FOUNDATION

fieldbus H1
The Future is Digital
 Do You Think the Future is Digital?
- Everything is going digital and getting networked
z Digital Music

z Digital Photography

z Digital Telephony
Should a
z Digital Mail "digital" control
system rely on
analog inputs
z Digital TV and outputs?

z Digital Instrumentation

21
 Topics Covered
z Fieldbus basics
z Fieldbus benefits
– Project benefits
– Operation & maintenance benefits
z Making fieldbus easy
– Easy to deploy
– Easy to operate
– Easy to run & maintain
z Specifying fieldbus

26
 Fieldbus Started With a Simple Idea
z Reduce cabling
z Simplify signal marshalling
z Digital closed loop control
z Multi-vendor interoperability
z All devices intelligent
z Predictive maintenance based on diagnostics
z Liberating plants from proprietary protocols

27
Fieldbus Basics
 FOUNDATION fieldbus H1 Basics
- Hardware
•Interface
z 31.25 kbit/s (25X) (LAS)
•Bus Power Spur
z Pure digital control
•Terminator
z Bus power on same two
wires: 9-32 VDC
z Intrinsically safe or non-
incendive; zone 0/1/2 C
z 1900 m total, 120 m spurs Trunk
T
z Shielded twisted pair cable JB

z Real-time and non-real-time

z Time synchronized &
scheduled LAS = Link Active Scheduler
T = Terminator
z Multi-vendor interoperability >> 30 I/O C = Coupler
z Multidrop: typical 10-12 signals
per pair of
devices; 3 I/O per device wires

30 z Permits temporary masters

 Many Bus Power Options to Optimize
for Different Needs
Dsgn Spur Trunk Device Live Work Live Work Redundant Devices Remarks
(Device) Zone on Trunk on Spur Power (@20 mA)
1 Exd Zone1 N N Y 16
2 Exia, Entity, IIC Zone 0 Y Y N 3
3 Exia, FISCO, IIC Zone 0 Y Y N 5
4 /14 Exib, FISCO IIC Zone 1 Y Y N/Y 6 Mult-seg
5 / 15 Exib, FISCO IIB Zone 1 Y Y N/Y 13
6 Exia, FISCO, IIC Exe Zone 0 N Y Y 16 HPT/HET
7 Exia, Entity, IIC Exia, Entity, IIB Zone 0 Y Y N 16
11 N.I. (Entity), IIC NNA, IIC Div 2 N Y Y 16
16 Exic, Entity, IIC ExnA, IIC Zone 2 N Y Y
17 Exic, FISCO, IIC ExnA, IIC Zone 2 N Y Y

z Hazardous areas are same as for hardwired

– Same protection options: ia, ib, ic, NI, d, and e
– Same zones/class/division: 0, 1, 2
– Same gas groups: IIC, IIB, A, B, C, D etc.
32
 Most “Digital Control Systems” Aren’t
Hardwired Fieldbus
Process Discrete Process Discrete
Analog Binary DCS Digital Digital
(4-20 mA) (On-Off) Real-time (FF) (FF)
control
Digital None AMS Digital Digital
(HART, Device (FF) (FF)
Brain, DE, manage
FoxCom) ment
Analog Digital
Digital Digital
Analog If it’s not Digital Positioner
Digital Positioner Digital Digital
Digital fieldbus, it’s
Discrete Transmitter Digital
Transmitter Dumb
not a digital Digital
Controller On-Off Valve
control Controller On-Off Valve
system

36
 Interoperability Tested Devices
z Device
– Physical Test
– Conformance Test Kit (CTK)
• Protocol
– Interoperability Test Kit (ITK)
• Blocks, Enhanced EDDL, Capability File (CF)
z Host (Software, Handheld)
– Host Profile Registration (HPR)
– System test
z Power Supplies (Conditioner, Barrier, Limiter)
– Physical Interoper
ability
z Coupler [wiring block] Technical No surprises
White
z Cable Paper
Available
37
 Fieldbus History
- Not That “New”
z FOUNDATION fieldbus is tried and tested

Shell Malampaya
2,000 FF Devices Qatar Gas LNG

IEC 61158
Standard BP SECCO
Fieldbus > 10,000 FF devices IEC 61804-3
Foundation Released
Established EDDL
Released
FF H1
Specification
Released

1994 1996 1999 2001 2005 2006 2008

38
 SECCO Ethylene Complex Project

9 Ethylene Furnaces

z US$2.7B Joint Venture Between BP, Sinopec, and Shanghai Petrochemical Corporation
z 10-plant facility which will produce 2.3 million metric tons of chemical products annually
z Large FOUNDATION Fieldbus Project– 14,000 Fieldbus devices
z Using DeltaV system to handle 150,000 I/O points(hard and soft)
z Major 3rd Party Sub-system – Intelligent MCC,VSD, GCs, MMS, Compressors, F&G

39
 World’s Largest LNG Project –
Qatargas Mega Trains
z Qatar Gas 2 - Trains 4 and 5
– JV between Qatar Petroleum and
ExxonMobil; EPC: Chiyoda-Technip
z Expanded to Qatar Gas 3/4 – Trains 6
&7
– QG3 JV: Qatar Petroleum and Conoco
Philips
– QG4 JV: Qatar Petroleum and Shell
– QG3/4 Offshore JV: Qatar Petroleum,
Conoco Philips and Shell
– Onshore EPC: Chiyoda-Technip JV
– Offshore EPC: McDermott
z MAC Scope; Qatar Gas 2 Alone Had
>20,000+ I/O, >120,000 Soft-points and
with 8,000 Foundation Fieldbus
devices
z Comprehensive 20 year Alliance
Agreement
z Major Asia-Pacific Involvement In
Project Execution

40
 China: Fujian Refinery / Ethylene Project
(FREP)
z Project Investment: ~US$3.5 B
– 8M tpa (160K bpd) refinery - 400K tpa polypropylene
– 800K tpa ethylene - 700K tpa PX/Aromatics
– 650K tpa LDPE/HDPE
– C4 - OSBL&Tank Farm
- IGCC
z JV of Sinopec (25%), ExxonMobil(25%), Saudi Aramco (25%) & Fujian
Province (25%)
– More than 10,000 FOUNDATION Fieldbus field devices
– Using DeltaV system to handle 160,000 I/O points(hard and soft)

41
 Fieldbus Success Stories Continue

Fujian FREP

Petrobras COMPERJ

Shell Prelude FLNG

Petronas FLNG

42
Fieldbus Project
Benefits
Reduced I/O Cards and Wiring
Reduced Device Count
Eliminate Proprietary Protocols
Faster Commissioning
 Multidrop: Minimize and Simplify
Hardwiring Fieldbus
z Familiar but tedious z Simpler “new” design
design z Flexible
z “Hard”, inflexible z Fewer cabinets

z Large footprint z Simpler installation

z Labor intensive

DDA A
IOIO
Let’s study each
Marshalling

FTA one...
P/S

24 24

2
FJB 2 C
2
2 22
M 6 S 6 T
JB
45
 Lower Cost:
- Fewer Cards and Cabinets
Hardwired Fieldbus
z One I/O channel per z Fewer I/O cards
signal z Fewer safety barriers
z One barrier per signal z No marshalling
z One pair of wires per z Reduced footprint,
signal weight, and heat load
z Signal conditioners
and relays
320 signal 250 device
cabinet with cabinet with
hardwired fieldbus
architecture architecture
46 110 devices 750 signals
 The FOUNDATION fieldbus H1 Card
- Virtual I/O or “Soft I/O”
z 2 H1 ports per card
– 16 devices per port (max)
– 150 ms macrocycle
z Redundancy
z Ability to perform control
– Extensive set of function blocks
– Synchronized with macrocycle
z Optional fieldbus power
‘96 Channel I/O
Card’
2 ports
16 devices per port
3 signals per device
(average)

47
 Reduced I/O Count and Wiring on
Complex Devices: Fully Integrated
Hardwired Fieldbus
z Lots of wiring and I/O z Multiple signals share
cards the same two wires
Cores I/O Description
4 3 DO Open/stop/close control z Reduces wiring for
Desired valve position
2 1 AO control electric actuators
2 1 DO Emergency shut down
Valve position status
3 2 DI (limit switches)
2 1 AI Percentage open
1 1 DI Available for control
1 1 DI Local/remote switch
Motor running open
1 1 DI direction With hardwired, many
Motor running closed device features
1 1 DI direction become too costly to
1 1 DI Torque switch tripped
use so MOV is not
2 1 AI Percentage torque
fully integrated
Motor thermostat
1 1 DI tripped
1 1 DI Battery condition low
48 22 16 ch TOTAL
 Fieldbus Eliminates I/O Cards and
Terminations
z The hardwired MOV z Fieldbus uses only 2
has 44 screw of these terminals for
terminals for signals all signals

49
 Eliminate Proprietary Protocols,
Gateways, and Software
Proprietary Bus Fieldbus
z Vendor dependency z Standards-based
z Gateways, mapping… z Simple architecture
DEVICE OPERAT. M.O.V. DEVICE OPERAT.
MGMT CONSOLE CONFIG. MGMT CONSOLE

F F M M F F
F F B B GATEWAY F F

FIELDBUS MODBUS FIELDBUS

P T M M P T M M

PROPRIETARY
P T M M P T M M

50
 One Device is Not One I/O Count
z The average device may have 3 signals
– Measurement, control, and feedback etc.
– Fully integrated
– Not even counting internal variables
Kind of Device I/O Count
Valve positioner (limit switch feedback) 3
Valve positioner (position transmitter feedback) 2
Electric actuators (motor operated valve, MOV) 16
On-Off valve 3
Coriolis mass-flowmeter 3
Magnetic flowmeter 4
Gas chromatograph 25
pH analyzer 2
Guided wave radar level transmitter 2
Process gas analyzer 5
51
 Lower Cost:
- Simpler Installation
Hardwired I/O FOUNDATION fieldbus
z A simple device z Fewer cable trays and
requires one pair of conduits to install
wires each all the way z Fewer cables to lay
to the rack room z Fewer wires to cut,

z Most devices require strip, label, crimp’ and

multiple pairs each connect – many points

52
 Lower Cost:
Fewer Connections to be Made
Devices FTA I.S. Barrier I/O
+ Assembly
- 1 1 +1+
2 2 -1-
+
-
3
4
z Hardwired 3
4 ++2-+ +
5 5 - - -
+ 6 – 160 connections 6 +
- 7 7 +3+ -
8
9 – 8 barriers 8
9
- - +
-
+ 10 10 +4+ +
- 11
12
z Fieldbus 11
12
- - -
+
13 13 +5+ -
+
- 14 – 55 connections 14 - - +
15 15 -
+
16
17 – 1 barrier 16
17
+6+
- -
+
-
- 18 18 +
19 19 +7+ -
+ 20 20 - -
- 21 21
22 22 +8+
23 23 - -
+ 24 If devices have more signals, 24
-
such as position feedback or
16 48 auxiliary inputs, the 48 32 16
16 27 reduction becomes even 6 4 2
Field more dramatic. Marshalling Cabinet
Junction Box
53
 Field Junction Box
Conventional Remote-I/O Fieldbus

0.5 m x 0.3 m x 0.2 m 1 m x 1.2 m x 0.4 m 0.5 m x 0.3 m x 0.2 m

8 kg 120 kg 8 kg
No power required AC power (redundant or UPS) No power required
~12 signals ~100 signals ~30 signals (~12 devices)

54
 Simplify I/O: Hardware Standardization
Through Software-Based Customization
Hardwired I/O Fieldbus is Soft I/O
z A plethora of different z One type of interface
hardwired signals card for all kinds of
z A bewildering array of devices:
I/O card types – Sensing
– Actuating
– “Analog”
– Discrete
DO
Rel
z Two ports per card
DI NC – Max 32 devices H1
DC
Low T/C – > 96 I/O signals

60
 Handle Late Changes Better
Hardwired Fieldbus
z Wait for final definition z Interface card that fits
of devices and any device and signal
signals, then build z Standard cabinets
Hardwired: 320 Signals

Fieldbus: 320 Devices

DO DI DI DI DO DI FF FF FF FF FF FF FF FF
AI AO
DC CO NA CO DC CO H1 H1 H1 H1 H1 H1 H1 H1

DO DI DI DI FF FF FF FF FF FF FF FF
AO AI AI AI
DC NA NA CO H1 H1 H1 H1 H1 H1 H1 H1

DI DI DO DI
AI AO AO AO
NA CO DC NA

DO DI DO DO DI DI DI DI
AC AC RE RE AC AC AC AC

DO DI DO DO DO DI DI DO
AC AC RE RE AC AC AC AC

61
 Wiring and Installation Savings
z Fieldbus and Remote I/O
System (FuRIOS)
– Independent study by
Aventis Pharma and
Infraserv
z Fieldbus saving over
local/central I/O is about
20%
z Fieldbus saving over
remote I/O is about 5%
z Back in 2002, fieldbus
devices and hardware
was expensive
63
 Easier Late Changes with ‘Late Binding’:
- Fieldbus ‘virtual marshalling cabinets’
Hardwiring FOUNDATION fieldbus
z More wires z No additional wires
z Changed connections z No connection change
z More I/O cards z No additional I/O card

z Change I/O card type z No I/O card change

z Change safety barrier z No safety barrier
type change
z Limited by multi-core z No spare multi-core
spares pairs used
Late changes:
•Add a device
•Change device type
•Use additional signals (in devices)
•Change power supply

64
 Multi-Channel Two-Wire Transmitter
- Takes the Place of Eight Transmitters
$1,200
Installed Cost Per Point

65 %
$1,000 Installed
Cost Savings
$800

$600
Ideal for
$400 temperature
profiling:
$200
•Reactors
$0 •Columns
Temperature 4-20 mA Temperature Multi-Channel
Input Card Transmitters Multiplexer Transmitter
with Comp. Wire AI Card

z Shorter sensor wires

– Less noise pickup
z Fewer transmitters and cables
– Lower cost
65
 IPAS: Integrated Process Analyzer System
- Electronic Sampling Line
Traditional
z Sheltered gas chromatograph

Sampling Line Modbus

Fieldbus Shelter

z Field mounted, no shelter

z Minimal sampling line (ideal for modularization)

z No Modbus mapping
AMADAS

Fieldbus

Gas
chromatograph
66
 Simplify Complex Device Wiring
- Liberating Internal Variables
z Hardwired z Fieldbus
– Electric actuator (MOV) – Many wire pairs eliminated
• Open, stop, close, ESD, – Installation reduced
overload... – Many DI/DO cards
– Valve positioner eliminated
• Setpoint, feedback, limit – Fully integrated
switches...
– On-Off actuator
25,000 I/O is
• Solenoid, limit switches... 8,000 FF
– Mass flow transmitter Hardwired: devices Bus:
• Mass, volume, density, Multiple pairs Single pair
temperature... Per device Many devices

67
 Lower Cost & Faster:
- Device Commissioning
Plug-n-Play
• Devices are
auto-recognized Only FF has
• Devices are automatic
auto-addressed addressing
• Devices identify
themselves

Hardwired Foundation fieldbus

z 2 hours / device for 2 z 25 minutes / device for 1
technicians technician
– Connect device – Connect device
– Five point loop check – Check signal with tester
• Not limited – Automatic or drag-and-drop
• Linearity commissioning wizard
– Verify link to control strategy

69
 Automatic Integration and Configuration
Download

Hardwired Fieldbus
z Configure device z Automatic
parameters with configuration
handheld download
z Check device z Compare
parameters with configuration faster on
handheld computer
70
 Automatic Commissioning Loop Check
and Documentation
z DeltaV Diagnostics checks that devices are
properly commissioned and the communication
signal OK; a digital loop check
z Page lists all devices with card number, port,
device tag, commissioning state, manufacturer,
model/type, revision, unique ID, and address etc.
z Also for discrete devices like on-off valves
z Also for complex devices and MOV and GC

71
 Same Tools as 4-20 mA Devices
- Permits Temporary Portable Master
z Only FOUNDATION fieldbus permits
visitor devices to be connected ad-hoc
to a running bus:
– Handheld field communicator
• Commissioning, configuration, check, etc.
– Documenting calibrator
• In-situ calibration
– Laptop/tablet PC with software
• Commissioning, configuration, check, etc.

Designed for
process control

72
Fieldbus Operation &
Maintenance Benefits
High Signal Integrity
High Signal Fidelity
Tighter Control
Signal Status in Real-Time
More Powerful Devices
More Device Diagnostics
Online Upgrades
 Digital Signal Integrity
- Better Accuracy
Hardwired Fieldbus
z Accuracy lost in signal z Measurements are not
conversations: distorted
– Digital to analog z Particularly important:
– Analog to digital – Tank level gauging
z Accuracy lost in – Flow totalization and
current calibration batching
differences

Digital Digital

AI
BUS CTRL BUS CTRL
Transmitter A/D
FF CPU Transmitter FF CPU
CPU D/A
FF CPU FF
4-20 mA Digital
Digital Digital
75
 Two-Wire Intrinsically Safe Fieldbus
Tank Gauging System
Hardwired Fieldbus

76
 Easier and Safer:
Fieldbus Has High Signal Integrity
Hardwired Fieldbus
z Analog gets distorted z Digital signal does not
– Increased resistance get "limited"
limits current z Any distortion of a
– Water increases
digital process
current
variable is alerted;
z “On-scale” distortion
overt
not detected; covert
Resistance = Voltage
Drop = Limited Current
Marshalling

4-20 mA
AI

Field Junction Box

Water = Conductor = More
77 Current
 4-20 mA ‘On-Scale’ Faults

For insufficient compliance voltage increasing PV Increasing loop resistance starves

limits output but still appears valid (on-scale) transmitter limiting output but still
appears valid (on-scale)

System cannot
tell the signal is
invalid as long
as it is between
4 mA and 20 mA

Water in housing increases current but still

appears valid (on-scale)
78
 Easier
- Real Number Engineering Unit
Hardwired Fieldbus
z Possible range z No range mismatch
mismatch z Unit downloaded
z Requires 5-point loop when device is
test replaced

Reading
61.728kPa
...alarms and trips
Range not working Range
0-400 kPa 0-400 kPa
AI CTRL AI CTRL
Range A/D CPU FF CPU
0-800 kPa
Transmitter Transmitter
6.47 mA 123.456
CPU D/A CPU FF
Process: 123.456 kPa Process: 123.456 kPa
79
 Easier and Safer
- Full Sensor Limits
Hardwired Fieldbus
z Limited low and high z Utilizes sensor limits
at the set analog 4-20 – Better understanding
mA output range during abnormal
Actual Process conditions
Does not saturate at range
Saturates at 20 mA

Saturates at 4 mA
Utilizes full sensor limits

4 mA = 0 inH2O LSL = -250 inH2O

20 mA = 150 inH2O USL = 250 inH2O

80
 Digital All the Way
- Digital Closed Loop Control
Optional Fault-
State Command

Validity:
Good/Bad/Un Limited: High/Low
certain Bumpless Transfer Designed for
Windup Protection process control
Fault-state Status
Speed Status Propagation (CIF & CIC)
z 25 times faster than z Validated information

hybrids of analog/digital – Quality and limits

z True 250 ms loops z Windup protection

z Real-time value and z Bumpless transfer for valves

status Only fieldbus z Optional fault-state for valves

eliminates the analog
z etc.
signal
82
 Real Time Status and Validity
Hardwired Fieldbus
z Two functions, one z Dedicated status
signal: signal
– Measurement value – Bad
– Failure signal – Uncertain
z Bad status flagged by – Good
masquerading as high
or low PV Value
Status (Bad/Uncertain/Good)
z Process problems not
distinguished from
device problems
4-20 mA
Measurement Value / Failure Signal

83
 Higher Availability: Distinguishing
Device Problem from Process Problem
Hardwired Fieldbus
z Device drives current <4 z Device health indicated by

mA or >20 mA on device associated status

failure – Good/Uncertain/Bad
– Looks like process problem z Controller holds last
z PID counteracts thus position on device failure
tripping the loop – Shutdown is optional
z Operator cannot tell the z Operator can easily
Burnout
difference between a Technical distinguish process
No process trip
on sensor
process alarm and a White problem from a device
failure
device alarm Paper problem
Available
Manual (Hold Last)
20 mA 100% 0% 4 mA Bad
AI PID AO AI PID AO
Fail Close Fail Alarm

84
 Valve and Positioner
z Actual valve stem position transmitter
feedback transmission on the same two
wires Continuous, real-
– No extra wire pairs time, actual
– I/O count: No AI card position feedback
– More than just value: status for every control
valve – in faceplate
z “Virtual limit switches” and logic
– I/O count: No DI cards
– No extra wire pairs
z Easy to add feedback as an afterthought Eliminate 1,000-
z Continuous performance diagnostics (“PD 2,000 I/O on a
project with 1,000
inside”) with alarm valves
z Bumpless transfer on local hand operation
– Smoother operation
z Bumpless firmware download
– Upgrade for feature enhacments while process is
85 running, without replacing circuit board
 Intelligent Two-Wire On-Off Valves
- Fieldbus Does Discrete Too
Hardwired FOUNDATION fieldbus
z Three pairs of wires z One pair of wires for
per On-Off valve multiple On-Off valves
z Three I/O channels z One pair of wires for
per On-Off valve solenoid and limit
z HART not applicable switches
to On-Off devices z Shares FF barrier with

z Problems finding other devices Fieldbus

Discrete
safety barrier z Diagnostics Technical
White
compatible with Paper
Available
solenoids

86
 Reduce Measurement Errors
- Eyelevel Indication without Impulse Lines
Old Way Fieldbus Way
z Impulse line z Direct coupling
– Prone to plugging z Easy to install later
z Easy to add variables

Pipe Rack

Fieldbus line
Impulse line (peer-to-peer
communication)

Eyelevel
Multi-point Fieldbus
87 Field Display
 Platform for the Future
Fieldbus multi-channel two-
wire temperature transmitter
• 8 channel, universal input

8 Point Fieldbus Indicator

Without
fieldbus you
cannot benefit
from new
innovations
Intelligent two-wire
intrinsically safe Fieldbus
Intelligent two-wire Fieldbus On-
inventory tank gauging
Off valve
system

Dual Fieldbus Temperature Transmitter

- 2 channels can be used for control
Fully integrated Fieldbus gas chromatograph
88
 Virtual Flow Computer
z Built-in mass flow compensation
– Pressure and temperature received over fieldbus
– Displayed locally
– Standard transmitter hardware; firmware options

Pressure
Mass
Flow

DP

Temperature
89
 Reduce Measurement Errors
- Virtual Remote Seals
Virtual
Hardwired Fieldbus Remote Seal
Technical
z Capillaries z Cable White
Paper
z Temperature effect z Accurate Available
z Slow z Fast

` `

Field Field
Junction Junction
Box Box

` `

90
 All Devices Digitally Integrated;
- Predictive Maintenance for All
Fieldbus
GC
On-Off
Traditional Smart Valves
Devices

MOV

z “Complex” devices (many signals)

z Many more devices around the plant
can benefit from device management:
diagnostics
z No device left as an "isolated island"
91
 Simple Status Flags
- Easy to Understand
z Status flags as per NAMUR
NE107
z At-a-glance device health
– Click to drill down into greater
detail
z Independent of protocol

92
 Device Diagnostics is Important
z Field device failures cause production losses
much more than controller/system failures
z Therefore field device diagnostics is very
important
Controller 8% Diagnostics
Technical
White
Measurement 42% Final
Paper
Element 50% Available
Causes of Production Losses
Sources:
• Marsh & McLennan Protection
Consultants
• HPI Market Data 2003,Gulf Publishing
Company

93
 Reduce Maintenance Cost

“Unneeded” Trips To The Field

- Avoided Through Remote Diagnostics
63%
50%
Diagnostics

40%
35% Technical
28% White
Paper
30% 20% Available
20%
6% 6%
10% 4%
0%
Routine No Calibration Zero Plugged Failed
Check Problem Shift Off Lines Instrument

Source: Dow Chemical Company

94
 Easier and Safer: Central Diagnostics
for Troubleshooting
z Verify device problems are real before going to
the field; or unmanned platform
z Device tells technician when there is a fault or
performance is degraded
z Plan when to repair:
– Immediate
– Daily schedule
– Next turnaround

95
 Easier:
More and Faster Diagnostics Alarms
Model Type Diagnostic Differences
3051C Pressure transmitter Plugged Impulse Line Detected
Process Anomaly Detected (SPM)
Sensor temperature
3095M DP flow transmitter Sensor temperature
3144P Temperature transmitter Thermocouple Degradation
Min/Max Temperature Tracking
Process Anomaly Detected (SPM)
644 Temperature transmitter Sensor/electronics temperature
8800 Vortex flow transmitter Sensor/electronics temperature
8700 Magnetic flow transmitter Electrode Signal Fault
3900 Radar level transmitter Sensor/electronics temperature
5400 Radar level transmitter Sensor/electronics temperature
DVC6000f Valve positioner Continuous performance diagnostic; “PD inside“
Temperature High
Temperature Low

z Diagnostics for discrete too Diagnostics

Technical
z More power for sensors and White
greater processor power Paper
Available
z Faster detection and reporting
– Time-stamped
96
 Get Visibility Where There Was None
Before
z Intelligent On-Off valves with predictive
diagnostics
– Loss of supply air
– Valve jammed
– Etc.

•Opening time
•Close time
•Cycle count
•High temperature
•Low temperature

97
 Easier
Central Device Firmware Download
Designed for
process
control

z Upgrade field devices for feature enhancments online

without changing circuit board
z Dual memory bank bumpless upgrade of valve positioner
z Download firmware while process is running
98
 Four Options to Do Closed Loop
Digital Control
Controller z Control in Controller (CIC)
PID – Traditional way
Transmitter Valve
z Control in the Field (CIF)
AI AO
H1 Card – Single loop integrity when
used in conjunction with
Transmitter Valve
backup LAS
AI PID AO
– Less communication
– Synchronized: single cycle
Transmitter Valve
AI PID AO
– Devices must be on the
same bus
Controller
z Operator can't see the
H1 Card difference Technical
CIF

Transmitter Valve z 80/20 CIF/CICWhite

AI PID AO Paper
Available
99
 Time Synchronized Digital
Closed Loop Control
Hardwired (and other buses) FOUNDATION fieldbus
z "Free running" z Time synchronized
– Longer time – Scheduled
– Jitter = sampling period – Precisely periodic
not constant (isochronous)

⎛ 1 dPV ⎞
OUT = P × ⎜ e + ∫ e dt − D × ⎟
⎝ I dt ⎠
e = PV-SP
dt = sampling period must be constant

Designed for
process control

101
 Easy: Scheduling is Automatic

Schedule is
automatically
created

102
 End-to-End, Fieldbus Control is Faster
- True 250 ms
Hardwired Control Fieldbus Control
z AI scan, controller, z AI scan, controller,
and AO scan not and AO scan
synchronized synchronized
z True 250 ms

z Single cycle

250 ms Digital True 250 ms

Control
Technical
Controller
White
AI AI AO AO Paper AI PID AO
Available
Add Multiple IO and Control Cycle

103
 ISC Study #1
- The Control in the Field Option
z “Control in the field:
analysis of performance
benefits” study from ISC
(industrial systems and
control)
z 40-60% faster settling time
on setpoint change
z 30-50% better disturbance
rejection
z Most significant for fast
processes (flow and
pressure)
104
 ISC Study #2
- The Control in the Field Option
z For pressure and flow FF loops
performs 10-15% better than a loop
using 4-20 mA signals
z Most beneficial at slow [1 second]
controller cycle time
– Significant if loops are run slow to
decrease controller load
• More loops per controller

http://www.youtube.com/watch?v=oiCUYCPPP2I

105
 Reduced Process Variability Improves
Quality and Reduces Cost

Quality &
Throughput
Improved!

107
Making Fieldbus
Easy to Deploy
 In 2006 the Fieldbus Benefits Were
Already Proven, But...
Fieldbus Wish List
— FAT simulation
— Management of device diagnostics alarms
— Intuitive display of device information, and “wizards”
— Embedded communication statistics
— Faster download
— Faceplates with fieldbus mode and status
— Variable status in historical trend
— Load DD once
— Retain device factory settings
— Orderly device removal
— Only valid options to chose from

— Jonas Berge, 2006

109
 Integral Fieldbus Power
z No separate Fieldbus power supply
z Trunk lands directly on H1 card
– No marshalling cabinet
z H1 and power redundancy
z Fewer cabinets: smaller footprint, weight
z Simplified engineering
z Voltage and current diagnostics, statistics

‘96 Channel I/O

Card’
2 ports
16 devices per port
3 signals per device
(average)

111
 Eliminate Marshalling Cabinet
1st Generation Fieldbus Modern Fieldbus
z Separate fieldbus z Integral fieldbus
power supply power supply
– No marshalling cabinet
– Trunk lands on H1
card
FPS
FPS
FPS P P
FPS
JB T JB T
FPS
FPS

JB
CONTROLLERS MARSHALLING
CONTROLLERS JB
& INTERFACES & POWER
& INTERFACES
WITH POWER
112
 System Interoperability HPR
61b
- Host Profile Registration (HPR): 61b
z Test process ensures
Fieldbus is
implemented correctly
– Device commissioning
– Function block
configuration
– EDDL
– NE107 device diagnostic
alarm management
– Status handling

Profile: ’61’
Compliance
Level: ‘b’

113
 Easy Engineering
Control Strategy Configuration
CIF
Technical
White
Paper
Available

IEC 61804-2
function block
programming
language

z Central or field control from the same software

z Mode and status propagation works the same in
central controller and field devices
116
z Universal control strategy templates
 Easy and Fast Engineering:
- Virtual Fieldbus “Test Panel” for Full FAT
z No need to connect lots of devices
z Emulate
– FF modules
Very fast
– Fieldbus devices
– Function blocks
z Test
– Control loops
– Graphics
– Faceplates
– Scale/range, units, transfer function,
channel, fault-state
– Alarming

118
 Function Block Assignment to FF H1
Interface Card
z Time-synchronized
like control in the
field (CIF)
CIF
z Fast block Technical
execution White
Paper
z Large block library Available

119
 Easier FF Device Commissioning (and
Replacement)
z Commission (or replace)
device without touching
the software
z System automatically logs
process in background
Automatic
configuration
reconciliation
with device
database

Automatic
configuration
download

View details in
historian and
log
120
 Fieldbus Maintenance Made Easy:
Guided Device Commissioning Wizard

z Automatic address assignment

121
z Verifies correct device type
 Standardize Device Configuration
- Device Templates
z Create once, use for many devices
z Start from scratch or live device
z Eliminate download errors and non-functional
devices
z Reuse device templates on future projects

122
 Device Factory Setting Upload
z Upload and save working device factory
configuration into database (range and unit etc.)
– Ensuring it is not overwritten at download

123
 Fieldbus Maintenance Made Easy:
Protective Decommission
z Removing device in
an orderly fashion
– “Safely remove
hardware”
z Temporary removal
– To remove for
calibration etc. with
intention to put back
into same place soon
after Control-in-the-field
z Permanent removal does not mean just
“simple” PID
– To remove for
replacement etc.
124
 Keeping System Up To Date
- Add Device Wizard
z Load DD files in one single place
– Automatically updates entire system
z Automatically puts DD files into the correct
folders
z DD for all devices loaded
– Ready for use if device comes into plant

125
 Guardian Automatic System Update
- DD Update Manager
z DeltaV and AMS Device Manager
automatically download new DD files from
the Guardian server
z The system is automatically kept up to
date, ready for new device types and
versions as they come to the plant
– No need to search for files
z Upgrade to DeltaV/AMS v12

Manual File
Transfer or
Network
Connection

126
 Automatic System Update
z The system is automatically kept up to date,
ready for new device types and versions as they
come to the plant
– No need to search for files

127
 Easy to Run & Maintain
- Single Device Integration Technology
z Only need the DD files
– Don’t need to worry about DTMs programs
z System is shipped with DD for all devices in the
market loaded whether used on the project or not
– Chances of support for devices missing is low
– Could not be done with DTM
z DD file for all FF devices available from the FF
site
– Can’t find DTMs there
z Easy to copy the DD files onto the system
– DTMs have to be installed

128
 Faster Project Startup
Express and Batch Download
z 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

129
 Faster Commissioning:
- Skid/Package Import
Optionally retain the commissioning state of FF
devices upon import of configuration

Eliminates the need to commission FF devices at both

the skid vendor’s location and the final installation
131
 Easy Engineering
Multi-Vendor Fieldbus Validation Software
z Multi-vendor
product data build
into database
– Power supplies
– Coupler Design
Makes bus segment Process
validation work for – Barriers Technical
EPC easier – Devices White
Paper
No need to spend Available
time looking up
product specs in data
z Validates segment
sheets design
– Lengths
– Current
– Voltages
http://www.emersonprocess.com/Systems/support/segment/

133
Making Fieldbus
Easy to Operate
 Fieldbus Faceplates and Detail Pages
z Full FF
support
– Mode
– Status
– Alarms
– Actual
position
feedback

135
 Easy Operation
- PID Auto Tuning for CIF
z On-demand or adaptive
tuning of PID
– In DeltaV controller
– In Emerson fieldbus
devices
z Recommends tuning
based on test
z Loop remains under
control during test
CIF Control-in-the-field
Technical does not mean just
White “simple” PID
Paper
Available

136
 Easy Operation
- Status in Historian
z Status logged and shown next to value and color
codes trend

137
 Availability: Operator Receives
Critical Diagnostics Alarms
z Device tells the
operator
z Only critical
problems that
affect the
operator’s process
z NAMUR NE107

FF

139
 Smart Diagnostics
- Integrated Device Diagnostics
z Normal operation... Faceplate Detail Help

z Critical device
failure...
z Alarm Faceplate...
z Diagnostics
– No device
configuration by
operator
– Displayed the way
the device vendor
intended
Detailed diagnostics in two
clicks
Help on the third
140
 Real-Time Decisions
- Integrated Device Diagnostics
z Engineering station z Maintenance station
– System configuration – Device management
– FF device commissioning – Process visibility
– Device configuration
z Operator station
– Process operation
– Process alarms
– Critical device failure
diagnostics
Plus: Traditional
Plus: Plus:
Device Configuration Architecture
Device Diagnostics Process visibility
Engineering Operator Operator Operator Maintenance

141
 NE107: Critical Device Alarms to the
Operators

z NE107 prevent alarm flooding

142
Making Fieldbus
Easy to Run &
Maintain
 Integrated FOUNDATION fieldbus Support

No need to jump
over to separate
workstation for
device
management

144
 Task Oriented User Interface for Intelligent
Device Management (IDM)
Overview Calibration

Configuration Diagnostics

145
 Making Fieldbus Easy
- Human Centered Design: Dashboards
Old: Block-Based New: Task-Based
z Information split z Information
across different blocks consolidated based on
task

146
 EDDL Provides Full Support for
Device Functionality

Radar Level Temperature Valve Positioner

MagFlow Mass Flow

Pressure

pH Ultrasonic Flow
150
 Fieldbus Maintenance Made Easy:
Calibration and Setup Wizards

Zero This
Transmitter!
Calibration

Tutorial

Available

1. Set MODE_BLK.TARGET to OOS

2. Apply zero pressure to the sensor and allow the to
reading stabilize Takes the mystery
3. Set value CAL_POINT_LO to 0
4. Set SENSOR_CAL_DATE to the current date.
out of fieldbus
5. Set SENSOR_CAL_WHO to the person responsible
for the calibration.
6. Set SENSOR _CAL_LOC to the calibration location.
7. Set SENSOR_CAL_METHOD to User Trim
8. Set MODE_BLK.TARGET to AUTO

151
 Easier FF Device Replacement (and
Commissioning)
z Replace (or commission)
device without touching
the software
z System automatically logs
process in background
Automatic
configuration
reconciliation
with device
database

Automatic
configuration
download

View details in
historian and
log
152
 Fieldbus Maintenance Made Easy:
Device Replacement Wizard
z Guides technician through fieldbus device
replacement step-by-step
z Tells you which DD to get if not already loaded

Takes the mystery

out of fieldbus

153
 Early Detection of Communication
Problems
z No need for noise level measurement and scope
z No need for external “bus monitor” to track
communication statistics

Easily detect
devices with
water in
housing
154
 Easy
Maintenance and Troubleshooting
z Test tools for the trade are available

Same tools
as for 4-20
mA devices

155
Specifying Fieldbus
Not all Fieldbus solutions are
created alike – state your
requirements
 FF Device Requirements
z Diagnostics
– Pressure: plugged impulse line diagnostics, min/max tracking, abnormal situation
prevention (ASP)
– Temperature: sensor failure, thermocouple degradation, sensor deviation,
min/max tracking, abnormal situation prevention (ASP)
– Positioner: Step Response, Drive Signal Test & Dynamic Error Band, Valve
Signature, I/P and Relay Integrity Diagnostic, Travel Deviation Diagnostics, Relay
Adjustment Travel Deviation, Supply Pressure, and Air Mass Flow Performance
– Mass flow: slug flow, meter verification
– Magnetic flow: meter verification, tunable empty pipe detection, process noise,
ground fault
z Prioritized diagnostics alerts (NE107)
z Fast block execution time (300 ms loops)
– Caution: bus macrocycle determined by worst device
• The difference can be a factor of 4 times or more
z Complete library of blocks
– Additional blocks for control, computations, and diagnostics etc.
z Low power consumption
– Thus more devices
z Firmware download
– Without current consumption increase (thus more devices)
z Enhanced EDDL files IEC 61804-3
157 – With wizards (methods)
 Complete Range of Fieldbus Devices
Pressure Pressure Pressure Flue )2 Displacer Level Gas Analyzer On-Off

On-Off Coriolis Flow DP Flow Temperature Temperature Field Display Electric

Multi Temperature Magnetic Flow Vortex Flow Amperometric pH Conductivity Amperometric

pH Conductivity Radar Level Radar Level GC GC Flue O2

GWR Level .Mag Level Positioner O2 & Combustion Radar Level

158
 More Powerful Diagnostics
z Predictive diagnostics Sensor Failure
Min/Max Tracking
Travel Deviation Statistical Process Monitoring
Cycle Counter Sensor Drift
Valve Signature Thermocouple degradation
Step Response etc...
Dynamic Error Band
Drive Signal Reverse Flow
Output Signal Empty Pipe (Tunable)
etc... Ground Fault
Process Noise
Sensor Failure Meter Verification
Min/Max Tracking etc...
Plugged Impulse Lines Diagnostics
Statistical Process Monitoring Technical
etc... White
Paper
Available
Open Time
Close Time
Cycle Count

160
 Complete Range of Fieldbus Hosts
Flow Computer / RTU DCS (Power & Water) Flow Computer / RTU DCS

Tank Gauging System USB Interface Field Communicator

163
 FF Control Systems Requirements
z Hardware/Firmware
– Bus power built into FF H1 interface card
– FF-based function blocks in controller
– FF status propagation in controller
– Redundant H1 interface cards
– Control in the H1 interface card
z Operator Station
– Prioritized device alerts (NE107)
– Integrated host: integrated device management
• Device diagnostics (only) in DCS operator console
– Historian view of FF 'status'
z Engineering Station
– Host Profile Registration 61b
– Control strategies for control in the field
– Embedded communication statistics
– Device firmware download
– Auto-tuning of PID in the field device
– Fieldbus device replacement wizard
– Auto-replacement
– Fieldbus device commissioning wizard
– Express download (suspend control, batch)
– Fieldbus device simulation for FAT
164
 Asset Management
FF Device Management Requirements
z Multiple protocols: 4-20 mA/HART, FOUNDATION
fieldbus, PROFIBUS-DP, and WirelessHART
z Audit trail
z Enhanced EDDL IEC 61804-3
– Enhanced graphics
– FF device level access (DD v 5.1)
– Support for wizards (methods)
– Support for conditionals
z Integration in operator consoles
– Device diagnostics only
z Fieldbus calibrator integration
z Online OPC access to live data in any device

165
Availability and
Safety
 Engineering for Availability
z 8-12 devices per bus z Short circuit protection
z Only a few loops per bus – One device per spur
– One critical loop per bus z Control-in-the-field (CIF)
z Redundant interface with backup Link Active
cards Scheduler (LAS)
z Redundant power z Redundant valves and
Availability transmitters on separate
Technical
White Redundant buses
Paper Interface Redundant
Available Power One critical
loop per bus
Control-in- Short Circuit
Protection One Device
the-field &
Per Spur
Backup
Link Master

168
 Better and Easier
Non-Safety-Related Diagnostics Interlocks
z Diagnostics This is in
– Communication, sensor, and other addition to
failures mechanical fail-
z Predetermined fault state safe and SIS
etc.
– For non-safety-related process
interlocks
– Hold last position, open, closed

Fault State
In Positioner

169
Get Ready
Prepare yourself and your plant
 Where Can I Learn More?
z What is
FOUNDATION
fieldbus?
z Breaking the Limits of
Analog Technology
z Proven Benefits in
Projects Worldwide
z Enhanced Operations
and Maintenance
z Ease of Use
http://www.fieldbus.org/im
ages/stories/technology/a
boutthetechology/overview
/fieldbus_brochure.pdf
172
 Where Can I Learn More?
z Title: "Fieldbuses for
process control:
Engineering, Operation
and Maintenance"
z Author: Jonas Berge
z Publisher: ISA
z ISBN 1-55617-760-7
Contents:
•Introduction
•Benefits & Doubts
z Buy online:
•Installation & Commissioning
•Configuration www.isa.org/fieldbuses
•Integration & Migration
•Troubleshooting
•Operation
•Design & Engineering
•Maintenance
•Availability & Safety
•How Fieldbus Works

173
 DeltaV and AMS Device Manager
Evolution
Ver. Year Enhancements
V6 2002 • PW Alerts (prioritized device alarms)
V7 2004 • FF Tuning
V8 2005 • Macrocycle viewer
• Centralized device firmware download
V9 2006 • Function blocks in H1 card
• Greater function block capacity
• Enhanced EDDL (graphical device display)
• Macrocycle sub-schedule
V10 2008 • Device replacement and commissioning (without software)
• Express download
• HPR 61a host registration
V11 2010 • Integrated Power H1 Card (no marshalling cabinet)
• EDDL device level access (dashboards)
• HPR61b host registration
V12 2013 • NAMUR NE107 (prioritized device alarms)
• DD Update Manager (Automatic DD download)
177 • Device templates
 DeltaV – Leader in FOUNDATION Fieldbus

178 2002 2003 2004 2005 2006 2007 2008 2009 2010 2001
 The Digital Ecosystem
z Emerson devices work with third-party systems
z Emerson systems work with third-party devices
z Emerson devices with Emerson systems provide
greatest value
Third-Party Emerson
Digital
Ecosystem
Technical
Mandatory White
functions in any Paper
device works on Available
any system

Third-Party
182
 Third Party Systems Interoperability
Tested With Emerson Devices
z Yokogawa
z Foxboro
z Honeywell
z ABB
z FDT/DTM
z Etc.

183
 Shell Parameter Templates for Yokogawa
System
z Shell Global Solutions has defined parameter templates
for Emerson devices used on Yokogawa systems
z These templates have already been used on several
projects around the world
z Ensure optimum diagnostics and communication,
functioning device, and error-free download

184
 Practices and Procedures
z Design Guideline
z Checkout Forms
z Functional Design Specification Project
Execution
z Books Technical
White
Paper
Emerson Available
procedures and
know-how

www.fieldbus.org

185
 Let’s Stay Connected
z Jonas Berge

http://sg.linkedin.com/pub/jonas-berge/0/44a/b1a/

http://community.emerson.com/members/jonas.berge/

186