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FF Seminar
12th May 20111
Teo Puay Yong
Pepperl+Fuchs Singapore
On behalf of the Fieldbus Foundation
Commissioning Benefits
FF Seminar
12th May 2011
Commissioning Benefits
• Commissioning - Device integration
• Commissioning - Physical layer
FF Seminar
12th May 2011
Commissioning Benefits
• Commissioning - Device integration
FF Seminar
12th May 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
FF Seminar
12th May 2011
Easier - Real Number Engineering Unit
• No range mismatch
• Unit downloaded when device is replaced
Transmitter Positioner
FF FF
BUS
FF
CTRL
CPU
CPU
CPU
Digital
Digital
DigitalDigital
Transmitter
Range
0-800 kPa
System
Range
0-400 kPa
8 mAProcess
200 kPa
Reading
100 kPa
...alarms and trips
not working
AI
A/D
D/A4-20 mA
AO
D/A
A/D4-20 mA
RangeRange
FF Seminar
12th May 2011
Lower Cost & Faster
• Traditional: 2 hours /
device for 2 technicians
– 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
– 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
FF Seminar
12th May 2011
Fieldbus Maintenance Made Easy:
Device Commissioning Wizard
FF Seminar
12th May 2011
Fieldbus Maintenance Made Easy:
Protective 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
FF Seminar
12th May 2011
Easier FF Device Commissioning and Replacement
• 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
FF Seminar
12th May 2011
Faster Project StartupExpress 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
FF Seminar
12th May 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
FF Seminar
12th May 2011
Incorporating intelligent devices via
fieldbus integration streamlines work
processes, improves process and
product quality, maximizes plant
availability
integrates fieldbus seamlessly
Exploiting new levels of field device
information
Making 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
FF Seminar
12th May 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
ControllerDiagnosis
Maintenance
Calibration
Configuration
Parameterization
Commissioning
Operation
Display
Alarm signals
Process variables
Time synchronization
Status
0
7
Field Devices
FF Seminar
12th May 2011
Integrated Environment
• System integration makes
external tools obsolete
• Fieldbus topology planning
• Fieldbus application configuration
• Field device parameterization and diagnostics
• Device Asset Optimization
• Easy navigation through plant explorer and context sensitive menus
• All field device aspects are only one mouse click away
FF Seminar
12th May 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
FF Seminar
12th May 2011
Fieldbus and Change History
Maintenance Event
& Work Order HistoryCalibration Changes
Operator Changes
Configuration Changes
Process Event & Alarm History
Audit List
FF Seminar
12th May 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
FF Seminar
12th May 2011
Device Management
Device 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
System
FF Seminar
12th May 2011
Commissioning Benefits
• Commissioning - Physical layer
FF Seminar
12th May 2011
The physical layer – alive and well?
– Proper termination
– Water ingress
– Ground faults
FF Seminar
12th May 2011
The physical layer – alive and well?
– Proper termination
– Water ingress
– Ground faults
– Loose wiring
– Faulty devices
FF Seminar
12th May 2011
The physical layer – alive and well?
– Proper termination
– Water ingress
– Ground faults
– Loose wiring
– Faulty devices
– Unstable communication
– Short circuits
– Bulk power failure
– …
FF Seminar
12th May 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
FF Seminar
12th May 2011
Online monitoring of the physical layer
Time
Equipment Health
100%
Minimum device health FAILURE
Time to respond
Warning level
Monitoring the physical
layer protects you from
unwanted shutdowns!
FF Seminar
12th May 2011
Advanced Commissioning for physical
layer
•Integrated single tool for commissioning,
monitoring, and troubleshooting. Versions to suit
your every need
FF Seminar
12th May 2011
Advanced Commissioning for physical
layer
•A portable tool for commissioning, monitoring, and
troubleshooting. Versions to suit your every need
FF Seminar
12th May 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
FF Seminar
12th May 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
Ca
sh
Flo
w
Plan and
purchase
Install and
commission Operate and maintain
FF Seminar
12th May 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 Report
FF Seminar
12th May 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
x
FF Seminar
12th May 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%
FF Seminar
12th May 2011
Automated Commissioning Saves Time
• Case Study with cost comparison for pre-commissioning:
– 4…20 mA
– Fieldbus
– Fieldbus with Advanced Diagnostics
Case Study – Specifications
Number of instruments 1,200
Number of segments 100
Instruments per segment 12
Hours per work day 8 hours
Mean time to repair (MTTR) a
fault
4 hours
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 Diagnostics
Technical White Paper available from Pepperl+Fuchs Part No: 198636
FF Seminar
12th May 2011
Automated Commissioning Saves Time
Task 1 of 2 Model 4-20 mA
Fieldbus
without
diagnostics
Fieldbus with
Advanced
Diagnostics
Constructional checks:
Time/Unit 5 min 10 min Not required
Units 1200 loops 100 segments Not required
Total Time 12½ days 2 days 0
Construction failures (1%):
Time/Unit 4 h MTTR 4 h MTTR Not required
Units 12 loops1 Trunk,
12 SpursNot required
Total Time 6 days 6 ½ days 0
FF Seminar
12th May 2011
Automated Commissioning Saves Time
Tasks 2 of 2 Model 4-20 mAFieldbus without
diagnostics
Fieldbus with
Advanced
Diagnostics
Pre/commissioning instrument
checks:
Time/Unit 10 min 60 min 8 min
Units 1200 loops 100 segments 100 segments
Total Time 25 days 12½ days 1.6 days
Pre/commissioning failure:
Time/Unit 4h MTTR 4h MTTR 4h MTTR
Units0.5% =
6 loops
0.5% =
1 segment
1.5% =
2 segments
Total Time24 h =
3 days
4 h =
½ day
8 h =
1 day
Totals 46.5 days U 21.5 days U 2.6 days U
FF Seminar
12th May 2011
Commissioning saves time and money
– A few mouse clicks conduct automatic testing
– Reports on the actual installation with all devices
connected
– Automatic setting of warning and alarm limits
FF Seminar
12th May 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
FF Seminar
12th May 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 value
Maintenance required
Out of specification
FF Seminar
12th May 2011
Fault Finding is Easier
•Commissioning Tools delivers actionable
information to minimize the time spent for fault finding
1 Active messages
2 Actionable information with solution guideance based on
expert knowledge
3 History with timestamps
When the failure…
… occured
… disappeared
– Export function for external analysis and storage
FF Seminar
12th May 2011
Bad cable impedance
Loose 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.
FF Seminar
12th May 2011
Simplified commissiong leads CAPEX
and OPEX savings
– Rapid commissioning: Accelarates loop check
– Longer operation: Warns before failure
– Faster troubleshooting: Assists with actionable
information
FF Seminar
12th May 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
FF Seminar
12th May 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.
FF Seminar
12th May 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
FF Seminar
12th May 2011
QUESTIONS?
