureProcess ConditionConfiguration WarningPlugged Impulse Linesetc...

Travel DeviationCycle CounterValve SignatureStep ResponseDynamic Error BandDrive SignalOutput Signaletc...

Electronics FailureSensor FailureProcess ConditionConfiguration WarningRTD DriftRTD Life Estimationetc...

pH Electrode AgingGlass Electrode FailureReference Electrode FailureReference Electrode CoatingReference Electrode Poisoningetc...

Electronics FailureSensor FailureReverse FlowEmpty PipeCalibration ErrorProcess ConditionConfiguration Warningetc...


Results

Operations Literally

Over range

Sensor Fail

Empty Tube

Reverse Flow

Electrode coated

Sensor failure

Sensor disconnect

Leakage

FrictionRTD failure

Valve stuck

Coil open

Plugged lines

High Temperature

Travel Deviation


Example – Coriolis Meters

2. Event page

• Diagnostic event page.

• Icon/text according NE 107(F,M,C,S)

• Maintenance instructions

3. Info page

• An event occurred. Depending on event status the status symbol for the event level is shown

1. Measurement page with warning


Example – Easy Diagnostics in a Radar Level Transmitter

• The new categorizing in “failure”, “maintenance required”, “function check” and “out of specification”

• Failure -> change to manual operation+ call maintenance technician

• Maintenance required -> call/Request maintenance technician

• Function check -> configuration in progress• Out of specification -> check process environment

• Event Recorder• Failure / Maintenance / Check / Out of Spec /

Information• Optional – Trending of Events, More Events Recording• Backup / Copy / Restore functionality. Easy Electronic

replacement• The detailed diagnostic information shows …

… what happened … remedy information

• Histo Rom – Storage of Events, envelope curves & process values


Context of Application

FFIC : Automation 2011 - Mumbai

MaintenanceConsole

H1

Operator’sConsole

SD_MAINT_ALM

Active

SD_RECOMMENDED_ACTION

Clean Sensor

SD_MAINT_ACTIVE

Clogged Pressure Sensor


Context of Application

MaintenanceConsole

H1

Operator’sConsole

SD_FAIL_ALM

Active

SD_RECOMMENDED_ACTION

Change Sensor

SD_FAIL_ACTIVE

Pressure sensor failure


Example 3 – Implementation of Field Diagnostics

Manufacturer: Implementation User: Configuration

DiagnosticsSensor Highest SeverityElectronic Highest SeverityConfig. Highest Severity Process Highest SeveritySensor High SeverityElectronic High SeverityConfiguration High SeverityProcess High SeveritySensor Low SeverityElectronic Low SeverityConfiguration Low SeverityProcess Low SeveritySensor Lowest SeverityElectronic Lowest SeverityConfig. Lowest SeverityProcess Lowest Severity….Process Diagnostic 23….Process Diagnostic XProcess Diagnostic Z

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

…………………………………………

……………………………………………………………………………………

…………………………………………

…………………………………………

Assignment

Info 1

Info 5

Info 11

Info 16

Info 31 (max.)

……………………

……………………

Masking


Implementation of Field Diagnostics


Foundation Fieldbus Tools

Scanner Camera

WLAN / WWANPHONE / VOIP

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