FOUNDATIONTM Fieldbus technology

Introduction

1 FFTechnology/September2000
YOKOGAWA
 Business environment leads to needs
Lower installation cost
 Multiple instruments on a single pair of wires
 Faster commissioning - loop check
 Multi-variable transmitters

Operational improvements
 More real time information “about” the process
 Measurement validation - quality - safety
 Tighter control by distribution of control functions
 Mechanism for continuous innovation

Lower maintenance cost - predictive ...

 Remote access - unified tools
 Advanced process and device diagnostics
 Integrated plant asset management functions

2 FFTechnology/September2000
YOKOGAWA
 What is fieldbus
Fieldbus

Process Plant
L
Automation
and
display systems
F

Open, digital, bi-directional communications network

Among field measurement and control devices and
automation/display systems
It replaces the traditional point-to-point connections

3 FFTechnology/September2000
YOKOGAWA
Local Area Network for field instrumentation

Plant network Office automation

hierarchy Plant- and
wide departmental computers
Network

Automation and display

Control System
Local Area Networks systems

Network for field

Fieldbus instrumentation

4 FFTechnology/September2000
YOKOGAWA
Networks for field devices - 3 types

Process
Control
Fieldbus
Block level

Devicebus
Byte level

Logic Sensorbus
Bit level
Control

Simple Devices Complex Devices

5 FFTechnology/September2000
YOKOGAWA
 The OSI model
TAG TIC 101
Reactor Temperature
PV = 242 degrees C
 For meaningful communications
between fieldbus devices and host Mail message:
systems a common language must  Common language
 Read & understood
be used
User Layer
Paper contains:
Application
Application Layer
Layer  TO/FROM
M  Mail message
a Presentation Layer
Nn
e a Session Layer Envelope contains:
Network t g  Address TO/FROM
Management Transport Layer
we  Stamp
 Mail message on paper
o m  Location of information critical
r e Network Layer
k n
Data Link Layer
Postmaster: t Mailbox:
 Coordination  Holds envelope
Physical Layer  Address & flag

Wire Medium Truck transports envelope,

independent of message

6 FFTechnology/September2000
YOKOGAWA
 The OSI model
 Layers 1-4 handle the communications between processors
 Layers 5-7 handle the communications between applications
 The user layer is not defined by the ISO-OSI model
User Layer

Application
Application Layer
Layer
M
a Presentation Layer Fieldbus
Nn
e a Session Layer
t g
we Transport Layer
o m
Network Layer Devicebus
r e
k n
Data Link Layer
t
Physical Layer Sensorbus

Wire Medium

7 FFTechnology/September2000
YOKOGAWA
 Sensorbus - What is it?
 Simple, low cost implementation

 High speed, bit level

communication Process
Control
Fieldbus
Block level
 Simple discrete devices
 Push buttons Devicebus
Byte level
 Limit switches
 Optical sensors
Logic Sensorbus
Bit level
Control
 Implementations: Simple Devices Complex
 AS-i bus Devices
 Seriplex

8 FFTechnology/September2000
YOKOGAWA
 Devicebus - What is it?
 High speed, byte-level
communication

 Focus on Factory Automation Process

Control
Fieldbus
 More complex discrete devices Block level

 PLC and remote I/O sub-systems

Devicebus
Byte level
 Weighing systems
 Electric drive sub-systems Logic Sensorbus
Bit level
Control
 Implementations: Simple Devices Complex
 DeviceNet Devices
 Profibus DP

9 FFTechnology/September2000
YOKOGAWA
 Fieldbus - What is it?
 Digital replacement of analogue 4-
20 mA signal
 Unlocking advanced functionality

Process
 Focus on Process Control
Control
Fieldbus
Block level
 Simultaneous power and signal
on the bus - 2-wire Devicebus
Byte level

 Supports intrinsic safety Logic Sensorbus

Bit level
Control
 Implementations: Simple Devices Complex
 Profibus PA Devices
 FOUNDATIONTM Fieldbus

10 FFTechnology/September2000
YOKOGAWA
FOUNDATIONTM Fieldbus
How does it work?

11 FFTechnology/September2000
YOKOGAWA
 Past - Traditional instrumentation
Strengths
 OPEN, interoperable and
interchangeable
 Broad range of equipment I/O
 Multiple vendors
 Standard control system interfaces
 Standard support equipment 4-20 mA

Weaknesses
 Limited information transmitted
 One variable, one direction
Traditional analogue (4-20 mA)
 Point-to-point wiring and discrete instruments

12 FFTechnology/September2000
YOKOGAWA
 Present - Hybrid instrumentation
Strengths
 More information transmitted
 Bi-directional communications Proprietary or
I/O Custom Interface
 Improved performance and availability
 Faster commissioning - ease of
configuration
 Improved maintenance through on- PLC
line diagnostics

Weaknesses
 Limited interoperability
 Manufacturer dependancy Analyser

 Lack practical multi-drop capability Hybrid Instruments or Intelligent

 Requires special DCS interfaces Instruments with Custom Interfaces

13 FFTechnology/September2000
YOKOGAWA
 Fieldbus - Customer expectations
 Fieldbus is open and interoperable
 Supports interchangeability
 Supports various bus topologies
 Supports control and automation functions
High Speed Backbone
 Supported by multiple vendors
 Broad range of equipment
Bridge
 Standard control system interfaces
 Bi-directional communications
 More information transmitted - alarm reporting
 Improved performance and availability Fieldbus
 Improved maintenance - on-line diagnostics
 Standard support equipment
 Ease of configuration - single tool
 Faster commissioning

14 FFTechnology/September2000
YOKOGAWA
 FOUNDATIONTM Fieldbus is an “Enabler”
Fieldbus

Process Plant
L
Automation
and
display systems
F

Designed for total plant automation - control and automation

Vendor independent “Best in Class” solutions
Innovation - seamless integration new device functionality
15 FFTechnology/September2000
YOKOGAWA
FOUNDATION™ Fieldbus topology

Host
Interface

Ethernet Field
Device
HSE Fieldbus

Linking
Device
I/O
Interface
H1 Fieldbus

H1 Fieldbus

16 FFTechnology/September2000
YOKOGAWA
The H1 FOUNDATION™ Fieldbus model
OSI model based FOUNDATION™ Fieldbus H1 Model

USER LAYER USER LAYER

FIELDBUS MESSAGE
SPECIFICATION
APPLICATION LAYER 7
FIELDBUS ACCESS
SUBLAYER
PRESENTATION LAYER 6
H1
SESSION LAYER 5 “STACK”

TRANSPORT LAYER 4

NETWORK LAYER 3

DATA LINK LAYER 2 DATA LINK LAYER

PHYSICAL LAYER H1 PHYSICAL LAYER H1 PHYSICAL LAYER
1

The User Layer is not defined by the OSI Model

17 FFTechnology/September2000
YOKOGAWA
H1 practical implementation

SENSOR / ACTUATOR

SENSOR
USER LAYER
USER LAYER

H1
H1 “STACK”
“STACK”

MEDIA ACCESS UNIT (MAU)

PHYSICAL LAYER

Fieldbus wire Fieldbus wire

18 FFTechnology/September2000
YOKOGAWA
What does FOUNDATION™ Fieldbus do?
Moves data from
SENSOR ACTUATOR
here to there
USER LAYER USER LAYER
Controls, alarms

Ensures secure
H1 communication H1
“STACK” “STACK”

Connects to the
PHYSICAL LAYER PHYSICAL LAYER
wires here
Fieldbus wire

19 FFTechnology/September2000
YOKOGAWA
H1 Physical Layer
 IEC 61158 compliant

 Converts data from the “Stack” to physical

USER LAYER
signals on the “fieldbus”

 Transmission is “Synchronous Serial”; the

clock is encoded in the signal using
H1 Manchester coding
“STACK”
 Signalling rate is 31.25 kbits/sec

 Supports copper wire and optical fibres

PHYSICAL LAYER
 Supports Spur, Daisy chain and Chicken
foot (star) bus topologies

20 FFTechnology/September2000
YOKOGAWA
 H1 Physical Layer topology
 Up to 32 devices per segment
 Depends on several factors Spurs

 Uses (un-)shielded twisted pair cable

 Can use existing field wiring Daisy chain
 Fibre optic cable is optional

 Power down the bus

 Cable length up to 1900 m Star

 Depends on cable quality
 Up to 9500 m using repeaters

 Designed for intrinsic safety

21 FFTechnology/September2000
YOKOGAWA
 Number of devices on a H1 segment

Local Power Non I.S. I.S.

Rate 31.25 kbit/s 31.25 kbit/s 31.25 kbit/s
Mode Voltage Voltage Voltage
Topology Bus/Tree Bus/Tree Bus/Tree
Power Supply Separate DC DC DC
Devices recommended 2 - 32 2 - 12 2-6

The maximum number of devices on a H1 fieldbus segment may be

limited by the communication rates of the devices, the maximum
number of addresses on a segment (240), or the available power.

22 FFTechnology/September2000
YOKOGAWA
 Designed for intrinsic safety
 Based upon “Entity” concept

 Bus power defined as 1.2 W max.

 Us= 10.6 V

 Current available (cable type A)

 60 mA on a 1900 m segment
 90 mA on a 400 m segment
 Gas group IIB or IIC IS
Fieldbus

 Typically 4 devices on a segment

 Multi-barrier concept available One IS barrier, one pair

for many devices

23 FFTechnology/September2000
YOKOGAWA
 Intrinsic safety - Future direction
 Based upon “FISCO” concept

 Bus power defined as

 Gas group IIC - 1.9 W max.
 Gas group IIB - 4.9 W max
 Us= 12.6 V

 Current available (cable type A)

 110 mA on a 750 m segment IIC
 200 mA on a 750 m segment IIB
IS
Fieldbus
 Typically:
 6 devices on a segment in IIC
 10 devices on a segment in IIB

 Multi-barrier concept available One IS barrier, one pair

for many devices

24 FFTechnology/September2000
YOKOGAWA
Cable type versus segment length
Cable Type Gauge No. Max. Length
A: Twisted-pair with Shield
H1 (31.25 kbit/s) #18AWG 1900 m
B: Multi-twisted-pair with Shield
H1 (31.25 kbit/s) #22AWG 1200 m
C: Twisted-pair without Shield
H1 (31.25 kbit/s) #22AWG 400 m
D: Multi-core without Shield
H1 (31.25 kbit/s) #16AWG 200 m

Any existing, good quality #18 AWG twisted pair cable can be
used for fieldbus.

25 FFTechnology/September2000
YOKOGAWA
 H1 cable length calculation
Cable type H1 total length *
A 1900 m
B 1200 m
C 400 m
D 200 m
Homerun
Cable * Total length including all spurs

J Box # of devices Total max Spur length **

25 - 32 1m
Spur 19 - 24 30 m
Field Devices 15 - 18 60 m
13 - 14 90 m
2 - 12 120 m

** Maximum length of any spur

26 FFTechnology/September2000
YOKOGAWA
 Extending the length of a H1 segment
Repeaters are used to extend the length of a segment
 A repeater is an active device

Up to 4 repeaters can be used on a segment

 Maximum distance between any two devices on the network is 9500 meters

Fieldbus Segments
T T

T T T T T T T T
Fieldbus Fieldbus Fieldbus Fieldbus
Repeater Repeater Repeater Repeater

Fieldbus Network - up to 9500 meter

27 FFTechnology/September2000
YOKOGAWA
H1 communication stack
 IEC 61158 compliant
 Data Link Layer (DLL)
 Application Layer (AL)
USER LAYER

 Establishes basic communication services

between fieldbus devices
 Encoding and decoding of User Layer messages
H1  Deterministic control of message transmission
“STACK”
 Efficient and secure message transfer
 Supports scheduled messaging for time critical
communication (Publisher/Subscriber)
 Supports unscheduled messaging for
request/response communication (Client/Server)
PHYSICAL LAYER
 Supports unscheduled messaging for Event
Notification (multicast)
 Publishes the “time” on the bus

28 FFTechnology/September2000
YOKOGAWA
 H1 device types

100 Mbits/sec HSE Fieldbus

Host Interface Bridge Ethernet Field Device

 Basic device

 Link Master device

 Link Active Scheduler (LAS)
31.25 kbits/sec H1 Fieldbus

 Linking device (Bridge) H1 Field Device

29 FFTechnology/September2000
YOKOGAWA
 H1 Link Master - Link Active Scheduler (LAS)
Link Active Scheduler controls communication on the bus
 A device may send packets of information when permitted by the LAS

Maintains a list of all devices on the segment - “Live List”

Distributes time to all devices on the segment

H1 Fieldbus
LAS

BASIC LINK MASTER BASIC BASIC LINK MASTER BASIC

DEVICE DEVICE DEVICE DEVICE DEVICE DEVICE
(Primary) (Back-up)

30 FFTechnology/September2000
YOKOGAWA
 H1 Link Master redundancy - Back-up
LAS function transferred when primary Link Mater fails!

H1 Fieldbus
LAS LAS

BASIC LINK MASTER BASIC BASIC LINK MASTER BASIC

DEVICE DEVICE DEVICE DEVICE DEVICE DEVICE
(Primary) (Back-up)

31 FFTechnology/September2000
YOKOGAWA
 Scheduled data transfer - step 1

LAS = Link Active Scheduler

P = Publisher
Schedule S = Subscriber
CD = Compel Data
a
LAS
b Fieldbus Physical Medium
c

CD(x,a)

Device x Device y Device z

a b c a d a
P S P S P S

32 FFTechnology/September2000
YOKOGAWA
 Scheduled data transfer - step 2

LAS = Link Active Scheduler

Schedule P = Publisher
S = Subscriber
DL = Data Link Packet
LAS
Physical Medium

DL(a)

Device x Device y Device z

a b c a d a
P S P S P S

33 FFTechnology/September2000
YOKOGAWA
 Unscheduled data transfer step 1

Token LAS = Link Active Scheduler

Circulation P = Publisher
List S = Subscriber
PT= Pass Token
LAS x M = Message
y Physical Medium
z

PT(z)

Device x Device y Device z

a b c a d a M
P S P S P S

34 FFTechnology/September2000
YOKOGAWA
 Unscheduled data transfer step 2

LAS = Link Active Scheduler

P = Publisher
S = Subscriber
PT= Pass Token
LAS M = Message
Physical Medium

DL (M)

Device x Device y Device z

a b M c a d a M
P S P S P S

35 FFTechnology/September2000
YOKOGAWA
Publisher/Subscriber
 Synchronous data transfer
 Network scheduled
 Deterministic - control
 One-to-many
Temp: 23.4 C  Unidirectional
Data
 Used for publishing data

Compel Data

36 FFTechnology/September2000
YOKOGAWA
Client/Server
 Asynchronous data transfer
 Unscheduled
 One-to-one
 Bi-directional
Flow: 50 m3/hr  Used for operator messages
Response

Request

Pass Token

37 FFTechnology/September2000
YOKOGAWA
Event notification
 Asynchronous data transfer
 Unscheduled
 One-to-many
 Uni-directional
HI TEMP  Used for event notification and
Alarm trend reports
Data

Pass Token

38 FFTechnology/September2000
YOKOGAWA
H1 User Layer - Unique differentiator
 Provides the interface with the process
SENSOR  and for user interaction with the host system

USER LAYER  Standard Function Blocks

 Consistent definition of data for integrated and
seamless distribution of functions in field devices from
different manufacturers

H1  System Management
“STACK”  Deterministic scheduling of function blocks

 Device descriptions
 Host system to operate the device without the need for
custom programming
PHYSICAL LAYER
 Common File Format
 Off-line “system” configuration by host system

39 FFTechnology/September2000
YOKOGAWA
 Minimum 3 blocks reside in a device
The Resource Block
 Describes the characteristics of a device
 Contains manufacturer information

The Transducer Block

 Physical I/O interface with the actual sensor or actuator
 Performs A/D conversions, square root extraction, linearisation etc.
 Transmits/receives information to/from Function Blocks
 The Transducer Block is the window to the process - diagnostics

Function Blocks
 Similar to the function blocks in today’s DCS and PLC systems
 Mandatory is at least one Function Block depending on the type of device

40 FFTechnology/September2000
YOKOGAWA
H1 practical implementation

SENSOR / ACTUATOR

SENSOR
USER LAYER
USER LAYER

H1
“STACK” H1 “STACK”

MEDIA ACCESS UNIT (MAU)

PHYSICAL LAYER

Fieldbus wire Fieldbus wire

41 FFTechnology/September2000
YOKOGAWA
 Differential pressure transmitter - example

SENSOR

TRANSDUCER
BLOCK
USER LAYER

H1 “STACK”
ANALOGUE ANALOGUE
RESOURCE
INPUT INPUT
BLOCK
BLOCK BLOCK

MAU

DIAGNOSTIC DIFFERENTIAL STATIC

Fieldbus wire DATA PRESSURE PRESSURE

42 FFTechnology/September2000
YOKOGAWA
 Valve positioner - example

TRANSDUCER
ACTUATOR BLOCK

USER LAYER
ANALOGUE DIGITAL
DIGITAL
OUTPUT INPUT
INPUT
BLOCK BLOCK
BLOCK

H1 “STACK”
VALVE
POSITION

PID RESOURCE
MAU BLOCK BLOCK

DIAGNOSTIC LIMIT LIMIT

Fieldbus wire DATA SWITCH SWITCH

43 FFTechnology/September2000
YOKOGAWA
 Function Blocks
Monitor and control process applications
 Input blocks - AI, DI
 Output blocks - AO, DO
 Control blocks - PID, Ratio, Signal Characteriser, Lead/Lag etc.

Reside in any field device and/or host system

 Simple control functions may migrate into field devices

Form deterministic control schemes

 Interconnect over the bus to implement an integrated control strategy
 Interconnect to blocks in the host as part of an advanced control scheme

Execute periodically - cyclically

44 FFTechnology/September2000
YOKOGAWA
Control functions migrate into the field

H1 Fieldbus

Precise timing of block execution

OUT IN OUT CAS_IN OUT

AI PID AO

45 FFTechnology/September2000
YOKOGAWA
Distributed control applications

Fieldbus

Host Device 1 Device 2 Device 3

System
Application A Application B

Application C

Process

46 FFTechnology/September2000
YOKOGAWA
 Function Block structure
 Block appearance is standardised

 Algorithms are vendor specific

 Room for “differentiation”
Algorithm
 Consistent, easy, block oriented
Inputs Outputs
configuration
Example:PID

 Consistent definition of information

being communicated
 Standardised status indication
Alarm Mode Structure Event
Subsystem (Manual, Auto, etc.) Subsystem
 Common set of modes
 Standard method of mode propagation

47 FFTechnology/September2000
YOKOGAWA
 H1 Function Block execution scheduling
Scheduled Scheduled Request/Response
Function Block Function Block Communication
execution communication (unscheduled)

AI
PID
AO

LAS macro-cycle LAS macro-cycle

Precise timing of block execution - cyclic

Function Block communication over the bus is immediate

48 FFTechnology/September2000
YOKOGAWA
 Device Descriptions (DD’s)
Extended description of the capability of a field device

Written in a standard Device Description Language (DDL)

DDL technology implements the FF interoperability concept

Interpreted by host system and provide the information needed by

the host to see and use field devices
 Provided on CD or floppy or may be uploaded from the field device

Standard and Incremental DD’s

 Standard DD’s for standard Fieldbus Foundation device profiles, including Function
Blocks and Transducer Blocks
 “Incremental” DD’s to define manufacturer-specific extensions

49 FFTechnology/September2000
YOKOGAWA
 Common File Format (CFF)
Describes the functions and capabilities of a field device
In conjunction with Device Descriptions allows data exchange
among device manufacturers, system builders and end-users
 Capabilities File
Electronic form of device specification - used for device configuration
 Value File
Data to be downloaded
Uploaded data from devices

 Both are standard ASCII text files for human readability

Enable a host system to configure the system off line

 Yokogawa complies - Yokogawa’s main contribution to FF specifications

50 FFTechnology/September2000
YOKOGAWA
 What is “Interoperability”?
The ability to implement control strategies on a system
implemented with devices from multiple vendors

Delivered by:
Standard Physical Layer
Standard communication protocol (Stack)
Standard function blocks
Device descriptions
Common File Format

Freedom for end-users to chose “Best in Class” solutions

The ability to substitute a field device from one vendor for that
of another vendor without loss of functionality …..

51 FFTechnology/September2000
YOKOGAWA
 Interoperability fulfils the expectations of ...
Basic interfacing
 Interconnectivity

Support for innovation

 Seamless integration of new device features

Substitution
 Replacement of similar devices from different manufacturers
 Expectation established by the analogue 4-20 mA standard
 Substitution requires re-configuration

All layers of the OSI model plus User Layer must interoperate
 Physical Layer, Communication Stack and User Layer

52 FFTechnology/September2000
YOKOGAWA
 Conformity and Interoperability test procedure
Stack conformity testing Device interoperability testing

SENSOR ACTUATOR SENSOR ACTUATOR

USER LAYER USER LAYER USER LAYER USER LAYER

H1 H1 H1 H1
“STACK” “STACK” “STACK” “STACK”

PHYSICAL LAYER PHYSICAL LAYER PHYSICAL LAYER PHYSICAL LAYER

Fieldbus Fieldbus

 Stack registration  Device registration

 20 different stacks registered  100 different devices registered ®

 Basic and Link Master devices  Key to interoperability


FOUNDATION

53 FFTechnology/September2000
YOKOGAWA
 Will “interoperability” improve
Not all layers interoperate - tighten the specification
Capabilities File imperfections - vendors to fix
 Response time; device expects to have a response within “x” seconds

Bug’s in stack conformity tester - to be fixed

Lack of capability - parameters not in non-volatile RAM
 Problem reoccurs at power up; requires down load - vendors to fix

Host System testing being debated

Common File Format is key to interoperability
 Yokogawa complies - Yokogawa’s main contribution to FF specifications

54 FFTechnology/September2000
YOKOGAWA
FOUNDATIONTM Fieldbus
High Speed Ethernet

55 FFTechnology/September2000
YOKOGAWA
FOUNDATION™ Fieldbus topology

Host
Interface

Ethernet Field
Device
HSE Fieldbus

Linking
Device
I/O
Interface
H1 Fieldbus

H1 Fieldbus

56 FFTechnology/September2000
YOKOGAWA
The HSE FOUNDATION™ Fieldbus model
OSI model based FOUNDATION™ Fieldbus HSE Model

USER LAYER USER LAYER

COTS HSE
Commercial Of The Shelve APPLICATION
PROTOCOL
Ethernet equipment HSE
“STACK”

STANDARD STANDARD
ETHERNET STACK ETHERNET STACK

PHYSICAL LAYER PHYSICAL LAYER HSE PHYSICAL LAYER

The Application Layer is not defined in Ethernet

57 FFTechnology/September2000
YOKOGAWA
HSE Physical Layer
 High speed backbone

 Converts data from the “Stack” to physical

USER LAYER signals on the “fieldbus”
 Uses standard Ethernet electronics
 Supports redundant media and devices
 Provides interface to other protocols

HSE  Transmission is TCP/IP

“STACK”
 Collision detection

 Signalling rate is 100 Mbits/sec

PHYSICAL LAYER  Supports copper wire and optical fibres

 Up to 100 m using shielded twisted pair cable
 Up to 2000 m using optical fibres

58 FFTechnology/September2000
YOKOGAWA
FOUNDATIONTM Fieldbus integrated network

HSE Client

COTS
High
Spe 100 Mbit/s
ed
Ethe Switch
r ne t
High Spe
ed Ether
net Linking
net Device
r
th e
edE Linking H1
e
Sp
P

Device
gh
Hi
L

Plant

H1 H1 H1
P P P

L L L

Plant Plant Plant

59 FFTechnology/September2000
YOKOGAWA
HSE communication stack
 HSE stacks consists of
 Standard Ethernet stack
 FF-HSE Application Protocol
USER LAYER

 Establishes basic communication services

between Ethernet devices
 Encoding and decoding of User Layer messages
HSE  Deterministic control of message transmission
“STACK”
 Efficient and secure message transfer
 Supports scheduled messaging for time critical
communication (Publisher/Subscriber)
 Supports unscheduled messaging for
request/response communication (Client/Server)
PHYSICAL LAYER
 Supports unscheduled messaging for Event
Notification (multicast)
 Provides Bridging and Redundancy

60 FFTechnology/September2000
YOKOGAWA
HSE User Layer - Unique differentiator
 Provides the interface with the process
SENSOR
 and for user interaction with the host system
USER LAYER
 Standard Function Blocks
 Consistent definition of data for integrated and
seamless distribution of functions in Ethernet
(field) devices from different manufacturers
HSE
“STACK”
 System Management
 Deterministic scheduling of function blocks

 Device descriptions
 Host system to operate the device without the
PHYSICAL LAYER
need for custom programming

 Common File Format

 Off-line “system” configuration by host system

61 FFTechnology/September2000
YOKOGAWA
 Flexible Function Blocks

 Extends the Function Block model into

Discrete Manufacturing
FFB is a “Wrapper” for an
 Multiple I/O (MIO) Blocks Application-specific Algorithm
 8 channels per block
 Multiple Analogue Input
 Multiple Analogue Output
 Multiple Discrete Input Application-
 Multiple Discrete Output Specific
Algorithm

 Flexible Specific Blocks

 Application specific algorithm IEC
61131 compliant

62 FFTechnology/September2000
YOKOGAWA
Distributed control functions

HSE Fieldbus

AI OUT IN
PID OUT

BK_CAL IN

BK_CAL OUT

AO CAS_IN

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 HSE Function Block execution scheduling
Scheduled Scheduled Request/Response
Function Block Function Block Communication
execution communication (unscheduled)

AI
PID
AO

LAS macro-cycle LAS macro-cycle

Precise timing of block execution - cyclic

Function Block communication over the bus is immediate

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 FOUNDATIONTM Fieldbus
Designed for total plant automation - control and automation
100 Mbit/s Switch
HMI
Batch Controller

FFB

PLC Gateway

FFB FFB
FFB

Dry contacts Linking Device Net

Pressure Device Interbus S
switches
ASI bus
RTD,s & T/C’s
AI, AO, PID, FFB Profibus DP
Push buttons
Control Net
On-Off valves

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 High Speed Ethernet (HSE) - summary
Cost-effective, high-speed, plant-wide backbone

Standard Ethernet technology running at 100 Mbit/s

 Availability of standard Ethernet equipment
 Flexible Function Blocks
 HSE field device running standard function blocks

Fault tolerant communications and linking devices

Bridging of multiple H1 networks on a linking device

Interface to other protocols through gateways

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 FOUNDATIONTM Fieldbus
Impact on Engineering and Installation

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Simplified engineering and installation

4-20 mA

IS IS IS IS IS
Fieldbus

Traditional 4-20 mA wiring,

One IS barrier, one pair
one IS barrier, one pair
for many devices
for each device

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 Fieldbus cabling concept
Quick-connect junction box
bus terminator
Fieldbus H1 segment

Provides flexibility in “Plug and Play”

 General purpose and Intrinsic Safe concepts
 Monitors bus voltage and current
 Detects short circuits and other wiring problems

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 Multi-barrier concept by Turck
 Multiple EEx-e / EEx-i barriers for
improved solutions for Zone 1
Linking device hazardous areas
 Up to 4 devices per barrier
Fieldbus power conditioner  Typically up to 12 devices per
segment
Cabinet - Safe Area

I.S. Zone

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 Impact on Engineering and Installation
Increased capabilities due to full digital communications
 Less devices required - less process intrusions
 Reduced wiring and wire terminations - multiple devices on one wire
 Less engineering and cabling check-out

Increased freedom in selecting suppliers - interoperability

 Unified configuration and device management tools - self-documenting
 Download off-line configured network/device configuration
 Simpler and significantly faster commissioning

Reduced loading on control room equipment

 Distribution of some control and input/output functions to field devices
 Smaller control room footprint
 Simpler engineering effort

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FOUNDATIONTM Fieldbus
Impact on Operations

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Expanding the view of the process

4-20 mA

IS IS IS IS IS
Fieldbus

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 Utilising the intelligence of the field device
 On-board computing power enables
step changes in functionality

 Become the window to the process

 Become “information servers” in the

field based architecture

 Become an integral part of the

“system”

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 Increased process information
Fieldbus-based
Automation
Systems

Traditional Non-control
Automation Information
Systems
Control
Information

Today Future

Path to integrated Plant Resource Management

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 Control functions migrate into the field

AI PID PID
AO

4-20 mA Fieldbus

PID
AI
AO

In today’s systems, control functions all Fieldbus enables control and I/O functions
reside in central controllers. to be distributed to field instruments.

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Sources of process variability
All control loops Causes of variability:

30% Poor tuning

30% Poor field device performance

15% Control strategy design

5% Poor process design

15% Running properly

Source: Entech - Results from audits of over 300 DCS installations

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 Cost savings through improved stability
Product New Process
Specification Set Point
Process
Set Point

Impact of Move
reduced process
process set point
variability closer to
Increase Increase in Reduce Reduce
Increase in product
in Scrap Energy and Scrap Energy and
Quality spec.
Costs Feedstock Costs Feedstock
Costs Costs

Significant feedstock reduction; virtually no scrap costs

Improved plant productivity
Higher, more consistent final product quality

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 Impact on Operations
Improved process performance
 Improved accuracy of measurement

“Control Anywhere”
 Tighter control, improved responsiveness and reduced process variability
 Reduced raw materials usage - less wastage
 Stabilised product quality

Expanded view of the instrumentation

 Real time process data includes status information
 Improved process availability
 Unified Device Management Tools
Consistent device configuration and calibration

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FOUNDATIONTM Fieldbus
Impact on Maintenance

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 Simplified maintenance

4-20 mA

IS IS IS IS IS
Fieldbus

Traditional 4-20 mA wiring, one Process Value Mode, Value, Status, Alarms, Trends

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 Path to Plant Resource Management
Plant
Field based “information servers” Diagnostics
Field
Performance Level 4
Diagnostics

Device Level 3 process

Diagnostics equipment
Fisher

Communications Level 2 actuators, elements

Diagnostics valves, connections

Level 1
electronics

Fisher

communications

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 Field based information server
 Auto-tuning function
 “Matches” positioner with the valve

 Actual valve position feedback

 Tight shut-off
 Limit switches

 Valve travel accumulation

 Valve travel alerts
 Prevents packing leakage's
 25:1 “data explosion” in HART®
 Air supply pressure monitoring environment
 200:1 “data explosion” in Fieldbus
 Maintenance history environment

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 Impact on Maintenance
Field device has on-board diagnostics
 Increased measurement reliability and availability
 Eliminates unscheduled downtime

Trouble shoot field devices from central work station

Eliminates unnecessary trips to the field
Problem identification before getting out Primary element for
Reduced effort for field calibration measuring flow

Advanced diagnostics
 Clogged impulse line detection
 Transducer Block implementation
P transmitter

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Fieldbus - a revolution in plant automation

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