Professional Documents
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ISA Fieldbus For Process Control, Eng, Ops, Maint, Jonas Berg, OCR
ISA Fieldbus For Process Control, Eng, Ops, Maint, Jonas Berg, OCR
ISA Fieldbus For Process Control, Eng, Ops, Maint, Jonas Berg, OCR
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Fieldbuses for
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Contents
Chapter 1 INTRODUCTION 1
Digital Communication Networks, 1
Automation Networking Application Areas, 7
History of Fieldbus, 14
Evolution of Control System Architecture, 18
Basic Network Differences, 23
vii
Notice
The information presented in this publication is for the general education of the reader. Because neither the
author nor the publisher have any control over the use of the information by the reader, both the author and the
publisher disclaim any and all liability of any kind arising out of such use. The reader is expected to exercise
sound professional judgment in using any of the information presented in a particular application.
Dedication
Additionally, neither the author nor the publisher have investigated or considered the affect of any patents on
the ability of the reader to use any of the information in a particular application. The reader is responsible for Till min pappa ach till minne av min mamma
reviewing any possible patents that may affect any particular use of the information presented.
Any references to commercial products in the work are cited as examples only. Neither the author nor the
publisher endorse any referenced commercial product. Neither the author nor the publisher make any
representation regarding the availability of any referenced commercial product at any time. The manufacturer's
instructions on use of any commerci<~l product must be folhwed at all times, even if in conflict with the
information in this p11hlication.
Any trademarks or tmdenarnes reference bdong to the respective owners of the mark or name. FOUNDATION™
Fieldbus is a registered trademark of the l;icldbus Found<Jtion, HART® is a registered trademark of the HART
Communication Foundation, SERIPLEX® is a registered trademark of SquareD Company, Interbus-S is a
trademark of the lnterbus Club, DeviceNet is a trademark of the Open DeviceNet Vendor Association and
Contro!Net is a trademark of Contro!Net Intemational.
ISBN 1-55617-904-9
.Firs.t paperb_ack edition.
No part of this work may be reproduced, stored in a retrieval system, or tran.<;mitted in any form or
Py any means, electronic, mechanical, photocqpying, recording or otherwise, without the~prior writ-
ten permission of the publisher. -
!SA
67 Alexander Drive
P.O. Box 12277
Research Triangle Park, NC 27709
Berge, Jonas.
Fieldbuses for process control: engineering, operation, and
maintenance I Jonas Berge.
p.cm.
Includes index.
ISBN 1-55617-904-9 (pbk.)
1. Intelligent control systems. 2. Process control. 3. Industrial
electronics. I. Title.
1}217.5.847 2004
670.42'75--dc22
2004016957
"" ----~-------~--------- -
Table of Contents
Chapter 6 TROUBLESHOOTING
Device, 295
Communication, 301
Control Strategy, 309
295
1
Chapter 7 OPERATION 315
Getting the Most Out of Fieldbus, 316
Configuring the Process Visualization~ 318
Introduction
Performance Considerations, 329
Operating a Fieldbus Control Loop, 330
Chapter 9 MAINTENANCE AND ASSET MANAGEMENT 359 The first process control systems were understandably analog,
Asset M,•f":._~gemcnt-enabled Systems, 361 simple devices with signal formats that were essentially deter-
Calibrating Fieldbus Devices, 362 mined by the need for an architecture with a minimum number of
Diagnosing Fieldbus Devices, 367 costly CPUs. Networking was introduced into industrial automa-
Predicting Failures in Fieldbus Devices, 369 tion in the 1970s and first utilized in direct digital control (DDC)
Information from Fieldbus Devices, 372 systems between computer and 1/0 (input/output)_ Later, it was
Replacing Fieldbus Devices, 373 used in distributed control systems (DCS) and programmable logic
controller (PLC) systems to connect the controllers and operator
Chapter 10 AVAILABILITY AND SAFETY 377 consoles. However, digital communications in smaller devices
Fault-tolerant versus Safe Systems, 377 such as transmitters on the plant floor was not seen until the 1980s,
Improving Availability, 380 and true communication bus networking of field instruments did
Improving Safety, 393 not gain wide acceptance until the 1990s.
Balancing Availability and Safety, 401
At the other extreme, corporations network their plants across the
Chapter 11 HOW FIELDBUSES WORK 407 globe to the corporate headquarters via the Internet. The coordina-
Primcr,407 tion of production and other business functions has become an
Physical Layer, 409 integral part of the corporate information technology (IT) struc-
Data Link Layer, 414 ture. Networking has made it possible to collect more information
Application Layer, 421 from the plant and to disseminate it far and wide throughout the
System Management and Network Management, 432 enterprise. Geographically distributed components with lots of
User Layer, 433 "intelligence" are now expected to work together. Networking has
Fieldbus on Ethernet and IP, 441 become essential for automation and is changing the way plants
and factories work.
Appendix A SOLUTIONS TO EXERCISES 445
Digital Communication Networks
Appendix B PARAMETERS INDEX 453
Many networks, such as telephone, radio, and television, are pri-
INDEX 457 marily analog, but the trend is definitely toward all-digital com-
munication. So too, the networking used in automation is
Fieldbuses for Process Control
Chapter 1 -Introduction
predominantly digital, that is, data is transmitted serially between The advent of digital communications made it possible for the DCS
devices as a stream of ones and zeroes. Digital communications and PLC controllers to be placed away from the control room in an
now makes possible data transfer between devices such as trans- auxiliary rack room. All the supervisory information for hundreds
mitters, valve positioners, controllers, workstations, and servers. of loops and monitoring points could be transmitted to ~h~ opera-
tor console in the control room over a single network. D1g1tal com-
More Information munications carry not only I/0 like process and manipulated
A major advantage of digital communications is that a great deal of variables but also operational information such as setpoint and
mode, alarms, and tuning in both directions to and from the con-
information can be communicated on a single cable. Instead of one
hardwired cable for each variable, thousands and even millions of trol room. Communications thus enabled distributed processing,
and diagnostic, configuration, range, identification, and other
pieces of information can be communicated along just one network
cable. This makes it possible to extract much more information information could now be added, initially in controllers but then
from each device than was realistically possible using analog sig- also in field instruments such as transmitters and valve position-
nals. For example, before digital communications was introduced ers. Thanks to communications, field instruments now perform not
it was impossible to remotely transmit anything other than simple only a basic measurement or actuation but also have features and
1/0. Tuning and controller settings had to be done locally (figure functions for control and asset management.
1-1). Therefore all controllers had to be placed in large panels lin-
ing the walls of the control room to enable operation directly from Multidrop
the controller faceplate. Sensors and actuators were hardwired to A second major benefit of digital communications is the capacity to
their controllers using an individual dedicated pair of wires and connect several devices to the same single pair of wires to form a
transmitting nothing more than a single process or manipulated multidrop network that shares a common communications media
variable. The analog signal only traveled in one direction, from the (figure 1-2). Compared to running a separate wire for each device,
transmitter to the controller or from the controller to the positioner. this reduces the wiring requirement, especially for field-mounted
instrumentation involving large distances and many devices. Even
by putting just a few devices on each pair of wire, the amount of
cable required is greatly reduced, translating into hardware and
installation savings.
(
Fieldbuses for Process Control Chapter 1 -Introduction
The communicating devices on the network are called nodes, and is used by FOUNDATION Fieldbus for closed-loop control. Commu-
each node is given a different address that distinguishes it from the nicating from one device to another without going through a cen-
other devices. This makes it possible to interrogate and send mes- tral master is called peer-to-peer communication.
sages to any one specific device.
·--··-··---- ----··--··---
Process Automation
Host
Process plants in industry segments like refining, pulp & paper,
power, und chemicals are dominated by continuous regulatory
controL Measurement is analog (here meaning scalar values trans-
mitted digitally), and actuation is modulating. Of course, process
industries also use some discrete control and the predominantly
discrete manufacturing industries use some discrete. Fieldbus on/
off valves are alr€ady available in the market, as are small remotely
mounted I/0 modules for discrete sensors. In the past, a DCS or
single-loop controller did this. Conventional
flO--subsystem
Process-related networks include FOUNUATION Fieldbus, PROFI-
BUS (PA application profile), and HART-they ore the focus of this
book. All these buses as a category are now typically referred to as
field bus (without the capital f), though some would argue that one
or the other does not belong. These three protocols were specifi-
cally designed for bus-powered field instruments with predefined
Figure 1·6. Two-tiered automation network architecture.
__j
parameters and commands for asset management information like
identification, diagnostics, materials of construction, and functions
for calibration and commissioning. In terms of size, the networks Field Level
used in industrial automation are considered to constitute local
At the field level, the dominant protocols for process instruments
area networks (LAN) spanning areas no greater than a kilometer or
are HART, FOUNDATION Fieldbus Hl, and PROFIBUS PA. HART is
two in diameter and typically confined to a single building or a
significantly different from the other two in that it is a so-called
group of buildings. Networks that extend only a few meters are
smart protocol, that is a combination of digital communication
insufficient, and networks that span cities or even the globe are
simultaneously superimposed on a conventional 4-20 rnA signal.
overkill.
As such, the HART protocol has been an ideal intermediate solu-
tion in the transition from analog. HART is compatible with exist-
Field and !-lost Tier Networks ing analog recorders, controllers~ and indicators while at the same
Even within control systems for the process sector there is a need time it makes possible remote configuration and diagnostics using
for different network characteristics at each tier of the control sys- digital communication. The HART protocol does allow several
tpm hierarchy. At the field end there are instruments such as trans- devices to be rnultidropped on a single pair of wires, but this is a
mitters and valve positioners that have their specific needs, and at capability infrequently explored because of the low update speed,
the host level there are workstations, linking devices, and control- typically half a second per device. For a vast majority of installa-
lers that have other needs (figure 1-6). tions HART devices are connected point to point, that is, one pair
of wires for each device and a handheld connected temporarily
When fieldbus began to evolve, the process industry put a large from time to time for configuration and maintenance. Both FouN-
number of requirements on the field-level network that were not DATION Fieldbus HI and PROF!BUS PA are completely digital and
met by other types of networks. Many new design considerations even use identical wiring, following the IEC 61158-2 standard.
needed to be taken into account. On the upper tier, data from all However, beyond that there are major differences between these
the field-level networks have to be marshaled onto a single host- two protocols, and depending on the desired system architecture
level network that also serves any tasks the plant may have that one may be more suitable than the other.
seem related to factory automation.
At the field level, instruments appear in large quantities, often in
the hundreds or thousands. The wire runs are very long, as the net-
Fieldbuses for Process Control Chapter 1 - Introduction
work cable must run from the control room all the way into the encounter a steep rise in bandwidth requirements and must there-
field, up towers, and then branching out to devices scattered fore have o high~speed netv.!Ork at the host level.
throughout the site. Because there is a limit to the number of
devices that can be multidropped on each network, even a The field~level networks have made it possible to retrieve so much
medium-sized plant may have many network cables running into more data from the field instruments that an information explosion
the field, although substantially fewer than if point-to-point wiring has resulted, one that old proprietary control level networks. are
was used. The field-level networks were therefore designed to unable to cope with. Ethernet provides the thr~~ghput reqwred to
enable very long wire runs and to allow field devices to take their transfer the large amount of data used for traditional plant opera-
power from the network. Only a single pair of wires carries both tion and historical trending; for new capabilities for remote diag-
the device's pm,ver and the digital communications signaL This nostics, maintenance, and configuration; and for the quick
eliminates the need for a separate power cable, thus keeping the response necessary for factory automation task. EthNnet _was cho-
wiring simpJc and inexpensivc. sen for these applications because its high speed enables It to carry
all this information. Moreover, Ethernet is olready a standard and
J\s another measure to keep costs down, designers chose a moder- consequently is well understood and wi~ely u~ed. A l.~rge varie~y
ate field-level network speed so normol instrument-grade cable of equipment and solutions for Ethern~t IS avatlable. f:th.ern.et v.;,Jr-
could be used instead of special data cable. No special connectors, ing is discussed in chapter 3, "InstallatiOn and Commtsstonmg.
couplers, or hubs are required either, which makes it possible to
use rugged and weatherproof connections. The grade of cable used
for conventional instrument connections on most sites is more than
Host
sufficient for fieldbus networking. As a result, it is possible to reuse
that cable when an existing plant is migrated to fieldbus. In haz- Redundant
ardous process environments where flammable fluids are present
intrinsic safety is many times the preferred protection method. The
field-level networks were therefore designed to allow safety barri-
ers to be installed on the bus.
Chapter 1 -Introduction
Fieldbuses for Process Control
~ It is a good idea to look jtn complete open protocols based on Ethernet so ferent proprietary protocols were in the market, and products
., devices and sub::;y::;tems jro111 difjfrent sources can talk to each other, even could only work with other products from the same vendor. Mo~e
peer to peer. over, documentation on the operation of these protocols was typl-
cally not available, and the technology was generally protected by
Homogeneous Network Architecture patents. Other manufacturers would have to pay hig~ licensing
fees to implement the technology in their products-1f they were
Because of their almost opposite requirements, different network allowed to do so at all.
features are required at the field and host levels. Because the field-
level network is slow it is unsuitable for the host level, and because This situation resulted in several disadvantages. One was that no
the host level has too limited a distance it is unlikely it wm be seen vendor had a range of products wide enough to provide all. th:
in the field. The field-level network takes the place of the tradi- parts a site required. The selection of equipment :vas very hmtt~d,
tional protocols for smart instruments and 1/0 subsystems, and tlw so it was always necessary to mix and match cqtupment from dJf-
host-level network takes the place of the conlrol network and busi- ferent suppliers. Moreover, one supplier. is never the best at every-
ness network. The host-level network in the control system uses the thing, so it was desirable to buy the devtc~ types from the manu-
same networking technology as the busim'ss network so they can facturers that were specialists in each particular area. Because the
be integrated seamlessly. A simple router between the networks equipment from different suppliers had ir:comp~tible prot~cols a
safeguards performance by keeping pure business communication site was stuck with a few undesirable optwns: etther choosmg the
traffic separate from pure control communication traffic. preferred device despite its poor integratibility with t~e rest or set-
tle for the less-than-best device to gain better mtegratwn. Most of
For easy and tight system integration it is important to select a the time, however, it was not possible to network the parts
homogeneous network architecture in which the protocols at the together, resulting in isolated islands of automation.
higher and lower tiers are essentially the same but just traveling on
different media. This will ensure transparency and a minimum of In one common scenario, a PLC and a DCS would have to be con-
problems with communication mapping and interoperability. For- nected, but digital integration of the system was impossible since
tunately, there are protocols available in such "suites." Good com- each component communicated using a di~ferent protocoL If the
binations would be FOUNDATION Fieldbus Hl and HSE or manufacturers allowed licensing and provtded proper documenta-
PROFIBUS PA and PROF!net. If a proprietary protocol is used at tion, a communication driver could be developed-but at great
the host level or somewhere in the link between the instruments expense in time and money. A third party often developed the
and the operator important functionality and interoperability may drivers, and when communication problems arose the parties
be lost. This may force engineers to perform time-consuming map- would point fingers at each other. To complicate matters furthN,
ping of parameters between protocols. one driver was required for every combination of hardwa~·e and
software, producing an unmanageable situation for supphers too.
The use of the same technology throughout the system greatly sim- Many times no communication at all was possible, and to ~ass data
plifies the initial engineering and deployment of the system as well subsystems had to fall back on conventional analog and_dtsc.rete
as its ongoing operation and management. Engineers can readily signals. Because of the protocol differences third-party hel_d mstru-
work with different parts of the system without retraining. ments could not be integrated with the DCS to fully benefit from
their intelligence, nor could one supplier's handheld termmal or
History of Fieldbus other configuration tool work with a device from another.
The history of process control networks is very much the history of The Need for a Standard
the IEC 61158 Fieldbus standard.
Once a proprietary system had been purchased the plant was
Lack of lnteroperability essentially "locked in" by the manufacturer. To mamta~n system
integration the plant would have to purchase replacement trans-
When digital communications first began to appear every vendor mitters from the system supplier, who was also the only one that
invented its own protocol independently of others. Soon many dif- could do system expansions. Because the system supplier at this
Fieldbuses for Process Control Chapter 1 -Introduction
point no longer had any competition, replacement parts and extras Naturally, some companies and nations wanted to se~ their e~ist
would be much costlier than they were for the first system. Mcmy ing technology and national standards adopted as the mternahonal
plants were avvare of this but were still willing to pay the price of fieldbus.
being tied to a single manufacturer simply because of the high cost
of struggling with system integration in a situation where incom- These factors further contributed to the delay in the ratification of
patible protocols required drivers. the single fieldbus standard. The world failed to agree on a single
standard protocol, and as a result several competing and noncom-
Being locked in can be dangerously costly, so many governments patible bus technologies are now being included in a multi-part
prevent the use of proprietary teclmologies in public projects. standard that is not yet fully completed. Parts of both FOUNDATION
.Many instrun1cnt suppliers were also displeased with the situa- Fieldbus and PROFIBUS, though not HART, are elements of this
tion. Despite the fact that they often had higher-performance prod- standard, but devices of these two types cannot communicate with
ucts, the instrument suppliers were unable to compete with the each other since the protocols are not compatible.
systems suppliers simply because of the incompatibilities. Further-
more, adapting their products to a myriad of protocols was Industry Groups
extremely costly, driving up product prices. As is often the case
when standards are lacking, there was anarchy in the market. Frustrated with the delays in the development of standards, manu-
facturers and end users formed organizations to fast-track the cre-
ation of open fieldbus specifications. In 1992, the Interoperable
Standardization
Systems Project (lSI') was formed to develop a technology partly
Because the situation was clearly intolerable, in 1985 industry based on PROFIBUS and soon thereafter WorldFIP to develop
experts began W< ,-\ '· n a vendor-independent fie! db us standard. another based on FIP. Because these are open organizations that
Networking is a dement of an open system, and it was para- develop and maintain the technology, both projects have the open-
mount that an interoperable fieldbus be developed that was sup- ness of a true international standard. The organizations split and
ported by multiple vendors and based on a freely available merged, but for the process industries organizations had by 1994
standard without licensing. Standardization is an enormous task essentially crystallized into the Fieldbus Foundation and Profibus
that not only involves the development of a technology but has International.
economic and political implications for factories, manufacturers,
and even nations. FOUNDATION Fieldbus and PROFJBUS PA have a common heritage
in the !SP technology; therefore, the concept of block, parameter,
Because of the unique needs of the process control environment no mode, and status is very similar. The FOUNDATION Hl technology
existing standard for networking could be used. A new technology was released soon after followed by PROFIBUS PAin 1996. FOUN-
had to be developed for the standard that provided bus power, DATlON HSE was released in 2000, and by 2001 PROFinet was
intrinsic safety, the ability to communicate long distances over nor- already on its way. For several years now, manufacturers have
mal instrument wires, and so on. This development process led to been delivering products based on these specifications, and plants
an international fieJdbus that could not move as fast as other net- are already reaping their benefits. Large parts of the specifications
works that used an existing platform from telecommunications or are being adopted as national standards and will soon also become
automotive indus try. Nevertheless, it filled an important need. an international standard. However, some parts of both technolo-
Many of the systems suppliers who participated in developing the gies are still under the control of the organizations.
standard had vested interests in the old technology and a comfort-
able market share in the proprietary paradigm. Standards allow During fieldbus's long gestation period some originally propri-
competitors to take away customers that had previously been etary protocols such as HART and Modbus were opened up and
locked in to a particular supplier's proprietary technology. Thus, n1ade available to other manufacturers. These were tremendpusly
these proprietary suppliers had a responsibility to their sharehold- successful in filling the gap and now have an enormous installed
ers to see the fieldbus standard fail so they could avoid tougher base and will keep selling for years to come.
competition.
Fieldbuses for Process Control
Chapter 1 -Introduction
Advantages of Standards
ler was typically situated in the field and there operated locally.
C?nce th~ standa.rds w_ere in place plants could truly begin to benC'- There was therefore no system to speak of. With the analog current
f~t from mtcgrahon WI~hout paying the high price of being tied to a loop it became easier to bring a signal from the transmitters in the
~mgle ma~ufactur~r (figure 1-9). Standards have already resulted field to a central controller in the control room and then from there
m compatible eqUJpment now availablC' from several suppliers. back out to the valves again. In the completely centralized direct
More than one company now manufactures device types that arc digital control (DOC) architecture the complete control strategy
~ased on the same fieldbus technology. This has led to a competi- was executed in a computer. Because all the functions were concen-
h~e ope,~ market, a desirable development because it reduces trated into a computer the entire system with all of its loops would
pnce~. S1tes that employ standards arc protected from proprietary fail if there were even a single fault. For this reason, it was not
solutJons that force them to be dependent on a single vendor. Simi- uncommon to have local pneumatic controllers existing in the field
larly, the pl~nts that have adopted standards have many more on standby, ready to be put in operation once the DDC failE'd.
~phons a:allable for devices and software. This enables them to Clearly, the centralized architecture had some serious availability
~~nd solut10ns for th~ir very diverse application needs, needs that issues, which led in the early 1970s to the introduction of more
<.annot be met by a smgle supplier but require equipment from sev- decentralized programmable logic controller (PLC) and distrib-
eral manufacturers. Device manufactures can once again concen- uted control system (DCS) architecture.
trate on true innovations rather than tweaking communication
protocols. DCS and PLC Architecture
The DCS and PLC emerged with the advent of digital communica-
tion, but these architectures were also designed based on 4-20 rnA
for field transmitters and valve positioners. However, the DCS was
a great improvement over the DDC in that the controls were now
distributed over several smaller controllers that shared the tasks,
each one handling perhaps thirty control loops. This had the
immediate benefit that a single fault would only affect part of the
plant, not all of it as with the DOC In other words, a higher level of
distribution increased the availability of the system.
~1ad their own competing proprietary protocols. Thus, plants were programming language and powerful communications features
mclined to buy the field instruments from the system supplier enable is the ability to perform control that is distributed into the
rather than from third parties.
field devices rather than a central controller. For example, it is com-
mon for the valve positioner to act as a controller for the loop it is
A DCS can often have, in alt as many as four different tiers of net- part of. It executes the PJD function block but only for its own loop,
working, each with a different technology: device, l/0 subsystem, not for other loops. This new architecture based on field device
c~ntrollers, and plant-wide integration to business applications capability is called Field Control System (FCS) and is an alternative
(figure 1-10). All these levels of hardware and networking result in to DCS (figure 1-11) in that the architecture is not controller-centric.
a rather complex and costly system.
It does not treat every field device as a peripheral. Because of its
decentralized nature the FCS architecture has advantages Eke high
·------------ -------------- availability, greater scalability, and lower cost. The FCS architec-
ture has evolved from the concept of the DCS carrying the original
concept further, and the result is a system that is more distributed
and therefore less vulnerable to faults.
FCS Architecture
The FOUNDATION Fieldbus specification is uniquely different from I It may at first be hard to comprehend how small field device con-
trollers could replace a "unit controller" to control a large plant.
The secret behind this concept is that each device handles only one
~ther networking technologies in that it is not only a communica-
tions protocol but also a programming language for building con-
trol strategies. One of the possibilities that a standard I
i
loop. By networking hundreds or thousands of devices together
the combined power of the microprocessors exceeds that found m
earlier systems. The control task is broken up into its components
I
Fieldbuses for Process Control
Chapter 1 - Introduction
-----·--···------··----·---·
In an FCS the field instruments are an integral part of the system as
Host
a whole. All that remains of what used to be called the system is
the workstations and linking devices. The workstations that con-
nect directly to the host-level network are simply referred to as the
host (figure 1-12).
L_ __
Figure 1 ~11. FCS architecture with control in the field d~~ice~-:---------
held terminaL However, plants should enhance HART installa- simplification savings achieved by the FCS. Thus, one of the main
tions by integrating a permanently fixed communications criteria for selecting a bus teclmology is what architecture is
subsystem that is connected in paraJlel with conventional I/0. desired. For a DCS or PLCr either one can be used; for a full-
This brings full field device data into the control room, making it fledged FCS only FOUNDATION Fieldbus is possible. FOUNDATION
easy to benefit from device intelligence. A HART multiplexer is Fieldbus has a number of useful communication features not
connected to all smart devices.. giving the device configuration tool offered by most other protocols. These include automatic device
complete access (figure 1-13). Alternatively, an l/0 subsystem with detection and address assignment for Plug-and-Play installation
built-in HART capability may be used. Without digital integration and time synchronization. PRO FIB US has PROFisafe for commu-
many plant operation improvements are simply not possible. nication between instruments in safety- related systems, which
FOUNDATION and HART do not offer.
.-------··-----·-------··
Commercial Differences
Of course, there are other criteria to consider when selecting the
principal network to be used in the system. Are the device types
and tools the plant requires available in a version that has the
desired protocol? Are there multiple vendors of the product types
the plant requires so as to ensure a competitive price now and in
the future? Do the manufacturers of the products that will be used
have good local support through either their own offices or
multiplexer
representatives, or do the products have to be imported without
support?
EXERCISES
Figure 1~13. A HART multiplexer taps the digital signal from smart 1.1 Is all networking digital?
instruments.
1.2 Is HART a master/slave protocol?
Because HART blends the benefit of digital communications with 1.3 Is FOUNDATION Fieldbus also a control strategy
complete analog compatibility the transition from pure 4-20 rnA to programming language?
HART became easy and ffART's success was assured. In a pure
1.4 Is publisher /subscriber a more efficient way of
digital system based on FOUNDATION Fieldbus or PROFIBUS, full
communicating cyclic data than master/slave (client/
information access comes built in since all communication is digi-
server)?
tal, the networking infrastructure is in place lor I/0, and no addi-
tional hardware or wiring is required. 1.5 Which type of automation generally requires faster
network response times, factory automation or process
Other Technical Differences automation?
The HART and PROFIBUS technologies do not have a control 1.6 Is Ethernet a protocol?
strategy programming language. FOUNDATION Fieldbus has a stan- 1.7 Does a distributed architecture increase availability?
dard function block language and publisher /subscriber communi-
cation. It therefore has the ability to constitute an FCS, but it can
BIBLIOGRAPHY
also be used in a DCS or PLC. HART and PROFIBUS are only used
in DCS or PLC architectures, be it a traditional embedded PLC or 1. Application Guide, HCF LIT 34, HART Communication
PC-based software logic. A traditional DCS using FOUNDATION Foundation, Austin, TX, 1999.
Fieldbus would not achieve the controller reduction and network
Fieldbuses for Process Control
( (
,_
Fieldbuses for Process Control
Chapter 2- Benefits, Savings, and Doubts
ogy has made possible a wide range of new capabilities from one device to another, but without a user layer standard the
throughout every level of the control system that had not previ- meaning is not understood (figure 2-1).
ously been possible or fully explored. This includes more control in
the field instrmnents, the measurement and transmission of multi-
ple variables, and field device maintenance management based on
self-checks etc., among other benefits. These new capabilities bring
benefits that in turn translate into savings at various stages in the
system life cycle, as early as the time of deployment, during opera-
tion, or even at future decommissioning. Substantial savings are
achieved using capabilities that traditional systems do not have.
lnteroperability
lntcroperability is the ability of a device to work together with
other devices. This enables easy and tighter integration of devices Figure 2~1.- A physical layer standard does not ensure that the meaning of
from different manufacturers than what has previously been possi- the data is understood.
ble and to some extent the substitution of a device by that of
another manufacturer that also could not be done when protocols While most communications networks are only "data pipes" push-
were proprietary. Interoperability is made possible by the stan- ing information from one point to another HAKI, FOUNDATION
dards and specifications that have been laid down and tests to cer- Fieldbus and PROFJBUS PA have gone further than most proto-
tify that the standards are being followed.
cols. They specify a user layer with parameters for input, output,
alarms, tuning, diagnostics, and configuration and also indicate
Standard User layer
how the values are to be interpreted. Using these full-fledged pro-
A complete communications protocol performs many functions tocols, software and devices have a common understanding of the
that have been categorized in groups or layers, as detailed in chap- meaning of the bits and bytes and therefore a far higher degree of
ter 11, "How Fieldbus Works." The most visible parts are the physi- interopcrability than could be achieved by, for example, Ethernet
cal layer that covers the network media on which bits get from A to on its own. A seamless system can therefore easily be put together
B, that is, the wiring, and the user layer that defines the semantics ~thout patching by using drivers and data mapping or by falling
of the data, that is, what the bits and bytes mean. To be connected back on analog signals, as is the case with proprietary systems.
to the same cable the devices need to conform to the same physical Physical layer standards eliminate the need for special interfaces,
layer standard and to fully intemperate the devices need to con- and user layer standards eliminate the need for custom df~vice
form to the same user layer standard. RS232, RS485, CAN (Control- drivers. Using fieldbus technology it is possible to mix and match
ler Area Network), and Ethernet are well-known standards but the best instruments and software applications with a minimum of
basically only for the physical layer. None of them is a complete worry about incompatibilities between manufacturers.
protocol. They essentially just specify electrical signal levels and
the types of cable that can be used. These physical media do not Device Description
provide any guarantee of interoperability, but they are the basis for Hosts must access complex data from devices. FOUNDATION Field-
many protocols. Though many devices and systems on the market bus and HART utilize Device Description (DO). DO is a set of files
use Ethernet, they are essentially proprietary because they do not containing information about the information in the device and is
use a standard user layer. As a result, they force the plant to provided by the manufacturer of each particular device. DO works
develop costly drivers and configurations to enable the proper dis- like a kind of Rosetta stone in that it allows the host to interpret
play and action on the data. Manufacturers may not even make the any data and to work with all functions (figure 2-2).
necessary documentation for driVer development available to
another supplier. Bits and bytes may be transmitted successfully Using the DO the host can decode and display all of the field
device iri.formation so it becomes useful to the operator. The user
Fieldbuses for Process Control
Chapter 2- Benefits, Savings, and Doubts
newer and older versions of the same device type. All the user has BKCAL_~Nftc-123
to do is copy the DD files onto the host computer. Manufacturers \._1'10
can therefore supply devices that include special parameters or I ouff
unique features, and yet because of DD the access is assured
regardless of host used. In other words, DD allows manufacturers
to extend the usable device capability far beyond basic functions.
DD can be seen as a standardized mechanism for replacing propri-
etary driver schemes. \!\'ell-defined standards ensure that FOUNDA-
I l
BKCAL_OUT~~
J_CAS_IN
(Fv:1~
Figure 2-3. Basic PID control loop represented as a function block diagram.
TION field devices are interoperable and can exchange simple I/0
data with each other directly without the need for drivers.
Using a standard programming language offers several advan-
tages. Equipment from different suppliers are configured in the
Subsystem lnteroperability
same basic way, making it easier for engineers to work with equip~
Just as the field-level network standard gives sites the freedom to ment from different vendors, with little-or no retrain)ng. Training
select field instruments, the open host-level network lets sites mix received on one system can be applied to another manufacturer's
and match subsystems from different suppliers. Until now, inte- system too. Standard programming language also makes it very
grating such auxiliary systems from various manufacturers with ! easy and completely transparent to execute the control strategy by
the basic controls has been difficult because of the proprietary pro- mixing controlling devices from different manufacturers. Most of
I
tocols used by all parties. Because of limited driver availability cer- the time, a function block in one device is identical to that in
tain combinations of system parts were not possible. Using another, and blocks always operate in the same basic way. The
standard host-level protocol subsystems such as paper web scan- standard programming language makes possible great interopera-
I
ners, gas chromatographs, compressor and turbine controls, and bility between devices since the parameters for communication
burner management will be integrated as one. It is even possible between field devices have been tightly standardized. Such param-
for subsystems to use different field-level networks but be inte- eters now allow function blocks in the field devices to use the data
grated with each other through the same host-level protocol. from devices made by other manufacturers directly without fur-
Programming Language
The FOUNDATION Fieldbus is the only bus technology to include a
control programming language for building control strategies. This
II ther processing or interpretation. The status communication
between devices is not only for display; the receiving devices take
appropriate action for reset windup protection, cascade initializa-
tion, shutdown, and so on, resulting in better control and response
to abnormal conditions. Reset windup protection in the PID is
programming language is graphical. not textual. and uses the I assured through feedback even if the valve is operated by hand.
familiar function block diagram. A control strategy is built by
selecting function blocks and linking them together so process and
I The additional benefit is a bundle of functionality with a minimum
amount of engineering. Another great advantage of a standard
II
Chapter 2- Benefits, Savings, and Doubts
Field!Yuses for Process Control
programming language is that the execution of control strategy is product is sold. The rigorous testing ensures that devices s~ould
synchronized with the communication, even between devices from not have communication problems. A minimum of integration
different suppliers. This is possible because the communications problems will therefore be experienced once the device has been
protocol and programming language are defined in one and the put into operation.
same specification.
Greater System Functionality
Device Families and Transducer Blocks
Perhaps the most important benefit of digital communications is
There is device information that is unique to the measurement of a that a virtually unlimited number of parameters can be acc~ssed
particular physical property or a method of actuation and is simply from a device. This allows multiple measurements and a wtde
is not applicable to another. Often these parameters are related to a range of features to be crammed into advanced device ~irmvvare
certain measurement technology used by more th<1n one manufac- ancl accessed renwtcly by sophisticated software. The f1eldhus
turer. To this end, the PROFIBUS PA and FOUNDATION Ficldbus technologies thcrdore make possible a level of systc~ functi.on<~l
devices have subsets of parameters for information th<1t is applica- ity not previously found in field devices and hosts. ftcldbus mstru-
ble to a particular device type. For exr~mplc, there is information ments have capabilities far exceeding simple measurement an~
for pressure, level, temperature and flow transmitters, valve posi- actuation. Innovative products and solutions have become avml-
tioners and analyzers, and so on. These sets of parameters are able for those plants that have invested in these teclmologies.
grouped in transducer blocks that are tailored for the pressure, These standards boost innovation as manufacturers are able to
flow, level and temperature measurement, valve positioning and make devices and software do much more. They no longer need to
so on and contain information applicable to each particular device waste time reinventing the wheel but can take development to the
type. This includes, for example, temperature sensor type selec- next level. The biggest change brought about by fieldbus technolo-
tion, pressure sensor limit, calibration records and diagnostics. gies is not in the devices themselves but in a new clas~ of ~oftware
These transducer blocks are where the calibration and set-up of functions in the host. Today, third parties are developmg mnova-
devices is performed. Similarly, HART defines a device family tive accessories and software for devices they themselves don't
where each family has an associated set of commands for accessing manufacture.
information relevant to that particular device type.
Multiple Variable 1/0
Predefined parameter sets contain all the common information and
provide a fair amount of information access and interoperability. In the past, a two-wire transmitter had a 4-20 rnA output that could
Additional parameters supported by the device, beyond what is only transmit a single piece of information~-one measurement
specified in the standard HART commands and FOUNDATION value. Though two-wire multi variable transmitters have been
transducer blocks, are described in the DD for the respective around for several years they never gained mainstream acceptance
device. This ensures that no data is proprietary. because the digital communication was slow and as a r~sult only
one of the measurements could be used. FOUNDATION Field bus
Test and Certification and PROFIBUS PA are fast enough to communicate many mea-
surements per device in real time. For example, a density transmit-
For standards to be effective they have to be followed. If devices ter may provide the measured density, process temperature, and
didn't fully conform to the specification and manufacturers started the computed referred density (figure 2-4). A single temperature
doing their own thing interoperability problems would follow. The transmitter with two independent inputs can be used instead of
field devices based on these technologies are therefore thoroughly two transmitters.
tested by experts independent of the manufacturers or by the man-
ufacturers themselves using specially developed tools to guarantee Valve positioners transmit to the host a feedback of the actual_
that the devices are in fact interoperable. The testing includes elec- valve position and the actuator pressure over the sam~ two-wire
trical aspects as well as communication and device support file network on which the valve setpoint is received but Without the
aspects. This ensures the quality of the device communication and need for additional cables. Similarly, for many applications valve
catches any implementation errors so they are rectified before the position alarms can be configured in software and communicated
·-- Fiefdbuses for Process Control
Chapter 2- Benefits, Savings, and Doubts
nance tool. The operator may also see faults automatically without
the need for manual interrogation in the field using a handheld ter-
minal. For example, if the supply air to the positioner is lost it is I Simplicity
Many of the features of fieldbus devices enhance their sheer conve-
I
nience and ease of use in comparison to traditional analog equip-
indicated on the workstation. The health of any fieldbus device in
ment. Many functions are automatic or can be performed remotely
the system can easily be checked without having to Venture into
from a workstation without having to send someone into the field.
I
the field. As a result, a device that is not trusted can easily be inves-
tigated.
Fieldbuses for Process Control Chapter 2- Benefits, Savings, and Doubts
···--···-~···-····-------~
~any mundane tasks are eliminated or reduced. These simplifica-
tions often translate into savings too. Strategy Device
configuration configuration
-~~--····--·--------·----J
new devices intuitive. This feature compares favorably to the pasl
when each manufacturer had its own proprietary protocol. This
forced the sites to retain half-a-dozen handheld terminals, inter-
faces, and software so they could configure the site's different Figure 2~6. A system with proprietary language most likely has stand-alone
devices, each of which operated in a different way. device configuration.
Plug-'n'-play
Powerful Function Blocks
The communications protocol part of the FOUNDATtON Fieldbus
The standard function blocks that make up the FOUNDATION Field-
includes a system management function. A major benefit it offers
bus programming language are extremely powerfuL Each one typ-
is that it automatically detects, identifies, and assigns the address
ically groups the functionality corresponding to several blocks in
t~ ~evices a~ they are added to the network. This reduces labor sig-
proprietary languages into a single block. However, what really
mflcantly, eliminates human addressing errors, and instantly indi-
makes these blocks powerful is their ability to handshake and
cates if the device is properly connected to the correct and
propagate status along with the values that are passed from one
functioning network.
block to another. Because block behavior is standardized these
functions work across the devices of different manufacturers. The
Homogeneous Environment
blocks contain standard shutdown interlocks and cascade initial-
Because FOUNDATION Field bus is both the communications proto- ization me.chanisms using the status. This means that additional
col used fo.r device configuration and the programming language logic in different languages need not be configured to achieve
used to build the control strategy, it is possible for a host to have a these and many other functions. In other words, sites can take
sin~le integrated tool.that can perform both functions. A single advantage of the power not just of the individual block but the
environment for configuring and troubleshooting devices and combined power enabled by the standardized interoperation of
strategy simplifies work. With an integrated tool it is easier to keep links between these blocks.
devices and strategy in sync, without much manual intervention
required and without leaving the console. This compares favorably Accuracy
~ith traditional proprietary language solutions in which configur-
mg devices and building control strategy are done in different In a system based on 4-20 rnA the signals in a control loop undergo
applications using a variety of configuration languages and meth- several analog-to-digital (A/D) and digital-to-analog (D I A) con-
ods, often in different workstations or more typically on a hand- versions. A transmitter using an analog output will have to do a
held (figure 2-6). Inconsistencies between the controller and device D I A conversion to get the 4-20 rnA output transmitted to the DCS
databases can easily occur. 1/0 subsystem. The analog input module in the DCS will do an
AID conversion, which will allow the DCS controller to process
the signal. An analog output module does aD/ A conversion to get
a 4-20 rnA output signaL Lastly, a smart positioner must have an
Fieldbuses for Process Control
Chapter 2- Benefits, Savings, and Doubts
A/D converter to allow its microprocessor to accept the analog Lower Cost of Purchase
signal.
Because of its leaner architecture a system that is based on fieldbus
Each conversion adds an error called the "quantization error." The technology in general but has FCS (Field Control System) architec-
errors from the four stages of conversions add up, often exceeding ture in particular requires a site to purchase and install signifi-
1 percent. Digital networking eliminates the need for these conver- cantly less hardware than a traditional system. Fieldbus-based
sations as all microprocessors communicate with each other. This systems are therefore lower-cost systems. However, the manufac-
results directly in increased accuracy. Keeping the signal digital turers' development cost for conventional systems has usually long
from the very beginning to the very end 1nakes possible infinitely since been amortized, and when controllers and margins are mini-
more complex and precise signal processing. In HART, FOUNDA- mized the prices can come down low. Nevertheless, a conventional
TION Fieldbus, and PROFIBUS PA all scalar values are processed, system will be more expensive to operate in the long run, resulting
stored, and communicated using the standard 32-bit flo<Jting-point in a higher total cost of ownership.
format while maintaining seven-digit precision throughout the
system. Since the values are floating point and typically in engi- The savings apply to the part of a system that is purpose-built for
neering units there is no need in the vast majority of cases to enter fieldbus technology. Other sections of a site that use conventional
scaling or ranges. This simplifies as well as reduced the configura- technology will reduce the average savings. Some systems may be
tion effort. built on architecture that prevents some savings from being
achieved. Each installation is different, and therefore the total sav-
Achieving Fieldbus Savings ings vary, but significant savings can be expected.
The fieldbus technologies have features that lead to huge initial Fewer Parts
and long-term savings, but it is easy to miss the big picture. With fieldbus technology, reduction in hardware is seen at all lev-
Although the savings on cable are the most visible, they are neither els of the system architecture, from field instruments to the work-
the only nor the greatest form of cost reduction that can be stations. Fieldbus technology largely eliminates the need for the
achieved using PROFIBUS, FOUNDATION Fieldbus, and-for many I/0 subsystem. As the number of components that are needed is
points-HART (provided the host has permanent communication). reduced the panels they are installed in also become feWer and
The initial savings include lower costs for purchase, engineering, smaller. Thus, the large panels associated with traditional systems
and installation. The long-tf'rm savings include lower costs for no long('r need to be so large. Fewer, smaller, and lighter compo-
maintenance and opNiltion, thanks to nctwork-f'ni1hkd asset m~n~ nents also 1nectn u:-Juu:Ll ~!tipping (0:.)-b.
agement but also lower costs for expansion and change.
Because fieldbus-based systems can fully utilize multivariable
Cost savings can be substantial, but, of course, they vary with the transmitters and valve positioners the number of devices and asso-
labor costs of the country in which the plant operates, the plant's ciated wiring and I/0 can be reduced. For example, in a density
size, and the nature of the plant. There is no standard way to calcu- measurement on a tank a single transmitter can replace as man;r as
late savings. The savings in cost and time for the site may be ana- three transmitters. A single temperature transmitter with two inde-
lyzed in terms of its unique conditions based on the possibilities pendent inputs reduces the number of transmitters to half, result-
offered by the field bus technologies. Because long-term savings are ing in a 50 percent coSt saving. The only means analog systems had
greater than procurement and installation savings fieldbus equip- to detect device faults was using discrepancy checking to compare
ment pays for itself very quickly. It therefore also makes sense to the signal from two redundant transmitters~a solution too costly
re-instrument an existing site with field bus. PROFIB US and FOUN- for all but a few critical control loops. Devices using fieldbus tech-
DATION Fieldbus devices are more expensive than HART devices, nology detect their own fault and communicate their health. As a
which in turn are more expensive than their conventional counter- result, one device can be used instead of two, reducing costs by 50
parts. This fact offsets some of the savings fieldbus provides, but percent for such loops.
overall there is still a significant cost saving.
Fieldbuses for Process Control Chapter 2- Benefits, Savings, and Doubts
Since many devices can be multidropped on a single pair of wires barriers to be mounted outside the classified area where special
the amount of cable can be drastically reduced. The amount of enclosures are not required. This is explained in detail in chapter 3,
cable reduction depends on the wiring scheme, the number of "Installation and Commissioning."
devices installed on each network, the distances, and whether or
not the installation is in a hazardous area. The main cable reduc-
tion is seen on the multi-core homerun cable from the field junction
box to the l/0 marshalling panel (figure 2-7). By putting twelve
devices, some for control and some for monitoring, on each net-
work the cabling is already reduced by more than 90 percent,
which still leaves room for more devices. The cost reduction is sig-
nificant, especially for <urnored cable. Additional related hardware Homerun Cable
--- I
savings are gained since fewer conduits, cable trays and ladders,
and cable glands arc required than in a conventional solution.
Marshalling Panel
Homerun Cable
Similarly, the marshalling panel also becomes smaller and simpler
because the number of 1.vires is reduced as a result of multidrop-
subsystem ping (figure 2-8). When digital communication is used no costly
Termination
analog input and output modules are required. A typical scenario
would consist of a single linking device processor module with
Marshalling Panel four integral field bus ports connected directly to 64 devices. S~ch a
scenario reducE's the cost significantly compared to a conventional
system that \vould require eight analog I/0 modules of eight chan-
Figure 2-7. Traditional system architecture requires lots of hardware.
nels each. The simplification is greater still for the loops for which
redundancy is required. Depending on the fieldbus-versus-con-
Using the multidrop capability it is possible to connect several ventional mix the analog I/0 reduction can approach 100 percent.
devices to each safety barrier, thus reducing the number of barriers As the number of modules is reduced, the associated racks, nests,
required in an intrinsic safety installation. The number of devices I/0 network, and other mounting hardware are eliminated as are
per barrier depends on the devices' power consumption, the barri- the power supply components for all the modules. The termination
ers' current capacity, and the intrinsic safety method being fol- cards used for conventional]/ 0 are not required for field bus com-
lowed, among other factors. Using the traditional entity concept munications. The 1/0 subsystem for fieldbus devices is therefore
that consider the cable a concentrated capacitance and uses a linear very much simpler and less expensive than for a conventional
barrier some four devices can typically be connected to each bar- solution.
rier, but using the Fieldbus Intrinsically Safe Concept (PISCO) this
often increases to as many as eight. At the same time it also allows In a system based on a standard field bus technology the need for
for longer cable. That is, in terms of quantity the reduction in cable gateways between different network protocols is greatly reduced
is 75 to 87 percent, but because of the price difference the dollar and often eliminated. Similarly, there is no need to develop custom
savings are slightly lower compared to a conventional barrier. device drivers, which removes a large expense.
Cable length is a critical factor since longer cable allows the safety
~~~~~······ ..
Fie!dbuses for Process Control Chapter 2- Benefits, Savings, and Doubts
Using the FOUNDATION Fieldbus capability to distribute control blesome and disruptive, hence the system suppliers charged high
strategy execution into the field devices enables sites to drastically rates for engineering changes. As a result, in the past systems were
reduce the amount of centralized CPU processing power required. always purchased with lots of spare capacity for I/0 modules,
Hence, the number of controller modules can be cut since they are rack slots, controller memory, and processing capacity. This over
basically only needed for the less computation-intensive discrete capacity meant that plants were buying a system far bigger and
control tasks. Since these are expensive parts this elimination costlier than they initially needed just to be on the safe side.
results in great savings.
Expanding or changing fieldbus-based systems is much cheaper
Less Space and simpler because they have much less hardware, hence large
amounts of spare capacity need not be purchased at the time of ini-
The reduction in hardware means smaller panels and consequently
tial investment.
a smaller space requirement. Thus, the need for climate-controlled
ruck rooms for the panels is reduced too. Since the wiring is
Fewer Spare Parts
reduced there is often no need for elevated floors. This can add
noticeably to the savings, especially on rigs or other vessels where A lean system has Jess hardware that can fail in the first place.
space is at a premium. In some cases, it may also mean that a new Therefore, fewer spare parts need to be kept in the inventory,
rack room need not be constructed for an expansion. which further reduces the overall system cost. Standards-based
equipment is provided by many second sources.. so if a spare trans-
Less Expensive Parts mitter cannot be delivered in time from one supplier another brand
with shorter lead time can be used in its place. As a result, keeping
Sites that invest in a system based on open standard fieldbus tech-
in-house spare stock on hand is less critical, and expensive con-
nology further their lower system cost by not being tied to a single
tracts for the manufacturer to bond stock may be avoided.
manufacturer. Independent of which host is chosen for the system,
the field instruments and other system components and software
can be sourced from a variety of other suppliers. Selecting the Engineering Savings
device with the best cost-performance ratio is recommended. Open The simpler hardware architecture and reduced complexity of a
competition lowers prices. This compares favorably to traditional fieldbus system greatly simplifies project engineering and design
proprietary systems where field devices had to be bought from the work from the conceptual design stage, through the detail engi-
host vendor in order to achieve any integration. H.:wing locked the neering and documentation phases to training and so on. Fewer
customer in the supplier was in a position to chMge higher-than- engineering hours spent means lower cost. Projects can be run
normal market prices. "fast track" to get the plant up and running sooner and thus to
start paying back the loans.
Host-level networks based on Ethernet use standard interfaces and
other network hardware that utilize standard communications Faster System Design
software embedded in the workstation operating system. Ethernet
components are so-called COTS (commercial off-the-shelf) prod- For fieldbus devices it is easier to define host l/0 requirements
ucts, which are available just about anywhere at extremely compet- than for conventional systems. All that is required to get an esti-
itive prices.. pushed down through the economies of scale that can mate of communication port count is an estimate of how many
only be attained by sales volume in the millions of consumer goods fie! db us devices the system shall support. Unlike conventional sys-
units per year. Compared to proprietary networking parts, which tems all fieldbus devices are alike, so it is not necessary to specify if
are assembled only in the htmdreds, Ethernet is much cheaper. FOUNDATION Fieldbus or PROFIBUS PA devices are analog or dis-
crete, input or output, single or multiple variable, or used for mon-
Less Spare Capacity itoring or control. In these cases, there is no need to select different
types of 1/0 modules either, thereby reducing conceptual design
Adding control loops or monitoring to a conventional system time. The detail design phase is also faster as, for example, calcula-
meant adding lots of hardware. Installing additional equipment to tions for 1/0 module power consumption and the like need not be
accommodate later modifications from the original plan was trou- done. Simpler panels are designed faster.
Fieldbuses for Process Control Chapter 2- Benefits, Savings, and Doubts
In the case of FOUNDATION Fieldbus the functional requiren1ents The analog I/0 modules are essentially eliminated, and therefore
for control arc also much easier to define. Previously, it was neces- there is less need for I/O-subsystem configuration. This saves time
sary to explicitly define every required function in lengthy specifi- in comparison to a conventional system where racks, n:od~les, and
cations, for example, that the PID block should have functions such channels must be configured. 1/0 module auto-detection ts no
as reset windup protection, cascade setpoint, override, deviation solution for projects on the "fast track" since the engineering will
alarm, and so on. Now, the programming language defines the often be completed before the hardware is manufactured. Thus,
standard function block features, so the only thing that need be eliminating l/0 altogether is the fastest solution. A standard field-
specified is which one of the blocks is required since the block fea- bus protocol eliminates the need to program proprieta_ry prot~col
tures are implicit drivers and map custom data, which are time consummg, subJect
to error, and cause costly delays in projects.
Faster Vendor and Device Selection
For a host using FOUNDATION Ficldbus the standard programming
Jn the past, selecting a particulrtr brand of host and controller for a
system meant that the bulk of the field instruments had to be
I language facilitates the development of control strategy and
I
reduces configuration time. Many of the interlocks reguire ~bso
bought from the same supplier to ensure that they would work ]utely no additional configuration effort (see chapter 4), which
together. Selecting that one supplier was a difficult compromise~ minimizes configuration entry time. Thanks to a standard lan-
for example, choosing between the most powerful controller, the guage the system is truly open, which allows anybody to learn
most accurate transmitter, or the quietest valve. Controller features how to configure the control strategy without the need for expen-
and device performance for different systems had to be weighed sive services from the supplier, as is often the case for proprietary
against each other. A standard fieldbus simplifies the selection pro- solutions. Furthermore, some hosts have the device and control
cess since the best devices of each type can intemperate with one strategy configuration integrated into one and the same tool,
another, which makes it possible to finish the bill of materials which eliminates the need to switch between applications, enter
faster. Moreover, one type of cable is used for all fieldbus devices, the same information twice, or even work on two different work-
which reduces the types that must be chosen. Similarly, a single stations. The automatic device identification and address assign-
safety barrier type is used for all fieldbus devices, eliminating the ment makes possible configuration work that is based entirely on
tedious process of comparing entity parameters. When mul tivari- tag that is more intuitive, less subject to error, and infin~tely fast~r
able devices are used instead of individual units the number of than the mapping of device addresses and memory registers, as m
devices that need to be specified is reduced. older systems.
Faster Device and Strategy Configuration Less Documentation
Thanks to field bus technology, configuration development and Reduced hardware means that project documentation is also
entry time at all levels of the system from field device to host is reduced. Using multiple variable devices instead of many single-
reduced. For example, ranging is not necessary for field devices in point units means that fewer instrument specifications, indexes,
most applications because HART, PROFIBUS PA, and FOUNDA- and data sheets have to be generated. Multidrop wiring means that
TION Fieldbus use engineering units when they digitally communi- one single network drawing can be made per network instead of
cate a variable rather than scaled ranges, such as 4-20 rnA or 0 to sixteen individual loop drawings as in a point-to-point scheme.
100 percent. Unlike a conventional system, if the value in fieldbus This reduces effort by as much as 90 percent. Since the 1/0 sub-
is 200 kPa, two hundred is transmitted, not x% or y rnA. Since seal~ system is gone there is no associated cross-reference listing. A copy
ing is eliminated device configuration and verification work is of the fieldbus device configuration data, such as sensor types and
reduced. All device settings such as sensor type selection can be ranges, is stored in the configuration tool instrument database
made off line before the device is manufactured and downloaded ready for printout or export to, for example, Microsoft® Excel.
during commissioning. This allows configuration to start immedi- During the commissioning, the changes made are also stored, ~re
ately upon project kickoff. ating an up-to-date "as-built" configuration data~ase _electrom-
cally. Such documentation features were not possible m DCS
where a handheld was used for device configuration. Smaller con-
Fieldbuses for Process Control
Chapter 2- Benefits, Savings, and Doubts
Reductions in the amount of equipment means smaller panels that The fantastic reduction in wiring made possible by fieldbus device
h~ve l~ss _mars.h~lJing, termination, l/0 modules, and power sup- multidropping and multi variable capability means that fewer
t?lie~s ms1de. 1hts makes them faster to build and wire. Using a cables need to be pulled. Using fieldbus reduces what for conven-
hnkmg device with built-in device power and processor results in tional systems was a major logistical effort into a simple task. Con-
a solution that is significantly more compact and faster than con- sequently, fewer conduits are required for protection or to make
ventional I/0. the installation flameproof. A minimal number of cable trays and
ladders are required to support these cables. The man-hours spent
Easy System Verification to install all of these elements is far smaller than what would be
required for a conventional wiring scheme. Reduced wiring also
Before field bus, the I/O-subsystems calibration check of every 1/0 means fewer terminations, that is, fewer wires to cut, strip, crimp,
pomt was a long and tediOus part of the verification process that label, and connect. By using fieldbus, as many as ten terminations
was required to ensure that termination, fusing, l/0 modules, and per point can be eliminated, counting from device to n::arshalli~g
racks were functioning properly. Since these parts are eliminated in paneL Given that each termination takes a couple of mmutes thts
a fieldbus system there is no such test, and the total verification becomes a major cost reduction in comparison with a ~onventional
time is drastically reduced. A simple check of the communication system, especially in view of the large number of devices found
to verify the integrity of the communication port is sufficient. Since even in a medium-sized installation.
values are transmitted in engineering units there is a much less
pressing need to check the consistency of scaling between devices, ~l'aster Commissioning
controllers, and workstations. This is also a key time-saver since in
the past such checks were made from different software tools and a Unlike a traditional system, where commissioning is a very man-
~and held. This characteristic of fieldbus tcchnologiet. reduces the tJr11 and labor-intensive task; a fieldbus device, once connected to
n.sk of alarm and shutdown trips not working when they should. the network, can be commissioned from the workstation in the
Smcc communic~tions is base~ on tags, the process of verifying control room. This makes the commissioning procedure very sim-
parameter mappmg to the devtce address and memory registers ple and fast, ond for the most part it can be carried out by one per-
employed in other protocols is done away with. son. Once the host is connected to the field bus networks, all field
devices on the network are automatically detected in one go and
Less Installation Works the tags identified in the host's "live list" for each network. This is
far easier than the "ringing out" of instruments one by one that xs
Multivariable devices cut the number of devices to be installed for performed for conventional systems. That process requires people
certain application by a factor or two or three. Fewer pipe stands in the field equipped with simulators who maintain radio contact
and process penetrations mean a reduction in installation time. with the control room to verify correct wiring.
Depending on the ambient conditions the associated heat tracing
or shades are reduced too. With fieldbus it is possible to install The asset management features not available in conventional sys-
devices where they previously would never be installed because tems are very helpful during the commissioning process. It is easy
gaining access to check would have been too difficult. Because to identify a device by checking the manufacturer, device type, ver-
fieldbus allows remote diagnostics the devices will be physically sions, tag, serial number, and application descriptor. Likewis~, the
checked less frequently, which makes easy access less critical. Pip- fieldbus .device configurations are verified from the workstation,
Fieldbuses for Process Control
Chapter 2- Benefits, Savings, and Doubts
II
achieved provided that the maintenance tool is an integral and per-
manent part of the system so that diagnostics is continuous and
asset management functions can be carried out simultaneously
with normal operation. Handheld termin<1l or temporarily con-
nected software is an obstacle to efficient practices. This form of
network enabled asset management was not possible before field-
bus and is not available in traditional systems.
Less to Maintain
A leaner and less complex system based on fieldbus teclmology
has fewer parts that can fail in the first place thus there is less parts
to maintain. 1he elimination of intermediate 4-20 rnA signal means
Fig~re 2-9. Fi~ldbus reduces wiring. (Courtesy of Smar) that there is no need to check and calibrate I/0 cards, transmitter
current outputs and positioner inputs.
and any .configuration or range changes that have been done are Reduce Field Trips
automatically
h n:··,. ,rded in the database "as built"
~
wluc
· h· mam
· tams
·
t. e documentatwn as ready for printout or export. The configura-. l_n a ri.~tworked system several maintenance task previously requir-
hon for all devices can be downloaded with a single click. In the ing:a local field trip with the handheld terminal can instead be car-
past, changes made using a handheld terminal needed to be. manu- ·ried mit remotely from the workstation. The computer therefore
ally updat~d. The chances of spotting a range mismatch between becomes the most powerful maintenance tool reducing time-con-
the t~·a~~mitter and the controller were slim, which opened the suming field trips and cutting maintenance cost. The host retrieves
possibthty of a wrong reading and subsequently a nonfunctioning information from the field devices for asset management and dis-
control loop and trip poinl'>. semination throughout the enterprise independent of device man-
ufacturer. Traditional systems with no or proprietary field
Remote com~issioning of sixteen devices at a time speeds up the instrument communication do not have this capability.
process. The sJmulation ftmction may be used to verify that the sys-
te~; has the correct response by safely testing normal, abnormal, In a fieldbus host simple status is typically shown in operator
<~!~.1 ~angerous process conditions. This can easily be done without screens appearing as soon as the device diagnostics detects the
needmg t~ apply any physical input and even without using a sim- fault. Detail diagnostics is done using a maintt:nance tool. From the
ulator, whtch was a requirement in conventional systems. "live list" it is easy to tell when a device is disconnected, lose
power have communication problems or faiL Remote performance
Maintenance Savings testing exposes weaknesses and future problems e.g. it is easy to
test if a valve is able to respond to small demands by actuating the
The c?st of_maintenance can be reduced in many ways, e.g. by pre- valve in small steps, perhaps a fraction of a percent, while at the
emptmg failure but without unnecessary expenditure 0 ~ preven- same time remotely monitor that the valve is really moving. This
I
Fieldbuses for Process Control
Chapter 2- Benefits, Savings, and Doubts
was not possible in the past, as most positioners did not have bration for valve travel can also be invoked remotely. In field bus, it
actual position feedback to the control room. Many problems can is easy to gain an overview of which devices in the plant are due
be solved remotely by simple configuration changes such as direct for calibration. Conventional systems do not enable such calibra-
or reverse action, damping, or tw1ing. Remote maintenance is not a tion management.
luxury it is a necessity for savings.
No Unnecessary Maintenance
Preempt Failures
Detailed device diagnostics makes it possible for operators to
Network-enabled asset management features allow a proactive quickly determine if a process problem is caused by the device or
maintenance scheme in which operational statistics is used to esti- the process. In the past, technicians were often sent into the field
mate wear and tear. Together with information about exceeded on false alerts to bring back an instrument for testing and then only
operating conditions this wear-and-tear data determines how find that it was OK. Using fieldbus, it is possible to remotely check
much longer a device can opcr<1te before requiring maintenunce. It if the problem is genuine before going into the field, th~1s mainte-
is possible to more accurately anticipate and schedule a failure or nance is only performed when it is really needed. The ttme and
degrading device performance before it causes inaccuracies and cost saved by not having to bring only a few transmitters into the
faults but not unnecessarily early. Determining if a device may workshop is enormous. Less money is wasted checking and repair-
need to be repaired soon or even now based on the manufacturer's ing devices that are OK. By referring, for example, to the number of
life expectancy data for critical parts minimizes costly surprise reversals, a technician can decide whether or not to tear down a
shutdowns and reduces unnecessary maintenance cost. Thus, valve so as to replace a valve stem packing. Conventional systems
fieldbus drastically reduces surprise shutdowns caused by unfore- provide no means for achieving a comparable result.
seen failures and makes it possible to plan maintenance for many
devices on one convenient occasion. This could not be done by sys- Market-based Replacement Part and Maintenance Prices
tems in the past.
A system based on open-standards fieldbus also offers the benefit
Faster Repairs that failed components can often be replaced by components from
other suppliers if the original parts are overpriced. Open standards
Because the fieldbus network communicates defined faults more technology means less reliance on a single supplier. It is not neces- -
precisely immediately upon detection technicians can more accu- sary to get tied up with the coStly maintenance contracts associated
rately pinpoint the source of the problem, pick the right replace- with proprietary systems.
ment parts and tools before going into the field, and thus solve the
problem faster. Fieldbus also makes it is easy to retrieve informa- Operation Savings
tion on a device's materials of construction when selecting a suit-
able replacement part for the application. Traditional systems do Asset management does not deal directly with process control. Its
not provide sufficient level of diagnostic detaiL Moreover, when focus is on improving maintenance, which indirectly improves
technicians have installed replacement devices they can download control because when devices perform better and with fewer fail-
their configuration and put them into operation very quickly. ures better plant performance results.
?ver ~h~ ficldb~1~ network. Such consistency ensures product qual- devices themselves automatically ensure graceful shutdmvn with-
Ity ':"'1thm spcnhcd li~its. Using the status and diagnostics
out the need for a central controller. for example, a sensor failure
rctn:ve~ from the devices enables operators to quickly stop pro-
such as a burned-out thermocouple would be detected by the self-
duction m ~he event of failure before any out-of-specification prod-
diagnostics of the temperature transmitter, <1nd a bad status would
uct contammatcs good-quality product. Less time, raw materials,
be propagated through the control strategy. Control would stop
energy, and other resources are wasted to produce lower-grade
and status \Vould be further propagated to the valve positioner,
~~oduct or product ~hat cannot be sold. By using the FOUNDATION which would move to a predetermined position. Similarly, the
~1eldbus proi?rammmg language such interlocks are built in. The device diagnostics detect bad communication, \Vhich allows shut-
1mproved calibration scheme made possible by network-enabled
down action to be taken. Therefore, multidropping devices on a
as~et man~gement features makes it easier to remain in compliance
network is not dangerous. Manually configuring and verifying
With quality ar:d environmental management procedures. There
such a safety in a conventional system would be complex and con-
are no alternative means to achieve the same result.
ducive to error. The crude diagnostics in tr<1ditional systems makes
Greater Safety it difficult to balance safety and availability. Using fieldbus tech-
nology for basic controls is a good idea because it enables some of
Acci~ents carry high costs. It is obviously desirable to minimize the features and characteristics previously only found in a full-
the.nsk of harm to people, environment, and equipment. To avoid fledged safety-related system to be used in basic control.
accidents control must stop when a failure occurs.
WARNING-As has been the norm before, valves should still be
WARNING For those sites that have process units that have selected with mechanical fail-open or fail-closed as an additional
been assessed as having high risk or hazard an approved safety- level of safety. This provides a last line of defense in the event of
related system of a suitable requirement dass should be used. power failure.
~o: regular controls, fieldbus technologies have several character- Only safety-approved devices based on safety-approved protocols
Istics that sites may use to improve the safety of basic control sys- should be used with safety-related systems. One such networking
tems throughout the lifecycletoa level well above that of a technology is the PROF!safe profile of PROFIBUS, which can be
conventional. system. used for communicating between safety-related field devices and a
controller. The PROFisafe technology has received favorable
Undetected faults are very dangerous because th~ system is not reports lor use at safety level SlL3 (IEC61508) and AK6 (DIN V
shut down. In an analog system, a fault often goes unnoticed, and 19250) without using redundancy since redundancy is only
d~ngerous co~trol may continue because of an untrue value from a required for availability. The mechanism for safety is implemented
failed transmrtter. With fieldbus technology, such a failure is as software functions on top of the standard transmission system.
detected .and communicated, which allows the loop to be shut Because no modifications are made to the standard protocol, safe
d?wn. D1~gnostics is indicated as part of the status that is comrnu- and standard communications can be mixed, and both types of
mcated With _the measurement and control variables passed devices can therefore share the same wire. Safe transmission
between dev1ces. Because there is a distinction between minor includes several measures for discovering faults on the standard
"uncertain" and severe "bad" problems unnecessary shutdowns transmission system that have been caused by noisy line or hard-
can be avoided using fieldbus. ware or software failures. Errors that have to be detected include
repetition loss, insertion, incorrect sequence, corruption, delay,
In:erlocks may initia.te a shutdown by using the status received mix-up of safety-related and standard messages, and erroneous
With the process vanable from the transmitter in the basic control addressing. Measures taken in addition to the normal communica-
strategy. This can be done by setting the status on the rr:anipulated tion checks include sequential numbering and check of messages,
vanable to the valve posrhoner accordingly. If the FOUNDATION . comparing delays to expected time, authentication of messages,
F1eldbus programming language is Used, such shutdown logic is and additional data integrity checksum. At the time of writing no
already built in and only needs to be enabled. Thus, the field PROF!safe products have yet been made available. Other safety-
I
Fiefdbuses for Process Control
Chapter 2- Benefits, Savings, and Doubts
r~lated bus technologies exist for example, technologies for simple address range, and the like are approached. As CPUs get loaded
dtscrete l/0 and also proprietary protocols for safety-related con- with more and more loops to keep costs down, performance
troller communication over Ethernet.
suffers. Another restriction to be aware of is that older proprietary
protocols often have limited bandwidth of perhaps 500 kbit/s for
Less Training
the J/0 network and 1 Mbit/s for the control-level network.
Training is costly, but standards make it possible for devices and Ethernet at the host level running 10/100 Mbit/s overcomes this
softvvare to function and be operated in the same basic way. This limit.
r~duces the ~eed for ongoing training of personnel in the use of
dt~~erent equipment and tools w~i:e at the same time reducing con- In contrast to the traditional system, adding a device in an FCS
fu~wn and mtstake~. lnterop~rab1hty makes it possible to use only means adding resources. In the FCS, adding instruments means
a smglc too] to conftgure devices from different manufacturers more CPUs, more memory, and more computing powpr in the sys-
giving everything a common and u_scr-f riendly look and feel. . ' tem. Though it is counterintuitive at first, tlw more the system is
fo~JNUATION ~;ieldb\ts also specifies a programming language, "loaded" tlw more powerful il gets. Every device added is one
which mak~s 1t possible to build a control strategy using control- more CPU sharing the workload. This means that the system can
~ers from d1_fferent n:~nufacturers and then executing the strategy be continuously expanded and handle ever more advanced control
m a transm1ttcr, posthoner, or centralized controller. strategies without a corresponding loss of performance. Because
the FCS architecture is built by smaller decentralized components
Lower Cost of Expansion and Change sites can add instruments basically one by one without having to
add major components. For the same reasons, systems can eco-
For the same reasons that fieJdbus-based systems ilfe cheaper to nomically start very small and gradually expand as the demands
buy and deploy, they are also cheaper to expand and modify. How- grow. Similarly, since there is no heavy investment in a large cen-
eve!~ there are additional benefits that make them even more tral component, it is even economical to build a system with only a
advantageous in this respect. handful of loops.
Scalability
Easy to Modify
, Incr~ased produ~t demand may force a plant to expand, and a pro- A plant may ha~e to adapt to market requirements by changing
duction process 1mpro~ement may require that some additions be ~ Prod\1ct and production methods. Such modification is easier in a
made. If a network is not fully loaded field instruments ca~ be fieldbus·systerri be-cause new configurations can simply be down-
a.dded even without pulling new cable. Each leftover communica- loaded, prepadng the·ctevice for the new application. This pro-
tion port can handle sixteen new devices. Expansion becomes both vides a great deal of flexibility to respond to quickly changing
~.asy and cheap. Building large systems is a matter of linking more production demands, material conditions, and equipment situa-
held-level networks to the host-level network. tions. Unused functions can be put into use at a later stage. For
example, operators can put actual feedback from a valve position
The FCS architecture is the key to the ability of a system to expand into use without having to modify the valve positioner, running
at little a~~itional cost because there are no expensive central units. wires, or adding any AI points to the control system as was neces-
In a traditional system, when a site adds loops an additional I/O sary in the days of analog feedback. With a fieldbus-based system
subsystem or controller will soon be required because there aren't it is easier and more affordable to make small changes. Thus, small
enough l/0 channels or processing power. Adding that loop may improvements can constantly be made without costly change
be very expensn.:e, wh1ch may cause an idea to be cancelled or put orders to the suppller.
on hoi~. S1mple Improvements that were previously prohibitively
expensive become feasible using bus technology. The fundamental Protected Investment
hmtt.ahon of the scalability of the traditional system architecture is
that Its resources are .drained as loops are added. Every instrument A great obstacle to improvement may be finding that a system
added takes away some of the finite resources of the system. The bought only a few years ago has been replaced by a new model
hnuts for controller memory capacity, I/0 counts, controller that requires a complete replacement or expensive gateways, soft-
( I
Chapter 2- Benefits, Savings, and Doubts
Fieldbuses for Process Control
·ware upgrades, and services for integrating the nevv with the exist-
ing. However, once laid down standards don't change very
quickly, and therefore manufacturers are forced to go that extra
m.ile to follow the standard when inventing new features and
improving performance so products remain compatible with exist-
ing equipment. The stability of the fieldbus technologies therefore
protects the investment a firm has made in a control system from
the obsolescence that often occurs with proprietary technologies.
Future compatibility is ensured, and the threat of complete replace-
ment and reinvestments is removed.
Another trend is the move away from discrete switches, for exam- Migration and Integration
ple, for pressure, and toward the use of transmitters even in simple
trip applications. The reason is again that simple discrete devices Most sites contemplating the introduction of fieldbus technology
provide no diagnostics, and it is therefore imposs!ble to tell if the already have an existing system and :components that have to ~e
state really has not changed or the switch has failed. This uncer- integrated with the expansion. Even m the case of a new greenfield
tainty may lead to potentially dangerous situations. Transmitters
Fieldbuses for Process Control
Chapter 2 _ Benefits, Savings, and Doubts
project there is often one or more conventional subsystems that shutdown for safety reasons or vvould result .i~ great finadncialtloss
have to be linked up. A number of solutions already exist in the F st plants cntJcal loops o no
market, including converters for field instruments, gateways due to a production stop. or mo. f -' 1 I a traditional svs-
exceed 20 percent of all controls, and o t~n css. n .. ,-to
between networks, and OPC servers for systems. Old and new 1/0 modules were reqmred for the cnhcalloops
d
ten1 rc un and t f h · nodule
basic con trot advanced control_ safety-related control, and so on
ens:Ire that they arc still operational even i t e pnmaryl,/0 mo-d-
can therefore be integrated. Chapter 5, "Integrate and Migrate," . II y remove d . The cost for one-to-one
covers these aspects. fails or is accidenta f . lc I/0 and in
ule redundancy was more than double t_hat o smg
most cases made it prohibitive to use it tor all loops. A c?~mon
What If the Cable Breaks?
fieldb~~-level network solution is to allocate on!~ one ~ntJc~l~oi~~
er bus se ::rment, with the rest of the ~evtces on. t lC ne wor . e .
A field-level netvvork typically interconnects twelve or at most six-
teen multidropped field instnunents that provide power and com- ~sed for n~ncriticalloops or monitonng. Thus, Jf the c.able fatls, It
munie<ltion on th(' same pair of wires. The cabling is not redundant, affects only a single critical loop .. This ~~~l.os:.~~;~cy)J:l~~ci~!rallation
that is, there is only a single pair of wires, which of course means becomes the case for every loop Ill an m nnsi _' .' , -
that cable damage results in a loss of communication and power for where the network is divided up into s~vcral seg~1ents.by repe~t
the devices on that network. However, for most practical purposes ing isolated safety barriers. This is particularly scb) Jf cnftdity ~Ol'lC~~t
. h l'mits the num er o evices
sites do' not need to be concerned about the availability of multi- barriers are used smce t e power I I" Th tis almost every
dropping, and several measures (presented in chapter 10, "Avail- t hly equivalent to one oop. a ·' c
an a moun roug . h f ld-l· el network does sup-
cJbility and Safety") can be taken to minimize impact. A cable is a loop has its own Wire. However, t e Ie ev ven-
passive component and therefore rarely fails on its own. The great- port redundant linking devices and field power supp.ly. In ~~n
est risk to network integrity is during maintenance work when the tiona! s stems the wire pairs for sixteen or more devt~es v. _ere
' . Y· ' d , art of the same single multi-core cable,
wire may accidentally be disconnected or short-circuited. The sce- generally concentrate asP ld be lost even
nario is similar to the situation in which an I/0 module in a con- and in case of damage to the cable many 1oops wou
ventional system either fails as a result of over voltage, for example, if redundant I/0 modules were used.
or is mistakenly removed during maintenance.
The more distributed the system t he sm~ 11er fthe impact
1 a afew
failure
field
A field-level network populated with sixteen devices supports at would have on one of its components. 1here ore, on y
most eight control loops since a loop requires a minimum of one instruments rely on one wire.
transmittet~ one actuator, and often an additional device for an
auxiliary function. Furthermore, some of the devices are used for As far as the availabilily is concerned multidr~1p netfV:~~~i~!~:sed
. ,., i/0 modules Hovvcvcr, lC
equivalent to mu I tic 1tannl'
•
monitoring and alarm. Therefore, there may be on average perhaps . .. . l. 'I 'ndJ'cation
only five control loops per network. Because of the high level of sy'stems ;ne safer lJecause they P rov 1de better a1. urc 1 t ·
· therefore compare favora bl ), with conventJOna 1sys ems,
They
decentralization only a few loops, which corresponds to a very
small section of the plant, are affected by a single fault. The extent which do not detect transmitter and valve faults.
of the damage is no greater than that caused by an 1/0 module
failure on a conventional system since one module there may have What If the Controlling Device Fails?
as many as 8 to 32 inputs (and much less than that in the case of an .
111 FOUNDATION Fieldbus-based system when co~-
1/0 backplane failure). In other words, because of the high level of What happens a · e ositioner and that posi-
trol is performed by, for example,. a va1v P f
distribution the failure of a field-level network is far less critical
than the failure of a remote-I/O network or control-level network tioner fails? This situation is no different :r~~~~a~~it;oner the pro-
in a traditional system. By distributing I/0, a site does not need to conventional control system today. If t~e. ~he val~e will go to its
cess cannot even be controlled manua Y'
use redundancy to achieve sufficient overall plant availability. .. If th positioner does not opera 1e,
mechanical fail-safe positiOn. e . f t tworked solu-
having a controller makes no di~fere:lce. 1n 'tal ca,caonneventional ~na-
Plants normally identify a few critical loops arotind the site for . · 't' 1 in companson Wl 1
which they need higher availability than other loops. The reason tion agam fatrs posi IV€ Y f d' t' nd feedback
. h tt ' lack o 1agnos ICS a
for this is that a failure of a critical loop would either require a log solution because t e 1a er 5 . . h f 'led Therefore,
means it will miss the fact that the positiOner as ai .
Fieldbuses for Process Control
- . - - - - - . . , - - - . - - ...... -
Chapter 2- Benefits, Savings, and Doubts
The more distributed the system, the smaller the impact the failure
of one of its components will have. Therefore, only one loop relies
on each field device.
Ethernet Determinism
Earlier forms of sha.rc·d-mcdi;:~ Ethernet, such as lOBase-2 coax or
10Base-T with shared hub, arP considered "nondeterministic.'' This
is so because all the devices are fighting over the use of the bus,
and sometimes two nodes access at the same time, causing colli-
sion and a random pullback time. However, by using switching
hubs the network is not shared since the switch supports multiple
simultaneous communications between different pairs of nodes. EXERCISES
There is only one device per network, which essentially eliminated 2.1 Do the Ethernet standards define the meaning of the data
colllsions. on the bus?
2.2 Who provides the device support files, the device
The consensus appears to be that a network is deterministic if the
manufacturer or the host manufacturer?
chance of message delay is Jess than the chance of message loss as a
result of noise, that is, one in ten million. Ethernet behaves deter- 2.3 Are parameters associated with a particular type of sensing
ministically up to some 50 percent loading for switched networks. stored in a transducer block or function block?
This is quite easy to achieve for process control because themes-
2.4 Does diagnostics make devices safer?
sages are short, especially when using 100 Mbit/s.
2.5 Are fieldbus technologies that employ floating-point
Fieldbus Comparison Table format or scaled integers used for analog values?
The main features of the three field-level network protocols are 2.6 Does fieldbus require measurement ranges to be set?
summarized in table 2-1. The benefits that can be achieved from
2.7 Is foUNDATION Fieldbus configuration based on tag or
fieldbus depend largely on the technology chosen and how well it
address?
is implemented in the products chosen.
2.8 Does diagnostics improve system availability?
2.9 Can fieldbus technology be used in safety-related
applications?
Table 2-1. Comparison of field-level network characteristics.
Installation and
Commissioning
Before installing any device make sure you carefully read its
manual and follow the manufacturer's instructions and local
regulaticms.
HART
Devices that are a hybrid of the analog 4-20 rnA and digital com-
munications are called "smart." The communication speed is low,
and normal instrument-grade cable can therefore be used. Its pos-
sible to replace analog devices with smart devices without chang-
ing the wires. The HART communication is rnodu lated as an AC
signal superimposed onto the 4-20 rnA DC signaL The communica-
tion signal is symmetric and therefore does not affect the 4-20 rnA
signal. The digital communication and analog signal can hence be
used simultaneously, which makes it possible to do configuration,
diagnostics, checks and the like while the device is.operating in the
control loop. The HART communication signal is in a frequency
range that is filtered out by most analog devices. This allows them
to operate normally undisturbed by the HART signal. A device
67
(
Fieldbuses for Process Control Chapter 3- Installation and Commissioning
with 4-20 mA input or output can be connected in the loop as series, which causes a \'oltage drop ovL~r each. Technicians must
usuaL ensure that the power supply is sufficient for the total resistance of
cable and the input shunts otherwise there will not be sufficient
Topology operating voltage for the field device when current is at its
For the HART communications protocol there are two possible maximum.
topologies. The tnost common by far is point-to-point wiring that
input shunt resistors, must be 230 ohm or greater for the HAET at most 21 rnA, then the maximum allowed loop resistance is 571
signaling to work. Up to tvvo masters G1n be connected to a HART ohm:
netvvork at the same time. The primary rnaster could be a pcnna-
nently connected interface such as a remote terminal unit (RTU) or 1
24-12 571 ohm
a multiplexer for the host. The secondary master is the most com- 3
21 X 10-
mon tool and is generally a portable handheld terminal that is only
connected temporarily when vvorking in the field. In order for the
Given that one input shunt generally is 250 ohrn, the combined
interface to work it must be connected between the field device
resistance of cable and other devices shall not exceed 321 ohm.
and the resistor. If the interface is connected between the power
supply and the resistor there will be no communication because
the signal is short-circuited by the power supply. Output devices such as positioncrs and electric actuators in point-
to-point topology are connected to the single-loop controller or
Point-to-Point I /0-subsystcm output module just like their analog counterparts.
In the point-to-point topology only a single field device slave is for most output devices no resistor is required since the field
connected on each pair of wires. A transmitter may be loop pow- device itself has a sufficiently high resistance to satisfy the HART
ered or separately powered, b·i.it the connection is the san1e as that rC'quiremcnt (figure 3-2). The 4-20 mA output must be able to drive
of a conventional analog transmitter. Many times, a 230-ohm resis- a high en~:n.1gh load to overcome the voltage drop over the field
tor need not be added to the current loop since many recorders, device. The voltage drop across smart positioners is generally
indicators, single-loop controller, ;:md I/O-subsystem input mod- higher thi1n for conventional analog positioners. In split-range
ules alrcad~l ha\'l~ J 250-ohm shunt resistor on their input applications where two positioncrs are connected a distributor
(figure 3-1). may be required to generate two separate signals to drive the indi-
vidunl devices.
Power
Supply
+ 0----,-:::~:~- --r:~-'-H~~dhe: ~--~
d
----~-··~~-=------=~=,--~
r- - ~d~:~: ~--· l
_. : -
l__--".._1--- - - - - - -
Termmal
L_j: ~ Term>nal Ci~ J 1
,--
1
- - - - - - - - - -------- - - -
EXAMPLE 3-2
---
- ---------l loop powered or separately powered. Loop-powered .transmitters
ncnerally have their output set constant to 4 mA, that IS, the output
I A positioner may need a minimum of 11 V to operate and 540 m of I ~o longer reflects thL' process \'<lrioble. ThenAore, the current in the
wire carries no useful information.
cable to be connec_ted. Given that the current in the loop is at most 21
rnA and that there rs a cable that has a resistance of 22 ohm/km in
each of the two conductors, then the current output must be able to I
-r:.;l~~·"' J~~r~ r~
swing up to 11.5 V:
1
U ~ Rx! ~ 2x22x0_54x21xl0 +II~
I
1
I LSV
1
3~4.
§Terminal
·-·-·~"'"'-·-·-·
r --; Power
!''"Supply
+
----~==-~
I
/
Handheld
Termrnal
a
~
-~-~,;- .00
,--------------------------
EXAMPLE 3-4
3:J--------- --------·----------l
I
U = Rx 1 = 15x4x 10" 1 x(250 + 2x 22) + 12 ~ 29_6V
lEXAMPLE
Thi~ results in a large total current for a network with many Intrinsic safety put additional limitations on these lengths, in some
dev1ces. The voltage drop over a resistor would be too great. cases making the maximum distance shorter. The cable shield shall
Theref~re, HART power supply impedance should be used instead only be grounded in one point, generally at the I/0 subsystem.
of a resistor for rnultidropped controlling devices. BecauSe the
power supply impedance has a very small resistance the DC volt- Intrinsic Safety
age drop is smalL
Intrinsic safety is a method for preventing ignition caused by elec-
An in:portant consideration for HART multidrop networks is the trical faults by limiting the power available to the bus wires in the
scan h~ne. _Because it ~akes ab?ut a half second to one second to get hazardous area (figure 3M5). This allows devices to be connected
~ readu:g trom each field device, depending on the master and the and disconnected under power. The basic concept of intrinsic
slaves~ It may tak~ as much as 7.5 to 15 seconds to get the reading safety and area classification is beyond the scope of this book, but
f~~m flfteen m~lh~roppcd transmitters. Although this may be suf- Electrical Jnsfr111nents in Hazardous Locations (fourth edition, E.C.
fJcwnt for momtonng many processes, it is not fast enough for Magison, 1998, 1-55617-638M4) is an excellent reference on the sub-
most control loops. ject. Most of the intrinsic safety rules and principles that apply for
all systems, such as grounding, also apply to networks.
Cable
HART devices are able to w~rk with the type of cables commonly
:1s~d for mstrument mstaiiatton. Because of the electrical character-
IStics of cables the HART signal gets attenuated as it travels down
t~e _wires until it is too weak to be picked up. There is therefore a
Resistor
hm1t to the cable length (table 3-1).
Hazardous Area
I
l
networks. This is done either directly with an interface or via an
I/0 subsystem such as a multiplexer or conventional I/O modules
that have the ability to let HART communications pass through. A
multiplexer generally has many communication ports, thus sup-
porting several HART networks.
Figure 3·6.
Smar)
Handheld Terminal
Interface
Generally, the computer interfaces plug into the RS232 serial com-
munication port (figure 3-7). This makes it possible to use a note-
book PC for maintenance work. The larger screen makes it easier to
monitor the device data, eliminating several levels of menus.
Multiplexer
A multiplexer has several HART communication ports, each con-
nected point to point or in some cases multidrop to the field
devices. The multiplexer is typically a primary master that is per- Figure 3·7. HART interface for serial port. (Courtesy of Smar)
manently connected to the networks. The multiplexer continu-
ously scans the process variables from all transmitters,
independently of the host, and at the same time receives basic
device status inforn1ation. The host in turn reads the process vari-
ables from the multiplexer.
( (
7
Surge Protection
HART devices me generally designed to operate on voltages up to
-l
45 VDC. This is in about the same range as for FOUNDATION Field-
bus Hl and PROFIBUS PA because the IEC 61158-2 standard speci-
fies a normal range of 9-32 VDC, with a maximum of 35 VDC.
Therefore, the surge protection methods and equipment for all
three buses are very similar. A surge is a voltage that is much
greater than the normal operating voltage, typically only present
for a short time, and would damage unprotected electrical equip-
ment. A direct lightning strike, lightning strike to the ground
nearby, or switching of inductive loads may cause the surge. The
surge voltage can exceed tens of kilovolts and last only for a frac-
tion of a second. Damage can be prevented using surge-protection
devices. Direct lightning strikes are rare, but strikes to the ground
are common in some areas. They cause currents of tens of kilo
amps to flow through the soit which in turn cause large ground
potential shifts between points separated by some distance.
Although this does not present any problem within a confined
location such as a building, the electrical earth potential difference
between two locations can lead to currents of thousands of amps
flowing through and destroying a network connecting the two
points. Surge protection should not be applied only to the network,
but also to the power supply, telephone lines, and the like. A surge
protection device has to be installed at every field instrument as
well as at the marshalling panel where the field wiring enters to
the host (figure 3-8).
The surge protection device is normally deactivated, but when a Figure 3-9. Field device mounted surge protector. (Courtesy of Smar)
surge exceeds the threshold voltage the internal circuit, such as a
gas discharge tube, diode, and varistors, channels the current to
earth instead of through the de\Tice. Therefore, a good earth con-
nection is very important. The surge protection device for field
tiff! Fieldbuses for Process Control
Chapter 3- Installation and Commissioning
Good surge p~·otection devices survive repeated surges and let the
AI'\ Vcnfication can be tnkc11 further using t!JC loop-test paturc in
protected devices resume normal operation once the surge is over.
"flllhh transmitters. 1llrough the handheld terminal, the tm115111itter is set to
fhe ho~t~end surge protection device is typically mounted on a
DIN rail m the marshalling cabinet. generate a specific output curre/ll i11dependcnt of the applied input i11
order to simulate n11y partiwlar process co11dition. It is therefore po;;;sible
Device Commissioning to test oiJt the loop integrity and control strategy response for 110rmal and
c.rlreme process conditions without changing the process or having to
HART devices have two addresses, a unique hardware address ve1!lurc into the field with a simulator.
and a polling address. The unique hardware address consists of a
~~nufacturer code, a device type code, and a unique identifier. IEC 61158-2 (FOUNDATION Fieldbus H1 and
_fh1~ ensures that no two addresses in the world are the same, clim~ PROFIBUS PA)
matm~ the chance of conflict. Every device is shipped from the fac~
tory 1v1th thC' hardw~re address set. It cannot be chnnged and ccm Both FOUNDATION Fiddbus and PROFJBUS PA have physical lay-
therefore never be m1xed up. The hardware address is normally ers based on IEC 61158~2. This standard is purely digital, with no
~1ot shown to ~he us_er. For point~to~point mode the polling address 4-20 mA on the network as in the case of HART. Although they are
IS set to zero, m which case the 4~20 rnA output is still active for electrically identical, the two types of devices cannot be mixed on
transmitters. For multidrop mode the polling address is set in the the same network. The electrical installation is the same, but the
range of 1 to 15, which in the case of transmitter nwde sets the out~ specifications use slightly different terminology, and the commis~
put fixed at 4 mA. If multidropping is used, every field device sioning is done differently as well. Surge protection for FOUNDA-
should be configured with a different polling address before it is TION Field bus and PROFIBUS PA is performed in the same way as
connect_ed to ~he netw?rk. This is typically done by first connecting for HART because the operating voltage range is about the same.
the devtce pomt to pomt and manually assigning the new address The field-level network is relatively low speed. This makes instal-
from the handheld terminal. If the polling address is duplicated lation quite forgiving in comparison with many other protocols.
commumcahon cannot be established. The rules for topologies, cable, distances, device quantities, and the
like arc not very strict.
The digital communication makes commissioning a field device a
~uch faster process. Once installed, device information can be ver~ Terminology
tfled from the control room to ensure that the correct device has
been connected to the wire (figure 3-10). A network may consist of one or more segments, but in most
installations only a single segment per network is used (figure
3~11). Multiple segments are connected using repeaters or other
devices containing a repeater, such as a safety barrier. A segment
must have two terminators, one in each end. Thus, a network with
Manufocture:Srnar multiple segments has several terminators in total. Often, the ter-
Device Type: LD301
minator is built into another device, eliminating the need for a sep~
1643715
I ""'·"''•· Ser. #: ~.~Q.HQ ....
arate terminator. From a software configuration perspective the
Main Board Ser. #: ~~1.Q§.L. hardware network is sometimes called a link. Field bus devices
Software Vers. #: 5.06 connect to the network through their communications port. Field
HflRT Univ: 5 Spec.Rev: 3
instruments typically have only one port, whereas the interface for
the host typically has several ports in a modular fashion.
Figure 3~11. Simple network with only one single segment. Figure 3-13. Network with multiple series segments used for long distance.
which many devices are connected to a single interface port Devices on the field-level network may either be powered by the
(figure 3-12). network, that is, bus powered, or powered separately. Some
devices may be both bus powered and separately powered, as in
the case of many electrically actuated valves where the positioner
typically is bus powered while the actuator is separately powered.
The field-level network devices are powered either by a regular
power supply through an impedance or, in the case of intrinsically
safe installations, through a safety barrier.
Figure 3~12. Network with multiple parallel segments common for intrinsic The terminator (figure 3-14) is a simple component that does not
safety.
communicate. One terminator is connected in each end of the net-
work. The terminator has two functions, the first being the classical
terminator function Of preventing signal reflection and subsequent
communication errors. A device transmits by rapidly changing the
Fieldbuses for Process Control Chapter 3- Installation and Commissioning
---- ----------
mounted at the ends of this trunk. Because the power-supply end
of the network typically has a built-in terminator, only the field-
end terminator has to be purchased as an individual part. A seg-
ment is not a spur. Every segment of a network is using a repeater,
and each can have several spurs.
b n~~
up y a
e ermmator only
t I
Tecm\natoc
Trunk.
--<r-'>
~
I' Spuc
Junction Box ~
Terminator ft~"-BJ
, ___ ® I
~as ~o t~rmmals and IS polarity insensitive (figure 3-15). On a test
b e7~ 'a flel~bus network may function with only one terminator
u m a real mstallation with long wires it will not work reliabl '
Because there are different terminators for ea•'h type of t ky Figure 3-16. Bus topology with terminator at end of the trunk at last device.
is · t tt . . ._ nc wor 1t
sti~:k~:L~7n ~~~s;,1~~~r2mm~tor designed with the characteristi~s
1 ~ - anu not some other kind of bus.
The spurs may connect to the trunk either by using small junction
boxes (figure 3-17) or by using molded "T" connectors. The advan-
tage of the bus topology is that it minimizes the amount of cable
that is required to connect the devices. Hmvever, because several
junction boxes are required for the spurs there will be many con-
nections. The terminator is typically mounted in the furthest junc-
tion box along the trunk.
For tree topology, the trunk runs into the field where it branches
out into the individual devices from a single junction box (figure
3-18). Since the trunk ends in the junction box the field-end termi-
nator is mounted in the junction box. This topology minimizes the
number of connections, but the cable length will be longer, espe-
Topologies cially if the devices are not particularly close together. Tree topol-
ogy is common when older plants are reinstrumented while
The field-level network can be laid out in two basic to olo ie b retaining the existing wiring.
:o;ology and tree topology. An important difference ~etw~e:'th~s
v. o topologu:~s.ts where the terminator shall be motmted. For bus Devices can be installed and removed under power. However, care
topology, a mam cable called "trunk" typically runs f tl must be taken to ensure that the continuity of the trunk circuit is
shallmg panel n th rom 1e mar- maintained and that loose leads don't touch each other and short-
.t h ear e centra1 control room out into the field until
~ reac es the. last device., passing all the devices along the wa circuit the network. This would mean a loss of communication and
~om the ~am trunk shorter wires called "s urs" conn ~· . controls for the devices on the segment.
:~~~! d~~Ic~s easy~~ i~=~~~-
(figure 3-16). For bus topoloir, it is
lS e ongest cable: the trunk. The two terminators are
/
\
"-~;;~ FLJbcoes "" hocess Control
Chapter 3- Installation and Commissioning
L "~-~---~ ..
Figure 3-19. Wea "ther p-"roof quick~con~ect junction box. (C_o_u_rt_e_s_y_o-::f::T:-u--:rck)
Figure 3-17. Junction box suitable for tapping spurs off the trunk. (Courtesy
of Smar) spur is isolated from the rest of the bus to prevent prolonged dis-
ru tion of the network. Active junction boxes can be used _to ensure
th~t not all of the devices on the network will be affected tf a s~ort
circuit caused by improper handling_ of the :VIres occurs. Qmc -
connect ·unction boxes are typically mdustr~al_ly ~ardened ar:d
weather~roof, so there is no need to mount It mside another)unc-
Terminator
tion box. This eliminates the need for cable glands and termmals.
Terminator
Trunk~ Junction Box".,~
Terminator
--l
Trunk Junction Box
Figure 3-18. Tree topology with field-end terminator where trunk ends and
spurs branch out. Terminator
It may be helpful to use junction boxes with plug-in connectors. This will
facilitate the quick connection and disconnection of device wiring without
the risk of disrupting the bus !figure 3-19)"
Figure 3~20. Mix of bus and tree topologies.
Yes Yes
Size
I Length
O.B mm2 (AWG 1B) 1,900 m (6,200 ft)
Type
A
the n k • · n ges m erconnect
. 1any networ s throughout the plant, allowin dis ersed ·~····
Length
The total length surruning the length of the trunk and that of all the
spurs must not exceed the limitation for the particular cable type,
(
{
Fieldbuses for Process Control Chapter 3- Installation and Commissioning
for example 1. 9 km in the case of type A cable. For longer dis- Unless the distances at the site are very large because the control
tances,. a.network may reach farther thnt is made from several seg- room is located far from the field or the devices are widely spread
ments JOmed by repeaters because the cable limit applies per out, there may be no need to make cable-length calculations for a
segment. The shorter the total cable length the better, so avoid majority of the networks. For most installations, the total distance
uru1ecessarily long cable routing. For most of the distance, the of any network is far less than the maximum allowed for the type
main trunk typically is a multi-core homerun cable that is shared of cable used, and length is thus not a limiting factor. Perhaps only
by many networks from a field junction box into the marshalling in some suspect, borderline cases where wire has to run farther to a
panel. remote plant unit will calculation be required.
The total cable length for the network example in figure 3-21 is cal- Keep the parts of the cables that have no shielding, or where the
culated in table 3-4. conductors are not twisted, below 2 percent of total cable length or
8 m, whichever is shorter.
------------------
When bus-powered devices arc used, which is almost nlways the
case, the voltage drop along the wire G1ttsed by the current con~
sumption of the field devices also limits wire length. For maximum
range and number of devices the supply voltage shall be as high as
possible, the wire cross-section as large as possible to reduce resis-
tance, and the field device current consumption as low as possible.
The maximum distance can be calculated using Ohm's law.
--------
EXAMPLE 3-5
-------- ~-
- -------- - ---~
L ~
u 21-9
- - = ---,:_:__ · --- ~ 1.4
I Xr 12 X] 0 . X l6x 2 X 22
Number of Spurs 1 Device 4 Devices nals and non-field bus signals should not be allowed to coexist
-····- within the same multi-core cable because noise may be introduced.
25-32 - -
-
-
"
This is particularly true for switching of heavy loads and drives,
19-24 30m (100ft) - -
but even some older communication signals will cause noise as
r----- 15-18 60 m (200ft) 30m (100ft) -
-~·--· -··- -.. --~--- --~-----
well. If you must have the wires cross, make sure they only ~o so at
13-14 90 m (300ft) 60 m (200ft) 30m (100ft right angles. The ficldbus signal is polarized, but most devJCes
1-12 120m (400ft) 90 m (300ft) 60 m (200ft) 30m(100ft) have circuitry that detects and corrects signal polarity. However,
--
many bus-powered devices require correct polarity because of the
Particular attention should be paid to spur length with regard to power supply-
tree topology since every branch is a spur, and each branch may be
On the network all devices are connected in parallel, that is, all
quite lo~g- The junctio~ box should be mounted centrally among
the devtees to av01d wtre runs that exceed the limit for spurs (fig- negative terminals together and all positive terminals together.
ure 3-22). If any spur is longer than 120m the terminator should be Preferably, you should use color-coded and properly labeled wires
moved to make the spur part of the trunk to distinguish positive from negative and to identify pairs in multi-
core cables. Trunk cables should also be properly labeled in the
Fieldbuses for Process Control
Chapter 3- Installation and Commissioning
----~~- ··--·----~-·---~
Optional Earth
Figure 3~23. Plug~in type quick~connection for field instrument wiring.
{Courtesy of Smar)
ancc is free flo<lting in a balanced mode 1 th Every segment has to have a terminator in each end. However, typ-
impedance must be bal<lnced or galvanic~~~~ is~fa~~~~r supply ica1ly the repeater already has terminators built in. and all that
needs to be done is to make sure that the terminators arc enabled
Repeater or disabled as required (figure 3-26). Repeaters do not provide
pmver to the segments, so power must be supplied for those seg-
how long a network segment can b 1
Because of the signal attenuation a ion the wi ' . . .
res there IS a hmtt to ments that have bus-powered devices. Power must also be sup-
that refreshes the timing of the sign:l . rer:ca~e: contains a chip plied on separate terminals for the repeater.
boosts the level as the signal is regenc~=~=~v~ t~~~ ~~~end an?
t~e repeater restores the original symmetry and ~~r ~nd. /hus, AI". It is !Jelpful 1J the repmter is isolated and has a termifwtor built ill 011 both
stgnal, overcoming attenuation. There . cater i, a_m,r lt~ eo the .,.; ports.
typically golvanicaJly isolated. Repcat!s may ~~~~~~e,ch~I:al and
I~cct segments together to form a larger nehvork.ls c used to con- ----·~-----~- -----~---~ .. ----~--~------~--------~------- --·-
tcpeaters
I can be connected to the'"''lC. ne t wor'k segment
do
m.anyHow
os 32
~ve~, t 1ere nlay be no more than four repeotcrs between ~ny tw-
. evJ~es on tl:e network, that is, a maximum of five se o_
J<ltc two dcvtces. (figurt'- ~3-2")
-' · Iffour. repcatf•rs ~ . gmentssep,l-
d·
series, a total distance f 5 t. 19k c . are connccte m
o lmes . m or95k b h.
using type A cable. ~ · m, can e ac teved
Repeater
Repeater Repeater
~ .... ~---~·--~-~-:-::~c--- - - -
I
Chapter 3 _Installation and Commissioning
Interface
linking Device
data paths should be maintained all the \vay to the host worksta- tion. It is not reallv available as a device on its mvn but rather built
tion. This \Vill ensure that plant-floor data renches the operator into a multi-port linking device or interface card.
even if one interface fails by always providing a window to the
process (figure 3-29).
Field-level
(
r&~·-"
. ."Iii. Fieldbuses for Process Control
Chapter 3 _ Installation and Commissioning
___ , __
-·------[j----,-···-.'v··l
+
L~~
Terminator
i~'
~e;~~~~sf~:~~~~:1~~;'f~r s~~~~;~:o~~1~;;:::~~~~~~o};~~:~~::~~ons
· · .· ·-L<···~f_____ _LJ_L_I
Power,
--·/mpedilrlce
..-,··.·-.. .·.·.fl
>. .141"'
·•·• Terminator L -'
;Supply ·.-::-. '<.. 1 • ! rovided that they are mounted outside the hazardous ar~a or
fnside flameproof enclosures with proper seals and condmts.
t
cause failures. To achieve redundancy, make sure that for the ost
-------------- -------
:-=:;::;::-;;::;:~~~~-·-------~
Figure 3·33.--::;;-
The safety barrier separa t es th e safe and hazardous sites.
so as many devices as possible can be connected to each barrier. matching devices and barriers. Since several devices are multi-
.1 The pmver consumption is the main limiting factor to the number dropped off a single barrier you will need to compile the entity
of devices that can be used on the intrinsically safe segment. High parameters of all devices to match against the entity param:ters of
power consumption can push the limit well below thirty-two the barrier. Jn the traditional entity concept, the cable capacitance
devices. However, barriers may be multidropped, which still and inductance are considered concentrated and therefore must be
results in sixteen devices per interface port. The barrier may be a taken into account when considering the total capacitance and
zener barrier or an intrinsically safe galvanic isolator. Intrinsically inductance for the hazardous side segment of the network. For the
safe fieldbus devices arc current sinking and do not provide power entity concept, barriers with linear output c~aracteris~ics are used
to the network. Even devices that arc separately pm,·ercd draw (figure 3-34). For Exia TIC the output power IS approx~mately 1.2W
current from the bus to enable them to communicate. or some 60 mA at 11 VOC. Because of the current lnmt only a few
devices can be connected to each linear barrier. Similarly, the low-
The number of ~arriers tlmt are required can he minimized by enzployi! 1g voltage output limits the cable length since only a small voltoge
the lowest posszbft> power conswnption for the dct'ices. drop can be accommodated.
(
F .::e~ C~ .crd.
Chapter 3 -Installation and Commissioning
EXAMPLE 3-7
You can calculate the maximum cable length for the barrier in the
example due to capacitance to 670 m, by referring to the capacitance
left over in the budget after the capacitance of the four devices is
subtracted from the barrier limit:
C l54-4x5
L = - - = - - - - = 670
c 200
-------~--
--~-----~--
Uo/U h,'C'1"-~~~""
9V
C=Ccc+Ccs/2 C=Ccc+Ccs
lo
--~f-;:a
c 80-200 nF/km (24:sonF/1 ,ooo ft)
--1
Barrier requirement uo _ ·-•• _Po Em)
Selected Barrier
The effective cable capacitance depends on the connection of the
shield and must be calculated using the simple equations in figure
3-37. If the shield is connected to one of the signal conductors at the The output voltage, current, and power of the barrier in this exatn-
barrier the capacitance is higher than if the conducts are isolated ple is lower than the maximum allowed for the field devices, The
from the shield connected to earth, current provided is sufficient. Thus, the barrier can be used.
It is necessary to select a barrier that has voltage, current, and The maximum cable length is calculated for voltage drop just as it
power output that is lower than what is permitted for the field is for a normal installation becaw;e there is no capacitance or
device with the lowest corresponding parameter (figure 3-38). inductance limitation up to 1 km as long as the specified cable
parameters are followed.
An examPle of the parameters for eight typical devices is shown in
table 3-8. · For an intrinsically safe installation with eight devices using a
safety barrier with 13.8 V output the maximum distance is calcu-
Fieldbuses for Process Control Chapter 3- Installation and Commissioning
lated as 1.1 km, considering only the voltage drop. However, other
aspects set the limit for Exia IIC as 1 km.
Linking
Device
Safe Side
Barrier
Figure Jw38. IEC 61158w2 safety barrier for FISCO. {Courtesy of Smar)
~ Intrinsically safe installation becomes simpler and more economical if you
,_, use galvanically isolated barriers based on the FISCO model with a
lmilt-in repeater and terminator.
It is important that the barrier and field devices all be PISCO certi-
fied. Non-FISCO barriers and devices cannot be used in FISCO- Host Preparation
style installations. FISCO field devices must be able to handle the
high power output of a FlSCO barrier. To be compatible with a typ- For the host to work with various types of field devices made from
ical FISCO barrier the Pi (Pm<:~x) of the device should be larger than different manufacturers the appropriate device support files have
the typical 1.8 W provided by the barrier. to be loaded. If the files are not pre loaded in the host, they will
have to be installed. Typically, the configuration tool has a dedi-
Repeating Barriers cated folder for support files with subfolders for each manufac-
turer and device type (figure 3-40). To prepare the host you should
Because each safety barrier, and in particular a linear barrier, only copy the device support files into the appropriate folder. The sup-
connects a few devices it would be rather uneconomical to connect port files are normally shipped wHh the devices, or they can often
only one barrier per communication port. Some devices have a cur- be obtained in advance from the manufacturer's web site. This
rent consumption that is so high only two devices can be con- enables you to start configuration work before the devices are
nected to a linear barrier. If you use barriers with built-in repeaters received. As more devices and new revisions become available you
it becomes possible to run one safe area segment from the commu- must install their support files before they are used. The standard
nication port to several barriers, each one of which has a hazardous files defined in the specifications that the device manufacturers are
area segment. Thus, a larger network is formed and it is possible to required to provide are as follows:
have a full sixteen devices per network (figure 3-39). Built-in
repeaters eliminate the need for external repeaters. FOUNDATION Field bus: Two device description files (FFO and
SYM) and one capabilities file (CFF).
Fieldbuses for Process Control
Chapter 3- Installation and Commissioning I
PRO FIB US: One device data sheet file (GSD) for class I master Device Commissioning
and additional files related to class II master. Standard device
description files are not yet used. for FOUNDATION Fieldbus the node address assignment is auto-
matically handled by the linking device or other interface so the
To ell joy full intcropembility it is good idea to choose a host that can field device can be connected directly. For PROFIBUS, the device
suppo~t third-party devices without proprietary files from the host address must be configured manually before the device is installed
manufacturer. on the operational network Once the installed device is connected
to the network the linking device or other interface will detect it
Most configuration tools for FOUNDATION only require the stan- automatically. The device will then be displayed together with all
dardi~ed file~, but in some systems the host may require additional the other devices on the same network in the live list for each net-
propnetary files made by the host manufacturer for each device. In work in the host application (figure 3~41).
the cases where proprietary files are required the supplif>r would
typ~cally h;,:ve a shortlist of the manufacturers, device types, and
dev1ce versions that the host supports.
If the device docs not show up in the live list of the engineering
tool it is most likely connected to the wrong nehNork. In this case,
you can find it in the live list for another network Another possi-
IOSKB 5YM Fie
bility is that the device is not vvired or operating properly. You will
l6KB CFF fje then need to do some troubleshooting. The live list is thus an excel-
254K8 FFOF1Ie
120K8 $YMF1Ie
lent tool for commissioning, since it is very easy to confirm proper
161(8 CFFF1Ie wiring of the field instruments. To ensure that a device has not
258KB FFOF1~
IZHB 5YMH"
been mixed up with another one on the same network that was
16K8 CfFFde installed at the wrong location (process point), the device can be
temporarily disconnected to confirm that the correct tag disap-
pears from the live list.
Figure 3-40. Three FoUNDATION Field bus device support-files for each
version of each device type. It is a good idea to start the device configuration in the engineering
tool off line as soon as the detailed engineering is finished, even
before the devices arrive on site. Once the devices have been
PRO FIB US is drafting an FDT (field device tool) concept based on received and connected to the network the ready device configura-
Wmdows software components. An FDT is a frame application in tion can be downloaded immediately.
the host from which device configuration will be done. Each device
type will have DTM (device type manager) software supplied by For further reassurance use the engineering tool to retrieve
the dev1ce manufacturer, which should be installed onto the FDT. detailed identification information in any device. This information
When a certain device type should be configured the FDT will start will enable you to check the tag, descriptor, n1anufacturer, type,
executing the associated DTM software. The configuration will version, and overall health to confirm that it is the correct device
then be done from that software. and that it is functioning properly (figure 3-42). .
i ~ Fieldbuses for Process Control
Chapter 3- Installation and Commissioning
--~----
not detected at first you should set the interface to not skip any
address so no devices are missed. For FOUNDATION Fieldbus, the
device configuration database is prepared based on user-defined
device tags without any association with particular physical
devices. Therefore, the installed physical devices need to be associ-
ated with their respective configuration.
Steam Temperature
0
0 Each FOUNDATION Fieldbus device has a unique thirty-two-charac-
ter device identifier (Device ID), a kind of hardware address th<lt is
Simu!ation6,ctive totally unique and is used to unambiguously distinguish one
Online
device from the others. Like HART and Ethernet, this address is set
in the circuit board by the manufacturer and cannot be changed. A
Smar field device is associated to its particular configuration by correlat~
TT302 Temperature Tranwnitter ing the device configuration tag with its device ID. This is <t simple
1
point~and-click operation since all the IDs of the devices on the net-
3~
work are already in the host live list. If the device tag in the instru-
ment already matches a tag in the configuration the two tags will
automatically be associated. Once attached to the network the
physical device tag can be assigned, if it hasn't already.
.d'- Save time by ordering instruments tlzat have the device tag preconfigured
Figure 3-42. Detail device identification information found. in resou~~-.--" .,., by the factory so they will automatically be matched to the configuration.
block.
Once all the devices are associated with their respective device tags
FOUNDATION Fieldbus the configur<1tion can be downloaded, either for the entire network
at once or individually.
The _linking device or other interface handlesthe addressing of all
devtces on each network completely automatically. For all practical PROFJBUS PA
pur~oses, t~e node a~dress is hirlden and uninteresting to most
users, who mt_eract :'1th the system based on tn3s However, the If the address is not set correctly the device will not be detected
nod~ a?dress IS typically shown in the li\·e list for use by and may even disrupt the communication of the PA devices
spec1ahsts. As a result, FOUNDATION Fieldbus devices can be already on the network. The device address can either be set
commissioned from the control room. Once a device is connected locally at the device or remotely using the configuration tooL
t~ the network it will be det~cted within seconds. It is possible to Depending on the device, local setting may either be done in the
disconnect and connect devtces at any time without disturbing the device using internal hardware DIP switches or, in the case of some
network. devices, externally from the local digital display using local adjust-
ment keys. Remote setting is done one device at the time using a
After the device is identified it will automatically be assigned a configuration tool that is connected to a single device on a separate
node ad?ress on the network, a process that can take a minute or network so as to avoid disrupting the operational networks (figure
~o. In thts process, the device is first given a default node address 3-43).
~n the range 248-251 before it receives its final operational address
m the range 16-247. The device may disappear from the Jive Jist The address must be unique on the network. It is therefore impor-
momentarily during this process. The interface detects new tant to take measures to prevent any address duplication. Dupli-
devices by continually probing node addresses. To speed up the cate addresses may cause control to be disrupted. It may therefore
detectiOn the address range is often narrowed. Thus, if a device is be· a good idea to have a tag and address cross-reference list for
Chapter 3- Installation and Commissioning
Fieldbuses for Process Control
eliminates the chance of conflict. The user can set the IP netvvork
Change Nodeadd•e••
Old Address j@
13
.·I ~hanQe:AddreisS' I
l address or it can be assigned automatically.
(
Iii Fieldbuses for Process Control Chapter 3- Installation and Commissioning
Workstation ..Q.Workstation
Workstation
i ,g. workstation
rlp:c=:jhHub
j
--------------(-- ,_ ,_ J._
Linking
LinkingB ~~~Bunking
Device
Device !Ill Ill] Device
I
.Linking
under power .without_ disrupting other nodes. Because of the high ---::-=~-~D-ev-ice-
speed, the twrsted-parr cable is limited to 100 m (330 ft).
Figure 3-47. Star formation logically represented as a bus topology.
~---------
Although the network formation is a physical star, logically it is a For 10 Mbit/ s there may be no more than four repeaters or shared
bus st~ucture. It IS th~refore often drawn as a traditional multidrop hubs between any two devices on the network. That is, a maxi-
mum of five segments separate two devices (figure 3-49). Hubs can
~us ':tth the hub omitted to make the architecture easier to visual-
IZe (frgure 3-47). also be connected in series to overcome the attenuation associated
with long distances. If four repeaters are connected in series a total
Fieldbuses for Process Control Chapter 3- Installation and Commissioning
~----"
Hub Hub
[ ___ """-"--"-~~""""~
Figure 3-48. Tree topology from joined star formations. ~---J
I
distance of five times 100m (330ft), a network diameter of 500 m Figure 3~50. There shall be a maximum of four hubs between any two
(1600 ft) can be achieved" devices on a 10 Mbit/s network.
,----~~-"-~-----~
same time, causing a communication collision. In this case, they
will retry again a fraction of a second later, but not at the same
Hub Hub Hub Hub
time. All the nodes that share the same network are said to be in
the same collision domain. Because of the possibility that a random
100m 100m 100m 100m 100m delay may be introduced a shared Ethernet is said to be nondeter-
ministic. The possibility of a collision increases wi~h ~he number of
F-iQu_r_e-3--4-9.--Fo_r_1~0B_a_s-e--T-t"Ch_e_m_a-x"'i_m_u_m~n-et_w_o_r_k_d~iam~et'""e-r"'"is--::-50:c0:-m~""_ __j nodes and the network traffic. Collisions therefore put a practical
limit on the number nodes that can share a network, that is, the
number of nodes in the same collision domain.
When you use shared hubs in a tree formation to increase the num-
ber of nodes on the network don't forget that there may be a maxi- Hubs have the intelligence to monitor the comnumications on e<.1ch
mum of five wire segments separating any two nodes. This means port. If too many collisions occt1r the port is cut off or partitioned.
a maximum of four shared hubs can be connected together The hub rejects messages to prevent the maximum allowed by the
between any two nodes (figure 3-50). For 100 Mbit/s repeaters are standard from being exceeded <md to prevent jabber.
classified according to their latency. Class I repeaters are slower,
and the network is therefore limited to only one per network. Class Switching Hub and Bridge
II repeaters are faster, but there can still only be two of them, and
the network diameter is limited to 205m (673ft)" An Ethernet bridge connects smaller separate Ethernet networks
together to a larger Ethernet network (figure 3-51). These could be
The shared hub broadcasts a message received on one port on all networks operating at the same or different speeds and on the
the other ports" When shared hubs are used the network band- same or different media. The bridge has "intelligence" for keeping
width is shared among the usersr and each node gets only a part of track of the Ethernet MAC address of the devices on the local net-
the available bandwidth. When one node is using the network work. It typically learns these automatically by watching the traffic
another node cannot access it. However~ for shared Ethernet there and therefore does not require any configuration. The bridge acts
is a small risk that two nodes will attempt to use the network at the as a filter in which only those messages with Ethernet addresses
Fieldbuses for Process Control
Chapter 3 -Installation and Commissioning
destined for nodes not on the local network arc forwarded to the
~ili/i\1
remote network. A bridge receives the entire message and checks it
before retransmitting it. Erroneous messages are rejected. Bridges
operate independently of the protocol used and are therefore very
versatile.
Figure 3~52. Shared hub (left} vs. switched hub (right}.
•-:-----------,------c---
Figure 3~51. A switched hub connects separate networks together.
AIIJI'- Usc ~zuilching !zubs for best perjomumce n11d cJzoosl! the inrlustrial~o-rad, When several switches or bridges interconnect networks there is a
.,- vers1011 fvr reliability. " 6 L chance that redundant paths link some of the networks, which
then form a loop (figure 3-54). To avoid duplicated messages being
Sm~e Ethernet devices in the plant may be communicating at 10 forwarded by switches in opposite directions in the loop, a S\vitch
Mb1t/s an~ o~hers at 1~)0 Mbit/s. Some s-witching hubs have an must support the spanning tree algorithm. This algorithm prevents
auto-negotJatmg functwn. This allowed them to automatically a loop formation by disabling one of the bridges. Should a failure
de~ect ~he speed on the network connected to each of its ports and occur in a switch the disabled bridge is automatically enabled after
adJus: 1tself ~ccordingly. Messages are stored internally before for- some time is spent restoring communication.
wardmg, which solves the problem of speed differences between
networks. Switching hubs learn which port is a particular node's destination
Ethernet address by flooding the first message for an address on all
ports Clnd then waiting to seC' ·which port a reply is received on.
There is no limit to. the '- th a t cnn lJC
. number of bridges- and .S\VJ. tch"s
casca(j e d as there 15m the case of shared hubs and repc t . 'fl This MAC address learning method works fine when not too many
f h' · h a CIS. 1C
reason or t 1s IS t at other devices communic"te wJ'tl1 b ·ct d nodes are involved. Bridges and switching hubs are therefore suit-
h . • n~~
sw1tc es, not through them, as in the case of shared hubs and able for linking smaller networks, but when larger networks are
r_:peaters ..Therefore, bridges and switches are not delayin the joined it is better to usc a router. Similarly, bridges and switches
Ethernet sJgnal. g forward broadcast messages throughout the netvvorks, which will
adversely affect performance, depending on the amount of broad-
cast traffic. It is recommended that you partition networks using
routers for broadcast containment when you expect a lot of broad-
cast traffic.
Transceiver
A transceiver is media converter that is used to convert, for exam-
ple, from twisted-pair cable into fiber optics (figure 3-55). Trans-
ceivers arc also available to convert older forms of Ethernet like
lOBase-2 into JOBase-T.
Ethernet Media
Twisted-pair media use two pairs, one for transmitting and the
Et~ernet can be made deterministic by using IOOBase-TX and other for receiving. The two pairs are running inside one and the
SWitched hubs and by maintaining a maximum 50 percent loadin same cable, which makes connection easy. Standard Ethernet
through the use. of few nodes per network. In this way, the chanc! tv,risted-pair cable contains four pairs but only two are used. Simi-
of a message bemg delayed is less than the chance of a message larly, the fiber-optic media use two strands, one for transmitting
bemg lost due to noise. and the other for receiving. Standard Ethernet optic cable contains
both strands in one cable. When two nodes are connected directly
••
Fie/dbuses for Process Control
Chapter 3- Installation and Commissioning
---------
~~C.~NN
RT2·TXIFX
..A"'""~
the transmit frorn one node shall be connected to the receive on the
other node. 1l1is is called a crossover connection, and special cross-
over cables are available for a direct connection between nodes.
However, a hub takes care of the cross connection internally, so the
nodes in net\vorks based on hubs connect to the hubs through a Linking
straight-through cable. When two hubs are connected together a Device
crossover cable is also required between them, unless the hub has a
dedicated uplink port, which has this crossover built in (figure
3-56)_
Fi-Qure 3-57. Ethernet cabling model.
To make the netv,'orking easier to administer it is a good idea to
use a patch panel at the hub to facilitate changes. Use patch cords 0 t f the 100 m (330 ft) of cable that is allowed for the seghmendts a
to establish desired connections. For large systems hubs can be u o (33ft) can be used for pate cor s
installed in a dedicated closet. In the control room, workstations maximumk totallebnlgetsh ~~~~ ~bling practice should be applied,
and wor -area ca · b 1· d roper
can be connected through a telecommunications outlet using work which includes identifying cables through !a e mg an P
area cables (figure 3-57). A similar scheme may be implemented documentation.
inside the panel to make it easy to connect and disconnect the
Ethernet devices.
Fieldbuses for Process Control
Chapter 3- Installation and Commissioning
-
Figure 3-59. Wire pair arrangement in straight through {top) and crossover
{bottom) cable (front view).
Table 3-9 Pin assignments for straight through and crossover connectors.
Pair Pin Color Assignment Pair Pin Color Assignment I
1 5 WhitelB!ue Unused 1 5 White/Blue Unused
Unused~ 4 Blue Unused
~,_, ___ - 4 Blue -·
2 3 White/Orange Rx+ 2 1 White/ora·n·ge Tx+
6 Orange-··-·-- ~·--- -2 Orange Tx-
3 1 white/c3'reen
Tx+-·-- - ~ .3 White/Green Rx+
·-·-
Tx- -~ r-e ~crreen·--· --
Green2 Rx-
4 7 White/Brown un"used 4 7 White/Brown Unused~
8 Brown Unused 8 Brown- Unused
··-
Crossover {A) Straight through (B)
-- ~-
(
,~,-
Fieldbuses for Process Control
" Chapter 3- Installation and Commissioning
since c~n~ector crimping is not required, but they may be a bit For example, the 3 km optical segment in figure 3-60 uses multi-
more dtfficult to run through conduits. mode fiber with an attenuation of 3.5 dB/km. Using transceivers
with a 14 dB link budget, the margin becomes 3.5 dB:
Optic Fiber
Optical fibers are not electrical conductors and are therefore l4-3x3,S~3.SdB
i:nmu~e to elcc~rical nois~ and resistant to problems caused by
hghtrung and differences In ground potential. They are therefore If single-mode fiber is used instead, with 11 dB link budget trans-
ide~l for long distances, for example, between buildings. A fiber- ceiYers and maintaining a margin of 3.5 dB, the maximum distance
oph~ ~ort connects two strands, one for transmitting and one for becomes 25 km:
rece1vmg. The two strands are often included in the same cable
one with a protective sheath, called duplex cable. '
1 1-3.5
------ ~ 2Skm
Thcr~ are two ~ypes of optical fibers: multi-mode and single-mode. 0,3
The.fibe_r core IS made from glass and is very thin, typically 62.5
pm m dwmeter, and surrounded by a cladding of 125 pm for multi- Care should bC' taken with short optical cable because the receiver
~ode. T~is is us~tally expressed as 62.5/125 pm. Single-mode may be overloaded. Fiber optics is often used to link shared or
fiber-optic cable lS usually 10/125 pm. For new installations, it is switching hubs together.
~referable t~ us~ duplex connectors with physical keying for con-
SJStent polanzatiOn. The maximum distance depends on transmit- Fiber optics creates no spark and can therefore be run through haz-
ter power and receiver sensitivity and several factors in between ardous areas. However, care must be taken since a too-powerful
such as_ cable attenuation ("loss"), connectors, and splices. Multi- light emanating from a broken fiber could illuminate dust and
mode fiber normally has an attenuation of 3.5 dB/km, typically heating it to the point of ignition. For single-mode, a laser light
reachmg some 2 km. Smgle-mode fiber has much lower attenua- source is often used. Manufacturers have developed a number of
tion, norm~lly as low as 0.3 dB/km, which allows segments as long solutions for automatically turning off the transmitter if the cable
as 40 k~. Smgle-mode fiber is cheaper than multi-mode fiber, but breaks,
the devices are more expensive. Most devices do not have a fiber-
optic connection, so a transceiver has to be used (figure 3-60). Whenever there is a risk of electrical transients, make sure to
remove any metallic shield in the fiber-optic cable within a dis-
tance of one meter from the equipment.
Transceiver
Multi-Mode Wireless
l
I\,
devices do not perceive it since it appears like any other bridge.
Field buses for Process Control
Chapter 3- Installation and Commissioning
The standard for \Vireless Ethernet is the IEEE 802.1t but propri-
etary solutions also exist. Though many lEEE 802.11 bridges are
available, most are for indoor use and unsuitable for outdoor
applications. Rugged outdoor versions generally employ the fre-
quency-hopping option in the 2.4 GHz band, which requires no
user license.!EEE 802.11 supports 1, 2, and 11 Mbitjs bit rates. The
range depends on many factors, including radio transmission
pmvcr, receiver sensitivity, and antenna gain. The typical range is
Surge Protection Device
3-6 km, but conditions and equipment may allow for more. A free Surge
line of sight is also required. Protection
r--------------·-----------------
@7ij) .' ,..•,, ~
Linking
Device
~ ---ccc--- -----
J;L __ Radio
Bridge
Radio
Bridge
Figure 3-62. LAN surge protection.
L ___
Figure 3-61. Wireless bridge links two networks.
ente;s the hub. They take the place of the regular patch panel
(figure 3-64).
This book does not cover the basics of radio telemetry such as
antenna selection and installation. The general rules for radios
apply. Refer to Supervisory Control and Data Acquisition by Stuart A.
Boyer (2d ed., ISBN 1-55617-660-0) for more information.
For most applications, the Ethernet runs within one and the same
building, with no direct connection to the outside world. It is there-
fore not being subjected to the dangers of great earth potential dif-
ferences. When communication between buildings is required it
may be a good idea to use fiber-optic cable instead of copper wire.
However, if copper wire is used between buildings or locations
where ground potential difference or other sources of surge may
occur, you should use surge-protection devices. Good surge-pro- Figure 3-63. Ethernet surge protector. {Courtesy Phoenix Contact)
tection devices survive repeated surges and let the protected
devices resume normal operation once the surge is over. Install the
Ethernet surge-protection device in both locations, and let the net- IP Terminology and Basics
work enter the building close to where the main electrical supply
earth enters (figure 3-62). Both FOUNDAT!ON Fieldbus HSE and PROF!net a~e ~;~:I ont the
Internet Protocol (IP) RFC standards ~9~. ~5! ~~k to eac:Zther
LAN surge-protection devices are available in a single-port config- devices can exist on the same networ ~ n DP trans ort
directly. FOUNDATION Fieldbus HSE devices use the U p
uration that is suitable for remote-mounted linking devices
-l
Fieldbuses for Process Control
Chapter 3 _ Installation and Commissioning
For example, host-level Ethernet in the control system and the entrenched protocol in the process industries, <n1d it is im.portant
office Ethernet may be physically connected to allow some data to for any system to have a gate\vay to Modbus.
be exchanged while at the same time ensuring that office network
traffic does not load the control system network and vice versa OPC Server
(figure 3-65). Most software applications, with the exception of ~onfiguratio~
and maintenance tools, do not support protocols hke FOUNDA1ICJN
When a network becomes large it can be partitioned using routers Fieldbus l-ISE or PROF!net directly. OPC (OLE for Process Control)
to improve performance by localizing much of the traffic on is a technology that enables hardware and software to exchange
smaller networks. A router has an Ethernet MAC address, and
data. OPC is explained in chapter 7, "Operation." Mos: modern
when a node on one network \Nants to send a message to a node on devices come with an ore server for each type of devtce or proto-
another network the message is first sent to the router. When the col. Similarly, most software applications are OPC cllents. The OPC
router receives the message it examines the network addresses and servers arc device- or prolocol-tailorr.:'d software progran:ls that
forwards the message to the router on the appropriate network. provide the device data in a standard format fo~ the deviCe- and
The router on the destination network passes the message to the protocol-independent OPC clients that are m.akm~ rcq~tests to read
final node. Routers are typically configured manually at the time of and write. This is called a client/server relatJOnshtp (ftgure 3-66).
installation. A router is used to permanently connect a network to For example, a linking device comes with a~ OPC server, and a
the Internet.
process visualization software is an OPC chent.
A "brouter" is a hybrid of a bridge and a router. If the router func-
tion supports the network protocol of a frame that it treats it acts as
a router would; otherwise, the frame is treated as by a bridge.
Gateway
A gateway performs complete protocol conversion and can there-
fore be used to link together networks with different protocols. A
gateway is protocol specific and therefore must be purchased for
the desired combination of protocols, for example, Mod bus or
some other protocol to FOUNDATION Fieldbus l-ISE. A gateway
function may be built into another device as an auxiliary function,
for example, into a linking device. Routers are often erroneously
called gateways. It is therefore important to be clear about termi-
nology when discussing gateways.
There are OPC client/server relationships tailored for simple data
Typically, a gateway has to be manually configured by mapping access historical data access (trending and logging), and for alarms
the device address, memory register, data type, scaling, and other and e~ents. Many times, these functions are implemented in a sin-
information in the foreign protocol to the desired representation gle server or client application. Because not all forms of d~ta are
for every parameter that has to be communicated. For example, for supported by OPC the configuration and network analys1s to~ls
the FOUNDATION Fieldbus protocol information should be repre- must support the protocol and access the dev1ces d1rectly. OPC lets
sented as function blocks. This can be a rather tedious process that any software read and write parameters, but for download of the
requires careful test and verification to make sure it has been done control strategy and device configuration t~e softwa.re must fully
correctly. As far as possible, a single protocol should be used support the protocol. The O~C clients ru~ m the vanous wo.rksta-
throughout the system to avoid the need for gateways. However, tions for operation, engineenng, and rnamter:ance. F~r med1um
existing plants always have legacy devices that need to be inte- and large systems, the OPC servers may run m a d:d1cated com-
grated, and even for new plants some equipment may only be puter, whereas for small systems a server may run m one of the
available with foreign protocols. For example, Mod bus is a well- workstations.
( t (
Iii. Fieldbusesfor Process Control
Chapter 3- Installation and Commissioning
Sub net
It is a good idea to partition a large network using routers because
this will increase performance in networks that have many bridges
or lots of broadcast traffic. You can partition the host number por-
tion of the IP network address into a subnetwork number portion
and a smaller host number portion for each of the several smaller
subnetworks, each having fewer devices. In any case, a subnet
mask is used to point out which portion of the IP address is the
network identifier and which (the remainder) is the host portion
for device addresses. Every device must be configured with a sub-
net mask if you want it to be able to work out which particular sub-
net it is on and whether the devices_it wants to communicate with
are on the same or a different network.
Chapter 3- Installation and Commissioning
Fieldbuses for Process Control
-------· ---- - - - - - For simplicity, it is highly IYCOIIllllCiided tlwt you use sulmet masks that
are based 011 tire full byte, using either 0 or 255, that is, 255.255.255.0 or
255.255.0.0 or 255.0.0.0.
AND: 11100000.10101000.10100100.00000000
End address: 10101100.00011111.11111111.11111111
Destinationsubnet: 192.168.164.0
Subnet mask: 11111111.11110000. oooooooo. oooooooo
Subnet mask in decimal: 2 55 . 240 . o . o Since the source and destination subnets are different, the worksta-
tion knows it must send the message to the router for onward for-
The 255.240.0.0 subnet mask is then configured in all the devices on
the subnet. warding to the 192.168.164.0 network in order for the message to
reach the linking device.
(
(
Chapter 3- Installation and Commissioning
Fieldbuses for Process Control
Network:192.16i
Control System Office
Sub·network: 192.168.164.0 Sub-network: 192.168.165.0
. l;l
Subnet mask: 255.255.255.0 Subnet mask: 255.255.255.0
r- -t[e~~~il~;.;r.::::~=~=-~'::r~:::-~:.'..,--:,_-'-~----.:.:ee-l
Figure 3-70. Network partitioned using subnets.
·-···-·-·-·-·-J fi92J16s!164fi0o
It may be helpful to think of the JP address as a phone number
with the network identifier as the are.-,~ ;:,ssigned to the net-
work the device is located on. If the wn device has a differ-
ent area code then it has to make a }(l, ~- .,.:ance call. The sub net
mask is like the dash that tells you where the area code ends and
the phone number starts in the long string of digits that constitute
a phone number.
Manual IP Configuration
Figu~e 3-71. Linking device IP address configuration.
Once the IP address and subnet mask have been worked out they
can be set in the devices and workstations. If there is a router on
address cross-reference Jist for each network as part of the system
the network to link to other networks, you should also configure
the router IP address in the field tl~ pically called "Default documentation.
Gateway." If there isn't, leave it blank lilgure 3-71). The host por-
tion of the IP address cannot be set to all binary zeroes or all ones. Automatic IP Configuration
for workstations, configuring a manual address is straightforward Assigning addresses automatically is the easiest .solution, espe- .
since the information can simply be keyed in. However, to be con- cially for large networks. Automatic address assignment makes It
figured manually devices that have no local user interface usually possible for devices to simply be plugged into the network. To use
need to be connected to a computer on a separate network that is it the network must have a DJ--ICP (dynamic host confJgurahon
either running a special configuration tool or to terminal software ~otocol) server, which is software that runs on one o~ the co~put
like Telnet. The IP address must be set before the device is con-
nected to the operational system network to avoid disrupting the
=m ·
P · the network A DHCP server automatically assigns umque
·ct · d
IP addresses to nodes on the network. Thts address IS . ynamic an
.
operational network A manually assigned address is static. may change from time to time. All the user has to do IS to ensure
that the devices connected support the DHCP protocol and that
The address must be unique on the network. If the address is not the are configured to have the address assigned by a DHCP
set correctly the device will not be detected and may even disrupt ser~er rather than manually. Usually, devices are sh1pped ready to
the communication of the devices already on the network It is accept a DHCP-assigned address.
therefore important to take measures to prevent any duplication of
addresses. Duplicate addresses may disrupt supervision or even
controL It may therefore be a good idea to include a tag and
Chapter 3- Installation and Commissioning
Fieldbuses for Process Control
Media Redundancy
Media redundancy works entirely on the physical media level and
is therefore independent of protocol. Media redundancy can there-
fore be used with any protocol that travels on Ethernet. Dual-path
(
Ill' Fieldbuses for Process Control
Chapter 3- Installation and Commissioning
RS2-FXIFX
topology hubs to the standard devices. The ring topology creates a
dual communication path because the communication can go ..&"""'"
either clockwise or counterclockwise.
---------- --------~-
n$ 8P1
SmHy0 8RM
en
.,.2
- 1@
5f& 04
Jil
"
e~r..dh
(
Fieldbuses for Process Control
3.8
3.9
3.10
Can the spurs on a network of th" t
meters in length? Ir een spurs exceed 90
te
I
offline mode, the software tool is not connected to any device. The
configuration for all the instruments in the plant is prepared in
advance, even before the devices are manufactured, delivered, or
installed. The configuration is stored in a file, and once the devices
are commissioned the configuration can be downloaded. Actually,
a large number of settings must be made in the devices to make the
communication work, but the configuration tool typically handles
--------c--- this automatically. Parameterization is typically done on line in a
Figure 4-1. Software tool for netw~rk, device and strateQy configuration. plant once it is up and running.
and configuring the function blocks. Because HART networks are Network Configuration
usually stand-alone without a direct link to the host-level network
configuration is usually not required. As far as the user is concerned network configuration is a matter of
defining the network hierarchy for the host-level and field-level
FOUNDATION Fieldbus specifies a graphical control strategy pro- networks_ HART is typically used as a point-to-point topology on
gramming language that is based on the function block diagram its own whereas FOUNDATION Fieldbus Hl and PROFJBUS PA
concept PROFIBUS PA and HART do not specify any program- networks generally connect to the host-level network using linking
ming language, and therefore device configuration is done sepa- devices to form sophisticated network architectures. In other
rately from the strJtcgy configuration. In systems that usc words, for HART there is not really any network configuration to
PROF!IlUS and HART control is typically done in a centralized be perfornwd_ For both FOUNDATION Fieldbus and PROFJBUS PA
controller, and the strategy configuration language and strategy some quite sophisticated communication configuration must be
configuration tool are unique to whichever controller is used. performed, but it is generally done automatically by the
Whether the system configuration is simpler when device configu- configuration tool and is therefore not a matter of concern to the
ration is separate from or integrated with the control strategy con- user. These unseen details are explained in chapter 11, "How
figuration is up to the individual user's preference. PROFIBUS PA Fieldbus Works-"
has function blocks with parameters that arc very similar to those
of FOUNDATION Fieldbus but with an important difference: PROFI- Assigning addresses in HART and PROFIBUS PAis explained as
BUS PA function blocks cannot be linked. Because of their common part of device commissioning in chapter 3, "Installation and
heritage the parameters in FOUNDATION Fieldbus and PROFIBUS Commissioning."
PA are very similar.
To make it easy to cross-reference between the network configura-
HART devices are usually configured using a portable handheld tion and the electrical diagram for the network, it may be a good
terminal, but PC software is also available. There are also remote idea to enter the cable name and loop diagram drawing nun1ber in
terminal units (RTU) and calibrators that communicate with HART . the configuration tool.
instruments. HART devices are usually only configured on line,
that is, while connected to the device, although a handheld usually
( (
Fieldbuses for Process Control Chapter 4- Configuration
PROFIBUS any one time. The functioning link masters automatically negotiate
who will be the LAS. If the current LAS fails another link master
From a communications perspective, there are three types of
takes over automatically.
devices on the PROFJBUS .network: slave, class 1 maste 1~ and class
2 master. A class 2 ma.ster 1~ generally a configuration tool (figure
4-2). A class 1 master IS typiCally a centralized control! 1·k
PLCTh 1 ertea
. e c ass 1 master cyclically exchanges I/0 information with
the slav_es. A class 2 master acyclically exchanges configuration
and mamtenance information in the slaves.
--- ---------
Master (class 1) Master (class 2 )
Link
Figure 4w3. Bridge, basic and link master devices out of one is the LAS.
configured as the primary link master. By default, the primary LAS rent output shall be 4 rnA (O'Yo of range), and the upper range value
would generally be the host interface. The host auto-detects and (URV) is the value at which the current output shall be 20 rnA .
identifies new devices on HI and HSE. (100% of range). The difference between the URV and the LRV IS
called the span. LRV is frequently called zero. It is very important
Device Configuration to configure the range of any displays, contr_ollers, ~r h?st ~n the_
system to the corresponding values; otherwise, the md1catwn ~·Ill
HART, FOUNDATION Fieldbus, and PROFIBUS PA all cater very be false, and the control strategy will not function properly. It IS
well to d~vtce configuration. These three protocols all have therefore crucial that you carefully document and cross-reference
standardized para~ne_ters for configuring the devices' operation, a the ranges between transmitters and displays and manage any
common charactenstiC that sets them apart from other protocols. changes to reduce inconsistencies. When you perform the trans-
!hese are therefore the most common protocols for field mitter reading using the digital communic(ltion the process value
mstruments. The parameters for Pl{OFIBUS PA and FOUNDATION is displayed in engineering units independent o_f the range.
field bus are ~rganize.d in b~ocks. It is a good idea to use templates
that have devtce configurations prepared and verified in advance.
Doing so makes configuration faster and reduces mistakes.
( (
(
tterit.fr
Chapter 4- Conftguration
Fieldbuses for Process Control
zero, press the Set LRV button to the applied input and the output
becomes 4 rnA. The LRV has automatically been set to the applied
input, which cancels out the pressure from wet leg and even any
erroneous engineering unit reading. ln other words, it is not neces~
sary to know what the actual input is since the transmitter just
makes sure that whenever it is at that value the output is 4 mA. E
Likewise, if the tank is just full press the URV button to make the :1\
0
output 20 rnA. The URV button does not affect the zero.
The second method for setting the range is simply to type in the
desired values from the handheld keyboard. If a particular range is
required, just key it in regcudless of what the present input is. The E
second form of re-ranging does not require you to know the
present physical input, and it can be done remotely using the
HART communication.
Figure 4-5. Level measurement with wet-leg.
J
EXAMPLE 4-1
For example, the liquid in the tank in figure 4-5 has a density of BOO
kg/m3. The range shall be set to measure the level up to 0.56 meter
above the level tap. The transmitter is mounted 0.19 meters below Ac:t:ual PV Unit::k.H20
the level tap. The local gravity is 9.81 m/s 2. To cancel the hydrostatic PV Uni't Family:..,. Pressure
pressure from the wet leg the range shall be set 1.49 to 5.89 kPa. PV Unit: ..,. inH20
URL: 200.000 inH20
LRL: -200.000 inH20
LRV =0.19x9.81 x800 = 1.49kPa Min Span: 5.000 inH20
Damping: ~,9.QQ.... ...... s
PV uni't will be se't wit:h
URV = (0.19 + 0.56)x9.81 x800 = 5.89kPa
Many changes made to the device configuration~ such as range, Fi-Qure 4H6. Sensor range limit information.
sensor type, and transfer function, will result in an instant change
of the current output. If no precautions were taken, this would be nt range limits for the sen-
The operator can review the measureme . . ) and the
interpreted by a controller as a sudden process upset, which it ( f 4-6) This includes the upper range hmlt (URL
would try to correct for. Although there is no real process upset, sor Igure . 11 h minimum span that the
lower range limit (LRL) as we_ ~s t e s an is the smallest absolute
the controller would cause one trying by to correct the one it transmitter can accept. The mimmunl : b t URL and LRL
difference bctwe~ the ~R:t~:ti~Va~;~~~ c=~~~ set. ~ote that
mistakenly perceives. Therefore, the operator should put the
control loop in manual mode before n1aking such a change. Most
handheld terminals will display a message advising the operator are the hmltS Wit 1~ ;IR~c and LRV to suit the application, whereas
to do so before the change is actually effectuated. Once the change ~~~P~~~to:~~n~~imum span are fixed constants that de~enl dton
' ~, . . · a limit imposed mam Y o
has been made the operator is reminded to return the loop to the sensor type. The mimmum spa~ IS hi h-ran e transmitter to
automatic. prevent misapplication, such as usmg a . g g For both
measure small values. This would result m po?r ac~turhacycks. fhe
The operator can change the engineering unit without affecting h ets the transmitter 1 c e
forms of range, whe~ t e user: to set against its limits to either
output because the transmitter automatically recalculates the range range value the user IS attemp mg
values in accordance with the new engineering units.
Chapter 4- Configuration
Fleldbuses for Process Control
accept it or reject it. Range violation messages will accordingly be square root extraction. In most other applicati~ns the trarlsfer
displayed in the handheld. If the UI\L or LI\L would be exceeded function shall be linear. Some pressure transmitters may have
the technician must use a sensor module with a higher range. If the other options for obtaining the volume o~ the tank, such as a look-
span would be too small the technician must use a lower-range up table for freely configurable linearization or square roots of the
sensor module. third and fifth powers used to measure open channel flow.
~ Don't confuse range setting with calibmtimi; they are f'wo different fOUNDATION Fieldbus Devices (H1 and HSE)
•;t things. Calibration means correcting the sensor reading to match the
Configuring a device includes the process of entering the selection
applied quantity. Setting the range means selecting at which values the
of the field-level and host-level devices that will be used and the
current output shall be 4 mA (U%) and 20 mA (100%), respectively.
Setting the range docs not correct the sensor rending ill the transmitter configuration and parameterization of.the resource. block an~
transducer blocks. The engineer will grvc each dev1ce a phys1~al
itself The technician om set the range renwtcly without applying any
device tag (PD_TAG) to identify it. The device tag m~lst be un1que
input, [}f(f by definition calibration means t!mt a known input from a
in the system and can be up to thirty-two characte~s m l:ngth, for
standard hns to be applied. For the HART protocol, calibration is usualh;
example, "PIT-2308." The physical device tag that IS ass1gned
called "trim." Do not usc trim (calibration) to cancel out wet legs. ·
should be the same tag that is used in the network d1<1gram
document. Although hosts generally auto-discover connected
Current outputs below 4 rnA or above 20 rnA indicate that the
devices on both the Hl and HSE networks, this is only done when
measured value is out of the set range of the transmitter or that the
commissioning is done, after the devices have bee~1 installed. Since
sensor has failed. Most modern devices follow the NAMUR NE-43
standards, which dictate that the output can under-range and over- configuration generally starts long before the devices are
manufactured the device selection is typically entered manually.
range from 3.8 mA to 20.5 rnA; that is, 3.8-4.0 rnA and 20.0-20.5 rnA
can be seen as "uncertain." The operator can set the transmitter
fail-safe mode to bring the current output either high or low to Blocks
ensure that the action in the controller is correct. For the low The engineer sets parameters in the resource block and transducer
option, the current values in the range 3.6 to 3.8, and 20.5 to 21 rnA blocks to get the desired device cor:-figuration. ~hese blocks have
indicate a "bad." High is typicaJ1y the most suitable option since it many characteristics in common wtth the functiOn blocks that are
exaggerates; for example, a high temperature or pressure levels used to build the control strategy. The transducer, resource, and
automatically, which makes the controller take safe action. Some function blocks work the same way in Hl and HSE devices. Each
applications require a low fail-safe mode. device must be configured with one resource block, and all input
and output devices can be configured with at lea~t one transducer
To filter out noise on the measurement signal you can apply damp- block, essentially one per measurement or actuatwn. Transducer
ing. To adjust the damping you can configure the filter time con- blocks act as an interface between physicall/0 hardware and
stant, in seconds. Most devices have a write-protection lock to function blocks. The resource block contains information about the
protect the configuration from being tampered with, typically by device as a whole. Transducer blocks and the resource block have
using an internal switch or jumper. It is possible to review the no input or output parameters and cannot be linked. Each block
write-protection status from the handheld. should be given a block tag (FB_TAG) to identify it. The tags that
are assigned for function blocks should be _the same t~gs as the
Pressure ones used in the process and instrumentatiOn (P&l) dmgra~. The
block tag must be unique in the system and can be up to th1rty-tvvo
Plants often use pressure transmitters for inferential
measurements. For example, differential pressure transmitters are characters in length.
often used for flow measurements. For some flow applications, the
It may be tricky to come up with tags for the plethora of blocks in a
plant uses differential pressure producers like orifice plates and
system. Jt may therefore be a good idea to make tlze reso!lrce block tag the
pitot tubes and will desire a reading that is proportional to the
same as.the physical device tag and maketl1e transd!lcer block tag> the
volumetric flow. In this case, the engineer should configure the
transfer function of the differential pressure transmitter input to
I
( (
y Fieldbuses for Process Control
Chapter 4- Configuration
Parameters
Each block contains a number of parameters, all of which have
L
Figure 4~7. li
predefined names. The first six parameters are the same in every
FOUNDATION block and are therefore called universal parameters.
device. ag example for resource, transducer and function blo~k and
Many parameters are simple, that is, contain only a single piece of
information, whereas some parameters are really a record of
The standards include transducer bl k several elements, wherein each element is like a simple parameter
device types. Each one has a set of oc s for several different containing one piece of information. For example, many
tions for the quantity measured or rh:r~:eters for co~mon func- parameters consist of a value and a status {figure 4-8). Many
turers also add an extended set f rn of actuation. Manufac- parameters for options are bit-enumerated, meaning that you can
specifics of the sensing or act t~ parahmeters to cater to the select several options in a list within the parameter. The
ua wn tee nolog
f acturers may also have created bl k, f y emp1oyed. Manu- parameters in the resource block and the transducer blocks are all
~ua~tities or forms of actuation fo~~~. or the ~easuremcnt of "contained," meaning they cannot be linked. The parameter values
hon m the specifications. However thelch th.e:e ~~no recommenda- are either set by the user or by the block itself.
ufacturers to create blocks d ' spectficatwn requires man-
it. The specification also re~~~infs~me~ers that are c?nsistent with
blocks and parameters ust·ng th DDanu acturers to disclose these
· ' e so as t k ·
m open systems possible and confi . , ~ ma_ ? mteroperation
reason, users should not try to lea guratwnbmtwhve. For the same ..
· . rn every lock b h . . p..,cme~
written when the block is in a certain mode so as to ensure that the l.lltiversal Parameters
process control is not upset by a bump in process variable or con-
The tag descriptor (TAG_DESC) parameter may be used to
troller output. Parameters arc stored in one of three different ways:
describe the function the block is performing as a form of
• Static storage documentation that facilitates future configuration editing. The
• Dynamic storage description may be up to thirty-two characters in length. The tag
descriptor in the resource block m.ay be used to document the
• Nonvolatile dynamic storage function or location of the device as a whole, for example, "Boiler]
drum level." The tag descriptor in a function block can be used to
Static parameters do not change by themselves; either they are con- explain the function of the block, for example, "calculate setpoint
stant or it is the user who configures them, and the number of from wildflow." This parameter does not affect the operation.
chang('S <1re counted. Static parameters an:~ retained durjng power
loss. Static parameters that cannot be written by the user are con- The strategy (STRATEGY) parameter may be used to help group
stants set by the manufacturer. Most contained parameters are blocks by giving a number in the range of 0 to 65535. It does not
static since they hold part of the device and strategy configuration. affect the operation of the block. To help identify the location of the
Dynamic parameters continuously change and therefore do not block this parameter may be configured with a unique number, for
retain their value during a power loss. The process value is a com- example, for the control module as defined in ANSI/ISA-88.01-
mon example of a dynamic variable. Nonvolatile parameters are 1995, Batch Control Part 1: Models and Terminology.
like the dynamic parameters in the sense that they are typically
updated continuously, but like the static parameters they remain The number of writes of the configuration, that is, the revision
constant in certain modes, and the last value is retained during a level of the static parameters, is tracked by the static revision
power loss. Setpoint and output are examples of nonvolatile parameter (ST~REV). This parameter is incremented every time a
parameters. change is made to a static parameter, that is, the total number of
changes to the block. This parameter can only be read, not changed
~aram_eters_may b_e floating-point or discrete. Floats are generally by the operator. It may be used to monitor changes in order to
m cngmeermg umts rather than scaled into percentages, although detect tampering with the block. This parameter is ideal for use by
percentage is typically used for control output. The range for a asset management software to keep track of changes to the block in
float is from as small as +/-1.2 -lo-38 to as large as +/-3.4 ·1038_ order to establish an audit trail.
For certain parameters, floats can be configured os negative infinite
(-Inf) and positive infinite (+lnf) and used, for example, to disable To help sorting or directing alarms and block events the alert key
certain functions like alarms and integral action. Discrete parame- (ALERT_KEY) parameter may be configured with a number
ters have 256 valid enumerated states, which makes possible not between 0 and 255. The parameter has no effect on the block opera-
on Iy "t rue " or "fa Ise " b ut many o thers, such as "open," "close," tion. The alert key can be used for grouping associated alarms. For
and "stop," depending on the block type. example, it can be used for "First Out" alarming in the host, that is,
annw1Ciating when the first alarm in the group occurs but annunci-
Each device contains a tremendous amount of information, and it ating differently for subsequent alarms in the group. This prevents
is therefore easy to get swamped by data. Locating the correct "alarm avalanches" [see ANSI/ISA-18.1-1979 (R1992)- Annuncia-
information can be like finding a needle in a haystack. The FouN- tor Sequences and Specifications]. Alternatively, the alert key
DATION parameters are categorized, and generally the configura~ parameter can be used to help identify the location of an alarm.
tion tool has filters to hide the information that is irrelevant for the This parameter may be configured with a unique number, for
moment: example, for process cell or unit as defined in the ANSI/ISA-88.01-
• Input, Output, Contained 1995 standard.
• Dynamic A summary of the current hardware and software error status is
• Diagnostic, Service, Operate, Alarm, Tune and Local kept in the block error (BLOCK_ERR) parameter. This parameter
can only be read. The block error parameter is ideal for diagnostic
( ( (
r-ielaouses for Process Control Chapter 4- Configuration
overview and is used by asset management software to check chan ed affect the sensor reading or the positio'_l of th.e ac:uat~r.
health of a device. The following errors arc traced: Ther~fore,lor safety reasons during online conllgura~~~ son~
• Block configuration error anmeters can only be written when the block IS li1 m~ c.
Parameter Status Some of the "Bad" subqualities will only be seen in function blocks
The measured or processed t because they are associated with links and processed inputs. "Non-
function blocks consist f t parlame ers in the transducer and specific" is seen on outputs and is generally an indication that the
0 woe ements· val d
status element cont'I·ns 'dd't' l . . c ue an status. The function block has a "Bad" input. "Not connected" is seen on
" u 1 wna val d r · f
the value. It is very hclpf l t f J a ron m ormation about inputs and means that the input must be connected but isn't. "No
l ' u ore er to the stat · f communication" is seen on inputs and means that the output from
w len troubleshooting sine st t . d. us o parameters
communication, or other fa:Jlt~T~~~:~~ate~ har~ware, the connected function block is not being received because the
the source of a problem h es It easter to trace back to communication is not working. Depending on what the communi-
sue as sensor failt , Tl
llas three parts: Ire. 1e status element cation problem is the subquality can be either "No communication
-last usable value," which means that communication has been
• Quality working since the block was last in OOS mode but has nmv failed,
• Quality subst<~tus or it can be "No communication- with no usable value," which
means that communication has not been working since the block
• Limit condition
was last in OOS mode.
"Q,~ality,:· is the general validity of the value·" "" .
or Ihd. The quality substatus ex . . Good, Uncertam," The "Uncertain" quality is associated with measurement values
granularity. "Good" means tl t hplams the problem with a finer and means that the value is questionable and may not be totally
D d' c la t e value may b df
cpen mg on whether or not the block ( e use or control. correct. The problem is less severe than the problems associated
cascade structure the "Go d" r . ~utput can be part of a with "Bad." Function blocks offer the option of either continuing to
"Good (noncascade)" Th o qua Ity IS either "Good (cascade)" or operate using the associated value in order to provide a high avail-
"G d . e concept of cascad t
oo "subquality is explained in d . . c s ructure and the ability or rejecting the value as a safety precaution. The subquality
FOUNDATION programmin Ian ua etarl m the section on the for "Uncertain" can involve the following reasons:
subquality for "Good" g llg. ~e. In the transducer blocks the
genera y IS Nonspe ·r· " " • N onspeci fie
means that the value is not CJ IC. Bad" quality
t 1 . correct and should t b
con ro . The subquality for "Bad" ca . no e used for • Last Usable Value (input)
reasons: n assume the following
• Substitute (input)
• Nonspecific • Initial Value (input)
• Configuration error • Sensor Conversion not Accurate
• Not connected
• Engineering Unit Range Violation
• Device failure
• Subnormal
• Sensor failure
The "Uncertain" subquality "Sensor Conversion not Accurate"
• No communication -last usable value
means that the measurement has reached either nominallin1it or is
• No communication- with no usabl eva1ue degraded due to, for example, fouling. "Engineering Unit Range
• Out of Service Violation" means that the value has exceeded its range. "Subnor-
mal" means that one of many sources for a derived value is not
The "Bad" subqua rt 1 Y "C onf1guration
. er " good. For example, with dual redundant inputs "Subnormal"
parameter is out of the valid ran . ror. mear:s that some would indicate for 2oo2 that one input is degraded and the value is
selected, or the parameter h ge, an mvahd optwn has been based on one remaining input.
failure" means that the ass a~ ntedot been configured at all. "Sensor
u "t . OCla sensor has fail d "D .
re ypiCally means that the . e · ev1ce fail- Some of the "Uncertain" subqualities will only be seen in function
failed. If the block is in OOS as~ciated outputhardware has blocks because they are associated with links and processed
Service." mo e, the subquahty will be "Out of inputs. "Nonspecific" is seen on outputs and is generally an indi-
(
(
Fieldbuses for Process Control
Chapter 4- Configuration
Resource Block
Auto
Aulo:OOS
One resource block must be configured per device. The resource A~o
block contains information that is common to the device as a (none)
Online
whole. All the parameters are contained in the block, that is, they
cannot be linked (figure 4- J 0). The block is responsible for the Smar
device's overall diagnostics. Setting Out-of- Service mode in the LD302 Pressure
1
resource block stops all function blocks in the device. Automatic is 3
the normal mode of a resource block.
ln case parameters classified as nonvolatile are not stored in non~ • Fault state
volatile memory their values are copied to nonvolatile memory • Soft write lock
with an interval that is set in the nonvolatile cycle time
(NV_CYCLE_T) parameter. If the time is set to zero, variables will • Hard write lock
not be copied and will therefore not be volatile. This parameter is • Output readback
configured in units of 1/32 of a millisecond just like the report con-
firmation time. Independent of the cycle time configuration, \'a lues • Direct output write
entered by the user are always copied to nonvolatile memory. • Change of bypass in Auto allowed
Through the restart parameter (RESTART), there arc three ways to • MVC supported
restart the de\· ice:
Using the fl:ature select (FEATUEE~SEL) paranteter it is possible to
• Resource choose which optional features of the device can be used. For
• Uninitialized example, the software write locking can be activated to prevent
configuration chnngc. The feature options are best described in the
• Processor context of their respective features. "Change of bypass in Auto
allowed" is discussed in the section on PID block, "Output read-
Selecting the "Resource" option restarts the execution of the con- back" and "Fault state" are covered in the section on the output
trol strategy \Vithout changing the configuration. Selecting the class of blocks, and "Reports" is discussed in the section on alarms.
"Uninitialized" option resets the parameters to their default \·alues If the configuration tool has configured strings using Unicode
and then restarts the execution of the control strategy. The "Proces- chmactcrs instead of ASCII-for example, for the tag descriptor-
sor" performs a CPU reset. During normal operation this parame- this is indicated by the feature select parameter. Multi-Variable
ter displays Run. Container (MVC) is a feature used to reduce communication over-
head and thereby improve communication efficiency. If both the
The coordination of the function block execution is configured by device and host support MVC, it is a good idea to enable it.
the cycle select parameter (CYCLE_SEL) from the available options
identified by the cycle type parameter (CYCLE_TYPE). There are If the device has a write lock to protect the configuration from
three possible options: unauthorized tampering or accidental change the operator can, in
• Scheduled the event of soft write lock, set the write lock (WRITE_LOCK)
parameter, to protect the configuration from external writes. In the
• Event driven event of hardware \".'rite lock the parameter can only be read. In the
• Manufacturer specific event of soft write lock the protection may be switched off by dear-
ing the write lock, \Nhich will generate an alert to the host The pri-
The minimum cycle time parameter (MIN_CYCLE_T) indicates the ority of the write alarm is configured by the write priority
shortest macro cycle the device can accept. This parameter is set by parameter (WRITE_FRI) in the same way as for the other alarms
the manufacturer in units of 1/32 of a millisecond, just like the described in the section on FOU:\JDATION function block. The write
report confirmation time. The cycle time parameters are explained alarm parameter (WRITE_ALM) contains the information for the
in more detail in the section on FOUNDATION function blocks. latest occurrence of the write alarm. Remember that you have to
disable the write lock parameter before the software write lock in
The special characteristics of the device are listed in the features the feature select parameter can be deactivated.
(FEATURES) parameter. This parameter cannot be changed. The
de,vice features that are covered are the following: Most configuration tools internally keep track of the resources in
each device, the resources required for each function, and how
• Unicode strings much of the resources are available. It is also possible to check this
• Reports information on line in the device. The free memory and execution
time parameters (FREE_SPACE) and (FREE_TIME) inform you of
(
(
l.j. Fieldbuses for Process Control
the percentage of available memory and execution time, respec- the features that set one type of transmitter apart from another.
tively. The available memory in kilobytes can be read from the Transducer blocks handle not only measurement but also actuation
memory size (MEMORY _SIZE) parameter. and display. For this purpose, there are three types of transducer
blocks:
If the device supports Fault State for the output class blocks, all the
• Input transducer (transmitters and analyzers)
output class function blocks in the device may immediately be
forced into the fail-safe option that they have been configured for, • Output transducer (final control elements)
thus shutting the loops down. Fault State is forced by the set fail-
• Display transducer
safe (SET_FSTATE) parameter, which ignores the fault state time-
out setting in the output block. The Fault State mode may be All the parameters in the transducer blocks are c?ntained and can-
cleared by the clear fail-safe parameter (CLR_FSTATE). The current not therefore be linked like function blocks. The mput and output
state of the force function may be read from the fail-safe parameter transducer blocks are associated with the input and output class
(FAIL_STATE).
function blocks, respccti\'el y. The transducer bloc~s interf~cc to the
function blocks over l/0 hardware channels, whiCh arc d1fferent
There is a time limit before mode shedding occurs in the function from function block links. The function blocks are assigned to their
blocks as a result of communication loss for aU the remote cascade transducer block thrmwh an l/0 hardware channel (CHANNEL)
parameters in the device. This limit is configured by the remote parameter in the corres~onding input or output function b~ock.
cascade shed time-out parameter (SHED_RCAS), and for the Function blocks can only be assigned to transducer blocks m the
remote output parameters it is configuration by the remote output same device.
shed time-out (SHED_ROUT). These parameters are configured in
units of 1/32 of a millisecond, just like the report confirmation For a majority of devices, engineers will need to configure very.fe"':'
time. This is explained in greater detail for the 1{Cas and ROut parameters in the transducer block because most of them only mdt-
modes in the section on function blocks.
cate limits and diagnostics. In most cases, only the n:~de parameter
has to be set, and sometimes maybe one or two addttwnal parame-
The GRANT_DENY, UPDATE __EVT, BLOCK_ALM,
ters. The transducer blocks for devices made by different manufac-
ALARM_SUM, and ACK_OPTJON parameters are described in turers are different, although the first two dozen or so parameters
the section on FOUNDATION function blocks.
often are the same. In other words, fieldbus devices from different
manufacturers are not identical. A transducer block configured for
Humans do not utilize the read and write test parameter one manufacturer's de\·ice can therefore not be used in another
(TEST_RW); it is provided solely for device testing.
manufacturer's device. However, since only one or two parameters
have to be set to configure the device it is still very simple to
Minimum Configuration
replace one fieldbus de\·ice with that of another manufacturer.
At a minimum, the following parameters must be set:
In addition to the universal parameters all transducer blocks have
MODE_BLK. Target a few standard parameters. The block error (BLOCK__ERR) param-
eter indicates the classification of any failures that were detected
Transducer Blocks by the device's diagnostics. The transducer error (XD_ERROR)
parameter indicates the diagnostics with a greater level of detml.
Transducer blocks interface the function blocks to the device l/0
The errors that the self-diagnostics check for are manufacturer spe-
hardware such as sensors, actuators, and display (figure 4-11).
cific. Only the highest-priority transducer error is indi~a~ed. The
These blocks are responsible for the information and functionality
transducer error parameter is discussed in greater detail m chapter
specific to, for example, the measurement of a particular physical
6, "Troubleshooting." The UPDATE_EVT and BLOCK_ALM .
property, such as pressure or temperature. Note that an analog
parameters are described in the section on FOUNDATION function
input block is the same in a pressure as in a temperature
blocks.
transmitter. The transducer blocks have parameters for handling
Fieldbuses for Process Control
Chapter 4- Configuration
----··----
which can be up to thirty-two characters long. The operating limits
for the sensor type may be read from the high- and low-range ele-
ments in the sensor range limit (SENSOR_RANGE) parameter but
cannot be changed since they are capabilities determined by the
physical characteristics of the device. Just as with scaling parame-
ters, the sensor range parameter has four elements: the lower and
upper sensing limits, the engineering unit the values are displayed
with, and the number of decimals the value should be displayed
with. The block diagnostics checks for configuration errors and
reports a block alarm for any inconsistencies it finds, for example,
if the AI block transducer scale (XD_SCALE) is set beyond the sen-
sor's range limits.
( (
Fieldbuses for Process Control
Chapter 4- Configuration
Since the calibration values are written and stored in the two cali-
bration point parameters they also indicate at which values cali-
bration was last performed. This makes it is easy to check if the
transmitter was Jast calibrated for a range suitable for the applica-
tion it is operating in. The smallest span~that is, the smallest abso-
lute difference between the calibration point values-for which the
sensor may be calibrated is informed by the calibration minimum
span value (CAL_MIN_SPAN). The unit of the calibration point 5068.98
values is chosen with the calibration unit parameter (CAL~ UNIT). 0
127
Changing the calibration unit automatically updates all the associ- mmH20 (68'F)
ated values to the new unit. The calibration unit comes in handy if Capacitance
you want to calibrate the transmitter in a unit other than the one in 5JJBD
which indication is normcdly done. For example, the AI block ·5000
mmH20 [SST]
XD_SCALE in a pressure transmitter may be set in kPa, but the 2
deadweight tester weights come in mbar. 15670B
FadOI}' stand:lrd calib!ation
1998·11· 22 09:39:59
To leave a calibration trail, the technician may store and verify the
data about the latest caJibration in the device, including the date,
the location, the method used, and who calibrated it (figure 4-13).
The time and date is stored in the sensor calibration date
(SENSOR_CAL_DATE) parameter. The sensor calibration location
(SENSOR_CAL_LOC) parameter can be up to thirty-two charac- Figure 4-13. Sensor range and calibration information.
ters long, for example, "in-situ," "workshop," or "NIST," and
informs the location where the last calibration was done. The name
of the person who carried out the calibration is retained and Most measurements require that an auxiliary sensor measure a sec-
checked from the "sensor calibrate whom" (SENSOlCCAL_WHO) ondary value in order to compensate for such ~fluer:ces on the pri-
parameter, which can be up to thirty-two characters in length. The mary value as ambient temperature, and the ltke. This second
procedure used for the calibration may be recorded in the sensor sensor measurement can be seen from the secondary value
calibration method (SENSOR_CAL..METHOD) parameter, which (SECONDARY_VALUE) parameter, which is displayed in the engi-
has the following options: neering unit set in the secondary value unit, .
(SECONDARY_ VALUE_UNlT) parameter. For most transm1tter
• Volumetric types the secondary value is temperature.
• Static weigh
Common Analog Output
• Dynamic weigh
Output transducer blocks are found in devices like valve
• Factory standard calibration
positioners and current as well as in pncu~~tic output converters
• User standard calibration connected to final control elements. In add1hon to the standard
transducer parameters, the common output block parameters are
• Factory special calibration
almost all the parameters that a simple output converter nee_d.s. A
• User special calibration valve positioner with a servo-positioning algorithm has additional
• Other standard parameters. The final value (FINAL_VALUE) parameter
comes from the AO block with the manipulated vanable lor the
final control element over the hardware channel. It shows the
A'- It is a good idea to update the calibration record for the transducer block
desired output value ill the engineering unit that was set in ~~e
W each time you have done a calibration in order to simplifiJ calibration
audits. final value range (FINAL_VALUE_RANGE) parameter. The fmal
- t-Jeldbuses for Process Control Chapter 4- Configurat;on II
value range also indicates the desired t
basic converters. It is usually set fr ~hu put operating range for The calibration trail parameter; XD_CAL_LOC, XD __CAL_DATE,
(XD SCALE) . om e transducer scale and XD_CAL_WHO have the same function and characteristics as
- parameter 111 the AO fun f bl k
inconsistencies and subsequent errors ~ t~n oc to ~revent any SENSOR_CAL_LOC, SENSOR_CAL_DATE, and
been set to 3-15 psi or 4-20 rnA . . . o example, It may have SENSOR_CAL_WHO in the input transducer block, respectively.
usually 0-lOOo' ·n I . _m a. Signal converter, but it is Valve positioners usually have an automatic setup feature that cal-
/o I a va ve posJtJoner. ibrates the travel to the fully opened and closed positions of the
valve.
Depending on the characteristics of the pos·t· 1
valve pack th wner, actuator or
age, e actuator fail action (ACT_FAlL ACTION Pressure Transducer
parameter may or may not affect th . - ) Pressure transducer blocks are found in pressure transmitters. The
ducer block and the actuator Mo t e otperatwn of the output trans-
have l . . ~ . s ac uators have, and should primary value type (PR!MARY_VALUE_TYPE) parameter
. 'a mec lantcal faJl-safc position that takes eff'
~mls, ~nd the actuator fail action merely reflec~s th~~tc~~-~~l:ll
e;se
indicates ·whether the sensor is for differential pressure, gauge
pressure, or absolute pressure. The sensor type (SENSOR_n'PE)
~r m ormatwnal purposes. In either cas i . .' TIS IC
figure the parameter correctI if onl to e, t ~sa go?d Idea to con-
L
parameter indicates \Vhich technology is used in the pressure
asset management. The opti:ns fo yh pro~Ide a~ mfo~mation for sensor: capacitance, resonant mode strain gauge, resistive mode
ter are as follows: r t e actuator fml actwn pararne- strain gauge, and so on.
(
~~~ Field buses for Process Control Chapter 4- Conf•guration - . -
The secondary value (SECONDARY_VALUE) parameter is the function block over the hardware channel, and there it is displayed
cold-junction temperature that is used for thermocouple compen- as the readback (READBACK) parameter. As explained in detail
sation. It may be useful to know when you are checking the cali- with respect to the AO function block, you m.ay ~ptiona~ly use the
bration of thermocouples. Some temperature transmitters are actual valve position to inHialize the PID. Th1s Will provtde true
constructed as an individual-module "hockey puck" that goes into bumpless transfer when an open loop is once again closed.
the transmitter housing. The module serial number
(MODULE_SN) may be used to track the device. You can tune the response of the servo-positioning algorithm to
suit the characteristics of small or large valves. The PID gains for
Valve Positioner Transducer (Advanced) the servo are configured in the servo gain (proportional), servo
Advanced valve positioner transducer blocks are found in control reset (integral), and servo rate (derivative) parameters
valve positioners that have a servo-positioning PlD algorithm for (SERVO_GAIN, SERVO_RESET and SERVO_RATE), respectively.
controlling the valve. In addition to the basic positioning analog
output transducer parameters, the advanced positioner also has PROFIBUS PA Devices
parameters for feedback and servo tuning. The final value range The process of configuring devices consists of entering the
(FINAL_ VALUE_RANGE) in a positioner would typically be set as selection of the devices that you will used as well as the
0-100% from the transducer scale (XD_SCALE) parameter in the configuration and parameterization of the blocks. In every PA
AO function block. The desired valve position is received from the device, you must configure a physical block similar to the
AO block over the hardware channel at the final value FOUNDATION resource block. Physical device tags are not used.
(FINAL_VALUE) parameter. To provide tight shutoff, you can set Sensors and actuators are configured in their corresponding
low and high cutoff limits for the final value in the final value transducer blocks.
cutoff low and high (FINAL_VALUE_CUTOFF_LO and
FINAL_VALUE_CUTOFF_HI) parameters, respectively. If the final PA function block links between devices will be handled in the
value is below the low cutoff value the servo will shut the valve future. PA function blocks are therefore not linked into control
tight. Likewise, if the final value exceeds the high cutoff value the strategy. Rather, they are the point where the central controllers .
servo will open the valve wide (figure 4-14). cyclically read and writes process variables and desired valve posi-
tions. Therefore, the parameterization of the PA input and output
block is a part of device configuration along with the physical and
valve position transducer blocks.
~ PRIMARY~VALUE~RANGE.EU100 Blocks
I FINAL~VALUE~CUTOFF ~HI
FINAL_VALUE_CUTOFF_LO
As in FOUNDATION Fieldbus, the PROFIB US PA blocks are logical
groupings of parameters. For the PA blocks, you should .conf~gure
the tag name in the TAG_DESC parameter. It must be umque m the
system and can be up to thirty-two characters m length, for
example, "PIT-2308."
- - FINAL VALUE The PA profile includes transducer blocks for several different
PRIMARY_ VALUE_RANGE.EUO
device types. Each block has a set of parameters for the common
Figure 4-14. Tight shutoff. functions of the device type. Manufacturers also add an extend~d
set of parameters to cater to the specifics of th:' s~nsin? or a~tuatwn
technology employed. Standard device descnptwn flies wrll be
The actual valve position value as sensed by the positioner feed- added later. Therefore, host and device manufacturers have to
back sensor is indicated in the final position value work together to develop device support files in order to n1ake
(FINAL_POSITION_VALUE). This value is also fed back to the AO interoperation in open systems possible.
Field buses for Process Control Chapter 4- Configuration
Parameters ami Status turer 1"d ent"f" t" n (DEVICE - MAN- ID) parameter.
1 ICa 10 . • .
The device
b ·
"d "f"
type 1 enh tea wn t. (DEVICE - ID) parameter rdenhfles
. fthe asrcd
PROFIBUS PA parameters have characteristics like those of
model of the device, and the revision of t~e.device so tware an
FOUNDATION when it comes to reading, writing, storage, and so on.
The concept of status is also the same. hardware is indicated by the software reVISI~~
(SOFTWARE REVISION) and hardware revrsron . .
(HARDWARE._REVISION) parameters, respectively. The devr~e rs
Universal Parameters
also identified by its serial number m the devlce senal num~e
Every PA block has seven universal parameters. Function blocks (DEVICE_SER_NUM) parameter. Theident number contra .
have one additional universal parameter. The ST_REV, STRATEGY, (!DENT NUMBER) is used to select erther the profrle-specrfrc or
and ALERT_KEY parameters function in the same way as they do manufa~turer-specific ident number. There are different prof.Jles for
for FOUNDATION although events and alarms will only be handled the various combinations of resource, transducer, and functlot
in the future. The TAG___ DESC parameter is used as the tag name to blocks that a device can have. The ident num~er tells th~ con tg~-
identify the block rather than as a function descriptor. Therefore, . I I. h f these profiles the devJce belongs to, that IS,
rahon too w uc one 0 ' 11 f 1 for
the TAG_DESC parameter must be parameterized so it is unique how the host will interact with the device. It is not rca y usc u
within the system. MODE_BLK is similar to the FOUNDATION humans.
parameter only that the Target mode, instead of being an element
in the MODE_BLK parameter, is a parameter on its own, namely, A summary of the current hardware and software error status~
the target mode (TARGET_MODE) parameter. The PA physical the device is kept in the diagnostics (DIAGNOSIS) parameter. 1e
block and the transducer blocks generally do not use the block checks it runs include:
mode parameter, so there is one thing less that has to be
configured. PA function blocks may support the OOS (out-of- • Electronic failure
service), Man (Manual), Auto (Automatic), and RCas (Remote • Mechanics failure
Cascade) modes. Advanced., class B, devices may also support the
• Motor temperature too high
LO (Local Override) mode. In PA, unlike FOUNDATION, the
ALARM_SUM parameter is also universal. Though it works in a • Electronic temperature too high
very similar way to the parameter in FOUNDATION, it currently
• Memory error
only supports the indication of the Current states of the alarms to
show which ones are active. • Failure in measurement
• Device not initialiZed (No self-calibration)
The batch (BATCH) parameter does not affect the operation of the
function block, but it may be used for identification purposes in • Self-calibration failed
batch control applications. The batch parameter has four elements, • Zero point error (limit position)
based on the ANSI/ISA-88.01-1995 standard: batch identification
(BATCH_!D) is a number from 0 to 4,294,967,395; the recipe unit • Power supply failed (electrical, pneumatic)
procedure (RUP) is a number from 0 to 65,535; the recipe operation • Configuration not valid
(OPERATION) is a number from 0 to 65,535; and the recipe phase
• New-start-up (warm start-up) carried out.
(PHASE) is a number from 0 to 65,535. See the separate section on
introduction to the ANSI/ISA-S88.01-1995 standard. • Re-start-up (cold start-up) carried out.
( (
i Iii Fieldbusesf~r Process Control
Chapter 4- Configuration
tion failure lasts for longer than half a minute the device will
enable the local adjustment; this will make it possible to trouble- .~
shoot and perform maintenance. ~11Clfi_J
PHIMARY VALUE
TRIMMED VALUE
-·+SECONDARY_VALUE_1
r----· -
Through the factory reset (FACTORY_RESET) parameter there are SECONDARY_VALUE_2
three ways to reset the device:
• Default values, maintain address
• Plain restart
Figure 4-15. PROFIBUS PA pressure transducer schematic diagram.
• Address reset
Like HART, the PA devices provide for basic device identification. Linearization
The thirty-two-character descriptor (DESCRIPTOR) parameter In addition to converting pressure into inferred measureme~ts for
may be used to describe its application, for example, "Boiler] flow, level, and the like in the AI block, for PROFIBUS PA th1s
drum level." Special considerations or instructions can be stored in same conversion can also be done in the transducer block. 1: rs
a thirty-two-character message (DEVICE_MESSAGE) parameter, important to make sure that the square root is not extracted m both
for example, "ladder needed for access." Lastly, the date of installa- the transducer and the AI blocks. It may be a good idea t~ adopt a
tion can also be entered in the date (DEVICE_JNSTAL_DATE) I ntwidc strategy for consistent implementation. To avOid any
parameter. The read-only device certification ~o~fusion, always do square root extraction in the AI block The
(DEVICE_CERTlFICAT!ON) parameter can hold up to thirty-two primary value type (PRIMARY_VALUE_TYPE) parameter selects
characters of manufacturer-entered data regarding approvals for the type of measurement that is done for the applicatiOn. That rs,
the device.
the conversion for the primary value (PRIMARY_VALUE)
arameter passed to the AI block and the options available for the
Transducer Blocks
~nit (PRIMARY_VALUE_UNIT)_ The first secondary value
The block mode parameter is typically not used in the PROFIBUS (SECONDARY_VALUE_l) is identical to the pressur~ readmg- The
PA transducer blocks. Most of the parameters in the transducer second secondary value (SECONDARY_VALUE_2) rs the
blocks are unique, but all analog input transducer blocks have a calibrated pressure reading, which is scaled to percentage o:er the
primary value (PRIMARY_VALUE) parameter, which is the range set in the input scaling (SCALE_IN) parameter_ After mput
measured value. For flexibility in linearization the operator can scaling the linearization deterrnmed by the pnmary type IS
enter a lookup table. There are several parameters that the host can applied to the second secondary ~alue. This is followed by output
use to display the table; all have a name that starts with TAB__ The scaling back to an engineering umt to obtam the pnmary valu:
number-of-points (TAB_MAX_NUMBER) parameter indicates the (figure 4-15)- The available primary value types are as follows_
maximum number of points that the table can have. • Pressure
• Field buses for Process Control
Chapter 4- Configuration
• Flow
• Level The units associated with the two secondary values are set in the
SECONDARY_VALUE_!_ UNIT and
• Volume SECONDARY_VALUE_2_UNIT parameters, respectively.
Temperature Transducer
The temperature transducer handles up to two inputs. There are
therefore two sets of parameters, one for each measurement point.
The two inputs must have the same sensor type and display in the
same unit. Additionally, the inputs have a few parameters in
common. The parameters for the individual inputs have names
ending with _1 and _2, respectively. For example, after the addition
FLOW_UN_SORT_POINT
of a bias (BIAS_*) parameter the two temperature readings are
SCALE_OUT <-.L.._ _ _ _ _ ___'S>_tE:<:C":ONDARY_VALUE 2
.EUO% 0 --------. displayed as SECONDARY_VALUE_! and
100% SECONDARY_VALUE_2, respectively.
Figure 4-16. linear interpolation below cutoff.
The measurement type (SENSOR_MEASUREMENT_TYPE)
parameter selects the measurement that is displayed in the primary
i~J
r:f
~~.:·.
b• •tc'c+rt- ! !
Fieldbuses for Process Control Chapter 4- Configuration
value (PRIMARY_ VALUE) parameter passed to the AI block. The parameters. A to tal of. four combinations of lead breakage and
available options for obtaining the primary value are as follows: short circuit are posstblC'.
• Input 1
. the two in F1utsi are captured in the
The extreme conditions tor
• Input 2 SENSOR VALUE_' one
parameters MAX_ - . . .. ·et by writing to them.
• Input 1 -input 2 MIN_SENSOR_VALUE_'. They me 1' 5
• Input 2 - input 1
Thermocouple . meter the
• Average of input 1 and input 2 ' d t mperJture transducer para
In addition to the stanuar e , p h ws the temperature
t (RJ TEM ) s o
• Average of input 1 and input 2, or "Good" if one goes "Bad" cold-junction tempera me . - 'fl r ~fcrence junction type
· d a t tl1.e se 1'sor 1
measure 'L ternuna _s. 1.e f""' ld junction
.
The unit for the primary value, the two secondary values, and the (RLTYPE) parameter_ selects ~}•e.ty\~ C')fl~; o~tions are the
b.ias parameters is set in the primary value unit compensation that will be pel ounce.
(PRIMARY_ VALUE_ UNIT) parameter. The linearization type following:
(LIN_ TYPE) parameter selects the type of temperature sensor that • None
is used for both inputs. The available options depend on the device
but typically include all standard thermocouples and RTDs. • Internal
Maintenance • External
ld-"tmction compensation
The operating limits for the sensor type may be read from the high- If the "None" option is selected no ~'~ntjrnal" option the cold-june-
and low-range sensor limit (UPPER_SENSOR_LIMIT and will be performed. If you select the terminals will be used. If
LOWER_SENSOR_LIMIT) parameters. However, they cannot be a:
tion temperature measured the sens~r manually entered at the
changed since they are capabilities that are determined by the you select the "External" optwn the va u(~XTERNAL Rj_VALUE)
physical characteristics of the device and sensor. external reference junction temperature ~ -
parameter will be used for the compensatiOn.
A summary of the current status for the malfunctions that affect
both inputs is kept in the general input fault
(INPUT_FAULT_GEN) parameter. Standard checks include: RID t transducer parameter, the
I s t a~ d,a rL:l tempera
In addition to t_1e
ure '
CONNECTION) parameter ts use o
. dt
• Reference junction error sensor connechon (SENSOR_ . f tl c sensor that is to perform
• Hardware error configure the electrical connectiOn o . 1 , nd. so on. The standard
.
the appropnate Iea d -\\,·m:~compensation..a
sensor connection options are as follows.
A summary of the current status for each individual input is kept
in the input fault (JNPUT_FAULT._') parameters. Standard checks • Two-wire
include:
• Three-wire
• Under range • Four-wire
• Over range . n manually enter the lead-wire
For a two-wire conn~ctiOn, Y.ou cam ensation (COMP-WIRE*)
• Lead breakage resistance, in ohms, m the wire co p
parameters.
• Short circuit
eumatic Positioner Transducer
The individual input diagnostics are performed, proVided they are Electropn . NING VALUE) parameter
enabled from the sensor wire check (SENSOR_WIRE_CHECK_') The demanded position c·alue (POSIT!fO the-AO block for the
· ble comes rom
with the manipulated \·ana
Fieldbuses for Process Control
Chapter 4- Configuration
final control element over the hardware channel. It shows the TRAVEL_LIMIT_UP
desired output value in units that are set in the output scale
(OUT_SCALE) parameter in the AO function block. To provide RATED __TRAVEL
tight shutoff, the engineer can set the low and high cutoff limits for
the final value in the final value cutoff low and high There are parameters for increasing (TRAVEL_RATE_INC) and
(SETP _CUTOFF_DEC and SETP_CUTOFF _INC) parameters, decreasing (TRAVEL_RATE_DEC) rate-of-change, which operate
respectively. These are similar to the FOUNDATION parameters like the FOUNDATION function block parameters SP__ RATE_UP and
FINAL_VALUE __CUTOFF_LO and FINAL_VALUE_CUTOFF _HI, SP_RATE_DN, respectively.
respectively.
Linearization
The engineer can tune the response of the servo-positioning algo-
rithm to suit the characteristics of small or large valves. The PJD Linearization is set by the linearization type (LIN_TYPE)
gain:-; for the servo arc configured in the servo gain (proportional), parameter and can be used to achieve .applie~ flo": .
servo reset (integral) and servo rate (derivative) parameters, which characterization (figure 4-17). The avatlable hneanzatwn types are
are similar to the FOUNDATION parameters. PROFIBUS PA pro- the following:
vides two sets of gains, one for increasing and the other for • None (linear)
decreasing. They are denoted by names ending with _1 and _2,
respectively: (SERVO_GAIN_ ', SERVO_RESET_' and • Equal percentage 1:33 rangeability
SERVO_RATE_ '). • Quick opening 1:33 rangeability
The actuator fail-safe position (ACTUATOR_ACTION) parameter • Equal percentage 1:50 rangeability
is similar to the FOUNDA TtON ACT_FAIL_ACTION parameter. The • Quick opening 1:50 rangeability
options for the actuator fail action parameter are as follows:
• Equal percentage 1:25 rangeability
• Self-closing
• Quick opening 1:25 rangeability
• Self-opening
• None/Hold last value • Table
• Linear
• Rotary - part turn
• Rotary- multi turn
( ( I
Fieldbuses for Process Control
Chapter 4- Configuration
The dates on which several important functions were carried out Controller LiHk
are stored in sixteen-character fields. The dates stored are the last . OFIBUS function blocks cannot be
valve maintenance (VALVE_MAINT_DATE), last booster installa- The main difference 15 tha.t PR rol strate . In other words, to
tion (ADD..GEAR_INST_DATE), last calibration linked to each other to bmld a cont AI bl;r is read by a central
(DEVICE_CALIB_DATE), and last configuration form a control ~oop t~e valu~ fr~~a~:ver rogramming language,
(DEVJCE_CONFIG_DATE). controller that lS configured m .
and the manipulated variable is wnttenC o
t the AO block. Because
d ·s the most
. k t used the R as mo e l
The total travel is accumulated and displayed in the equivalent function block lm s are no d~s. The manipulated variable is
number of full strokes in the total travel important mode for output blo . t in ut (RCAS_IN), and for
(TOTAL_VALVE_TRAVEL) parameter. In other words, it is like an written to the remote cascade setpm~ ltr must handshake \vith
odometer that may be used to target proactive maintenance by set- the cascade to be established the ~~7I{~A~ OUT) parameter of the
ting the total travel limit (TOT_VALVE_TRAV_LIM) parameter to a the remote cascade setpomt ouJ t ·nt input parameter and the
output block. The re~ote casca e sei~o~t and output parameters,
value at which the maintenance should be planned.
Alann Parameters
For the "Fail-safe" option in the event of input failure the output
(OUT) will be set to the value configured in the fail-safe value
(FSAFE_ VALUE) parameter with a status of "Uncertain." For the
"Last Usable Value" option, the last valid value becomes the out-
put with a status of "Uncertain." For the "Bad" option, the status
becomes "Bad."
where the rcadback \'alues comes from. Rather than setting output • Field device uncle~ local controL LOCKED OUT switch is in
action in IO_OPTS, it is set from the INCREASE_CLOSE gear
parameter. In addition to the readback parameter, there is also a • Emergency override active
discrete position indication (POS_D) parameter. It indicates if the
valve is fully opened, fully closed, or in some intermediate • Actual position feedback different from expected position
position. • Torque limit in OPEN direction is exceeded
In PROFIBUS PA, the active fail-safe mode is Auto instead of LO. • Travel time for actuator has exceeded
Since the remote cascade setpoint input (RCAS_IN) is the main • Actuator is moving toward open direction
input fail-safe gets activated if the remote cascade setpoint input
remains "Bad" for longer than fail-safe time-out (FSAFE_TIME), • Actuator is moving toward close direction
which is set in seconds. A loss of communication would be an • Static data changed
example of such an instance. Similarly, a controller with an
appropriate control strategy configuration can initiate fail-safe • Simulation enabled
action by setting "Initiate Fail Safe" status on the remote cascade • Internal control loop disturbed
setpoint input. When the fail-safe is activated the fail-safe type
• Positioner inactive (output status is "Bad")
(FSAFE_ TYPE) parameter configures three options regarding
what should happen: • Device under self-test
• Fail-safe • Total valve travel limit is exceeded
• Last Usable Value • Additional input is activated
• Actuator action
A configuration tool may use the check back mask
(CHECK_BACK_MASK) parameter to filter out the checks that are
For the "Fail-safe" option, in the event of activated fail-safe, the not performed by the device. This parameter is not really useful for
setpoint (SP) will be set to the value configured in the fail-safe
value (FSAFE_VALUE) parameter, with a status of "Uncertain." humans.
For the "Last Usable Value" option, the last valid value becomes
TOT - Totalizer Function Block
the setpoint with a status of "Uncertain." For the" Actuator action"
option, the action taken is defined by the ACTUATOR_ACTION The totalizer function block is very much like an input class block
parameter in the transducer block because it receives its input directly from a transducer block over a
hardware channel that is selected by the channel (CHANNEL)
Diagnostics parameter. The transducer block supports alarm detection (figure
The setpoint deviation (SETP _DEVIATION) parameter indicates 4-20).
the deviation of the read back value from the setpoint in percentage
terms. In other words, this is the deviation between the desired
and actual valve position.
-+TOTAL
A summary of the de\·ice's current hardware and software error
status is kept in the check back (CHECK_BACK) parameter.
Checks include the following:
• Fail-safe active
• Request for local Operation Figure 4-20: Totalizer function block schematic diagram.
-,,~
(
Field buses for Process Control
Chapter 4- Configuration
processors, it is recommended that you also select processors like PID control loops that "connect" to the process. The unit and
where controls are configured in the FoC.'\DATIO:\: Fieldbus func- the equipment modules are the most relevant physical levels for
t~on blo~k program min? language. \Vhen you do so, the configura- the procedural control in the batch management software.
t~on environment remams homogeneous by consistently using a
smgle standard language throughout the entire system.
familiar mode, setpoint, and tuning in the PID block. For a vast Control!
majority of parameters, the default values are used. An important. I Modul!_j
feature of a configuration tool is templates with prebuilt device
and strategy configurations. Templates simplify the process of ver- Figure 4-21. The ANSI/ISA~88.01-1995 physical model for processing
equipment.
ifying the system and make it easier to prove the correctness of the
control strategy.
The process cell is different from any other AN51/1SA-588.01-1995
ANSI/ISA-88.01-1995 Modeling abstraction in that it is a clear boundary where there is no or mini-
mal interaction between process cells. A process cell also encapsu-
The AN5l/!5A-88.01·1995 is a standard for batch control, but lates the related control activities. A configuration tool using
many of the models and terminology arc also useful for continuous ANSI/lSA-588.01-1995 forces plants to use a modular approach to
regulatory control. Instrumentation that is based on fieldbus build structured control strategies, which make the system more
technologies can be used in both continuous and batch control. For robust (figure 4-22}. Within a process cell there can be any kind of
example, the fieldbus devices may execute the phase logic based linkage, for example, between control modules. That is, a function
on the control recipe in the batch management software. Several block in one control module can link to a function block in another
configuration tools for fieldbuses make use of the AN51/I5A- control module as long as both are within the same process cell.
88.01-1995 models. Moreover, the PROFIBU5 PA specification has a Although it would be tidy to have only the instruments on the
universal function block parameter for batch identification that is same vessel on one network, it would be uneconomical to connect
based on the AN5!/ISA-588.0H995 procedural control model. just a few devices to a bus. The configuration tool can isolate the
control strategy from the fieldbus networking. That is, the control
The physical model deals with the way the processing equipment strategy is organized according to the processing equipment it con-
hke plant machmery and vessels are hierarchically structured. An trols, not the way the instruments are wired together. A control
area consists of one or nwre process cells and so on down to the module contains the function blocks for the flow, level, tetnpera-
control modules (figure 4-21}. The control module is the level that ture and pressure loop, for example, a_ basic PID, cascade of two
is most relevant to function blocks in fieldbus devices such as PIDs, or a ratio loop plus· alarms and totalization associated with
transmitters and valves, which make up simple control activities the loop.
Fieldbuses for Process Control Chapter 4- Configuration
Function Blocks
Each type of function block has a different internal algorithm and
several parameters that perform different types of functions.
Control Module 6 Function blocks perform the basic monitoring and control
functionality independently of 1/0 hardware. For example, the
analog input (AI) block provides the basic functionality needed for
measurement: simulation, inferential rangeJ transfer function,
damping, and alarm. The standard AI block in a pressure
Figur~ 4-22. The ANSI/ISA-88.01-1995 hierarchical structure is"~ transmitter is the same as that of a temperature transmitter. The
orgamze the control strategy.
standard PID block is the same whether it is in a transmitter,
positioner, or centralized contro1ler, independent of manufacturer.
Simplify the process of navigating the control strategy by naming the There are four subclasses of function blocks with different
proces: cells and control modules according to the processing equipment characteristics (figure 4-23):
(machrnes and vessels) they control. It may be a good idea to use the
• Input Class
strategy (STRATEGY) parameter to store a number that uniquely
tdentifzes the control module in which the block is used and to use the alert • Control Class
key !ALERT_KEY) parameter to store the process cell nnmber. This
• Calculate Class
makes tl eas1er for external software to identifi; where individital blocks
belong and where alerts come from. • Output Class
FOUNDATION Fielclbus Programming Language The input class blocks connect to sensor hardware via an input
transducer block over a hardware channel. Control class blocks
The function block progr~mming language is an integral part of perform closed-loop control and have back-calculation
FOUNDATION F1eldbus. It IS Ideal for building strategies for functionality to provide bump less mode transfers and reset
reg~latory con.trol and monitoring. However, several blocks are windup protection, among other features. The output class blocks
available for d1screte logic functions. By selectin r k" d connect to actuator hardware via output transducer blocks over a
pa t . . th bl g, m mg, an
'rame enzmg ese ocks you can make control strategies. The hardware channel and support the back-calculation mechanism.
transducer, r~source, and function blocks work the same way in Hl Calculate class blocks perform auxiliary functions required for
and HSE devices. control or monitoring, but they do not support the back-calculation
mechanism.
Terminology and Basics
Several types of standard function blocks created b th F" !db A large number of standard function blocks have already been
Fo d f "I bl , y e Je us defined by the Fieldbus Foundation. In addition to these, manufac-
un a 10n are avai a e to perform the various functions required
turers define specific blocks that may be extensions of standard
( ( (
"·-"~· ·I, "'
,_,
~~ Fieldbuses for Process Control
Chapter 4- Configuration
The type of blocks avai.lable in a device and the number that can be For example, in a PID block the process variable goes to one of its
used SimuJtaneously differ from one manufacturer and device t e inputs, the manipulated variable is one of the outputs, and the tun-
to another. Some devices may have a fixed set of blo k f yp ing parameters are some of the contained parameters. Parameters
plc, one each of three to four types. Advanced :1 . c sh, or exam- can be set by the user or by the block itself. Input parameters gen-
dy · 11 · . t eviCes ave
namica y mstantmble blocks. This means that th h 1 erally get their value from an output that is linked or set by the
l"b fbi k ey ave a arge
I rary o . oc types, and users can select as many blocks of the user, but the block itself cannot set its input values.
same or different type as the memory can hold Th f" .
tools th t t h d · e con Iguratwn
a suppor t e ynamic instantiation of function blocks Function Block Links
ensure that only supported blocks are allocated to a device and
t~at mem?ry and other device resources are sufficient. For exam- Function blocks are link~d to each other from output parameters to
p e, a device can have several PID blocks The d . . . input parameters. The link carries both the value and the status of
f bT . · ynamtc mstantia- the parameter. An output parameter can link to any number of
wn. cap~ I tty ma~es It easier to use the device to replace a failed
devtce, smce there ts a greater chance that then d . b inputs. Links between function blocks in different devices are
· t · · ew evice can e communicated over the network. Links within the device do not
ms an hated With the blocks used in the previous de . Oth
advantages of d . . VIce. er have to be communicated on the bus. They are therefore
. . ynamic .mstantiation include greater flexibilit for
bmldmg control strategies and applications of the device. y immediate and do not take up network bandwidth (figure 4-24).
As a result, it is desirable to reduce the number of communications
between devices. This can be done by allocating the function
blocks to the devices in such a way that as many of the links as
Fieldbuses for Process Control Chapter 4- Configuration
Figure 4-24. Function block links. "slave" PID controller. Cascade is here used in a wider sense for any
type of function block that receives a setpoint from anoth~r f~nc
tion block For example, the output (OUT) of a PID block IS hnked
An input p~r~meter may also be linked to another input parameter to the cascade input (CAS_IN) and becomes the setpoint of an ana-
?ut only w~tht~l the same device. It is customary to link inputs log output (AO) block and then subsequently as well for the servo
mstead of hnkmg the same output from one device to two or more that controls the position of the control valve_ Though this broader
inputs in another device; this reduces the number of external links. meaning of cascade may appear strange at fir~t, it soon ~akes
The configuration tool generally checks the control strategy for sense. Associated with the forward cascade lmk that brmgs the
unnecessary external links and converts them to internal links. All output from the upstream block to the cascade setpoint of the
output parameters with external links are "published'' on the net- downstream block, there is a backward feedback lmk from the
work, meaning that the output is available to any input that wants lower block back up to the setpoint source_ The backward hnk goes
to use it. Input with an external link "subscribes" to the respective from the back-calculation output (BKCAL_OUT) to the back-calcu-
output. If communication fails to update an input parameter this is lation input (BKCAL_IN) and is used to provide a number of use-
also reflected in the status, which allows the block to take action ful interlocks and bumpless transfer. The forward and backward
and bring it to the attention of the operator. Discrete outputs can cascade links are together called a cascade structure (f1gure 4-25).
~nly be linked_ to discrete inputs. Likewise, analog outputs only
lmk to analog mputs. The user may write input parameters that are Example: A basic PID loop is configured using three blocks: analog
not linked, but input parameters that are linked may not be writ- input (AI), PID control (PID), and analog output (AO)- Three func-
ten. There are three types of links: tion block links are required (figure 4-26)_
• Noncascade (forward)
The first link is from the AI block output (OUT) to the PID block
• Cascade forward
primary input (IN) for the process variable. The second is from the
• Cascade backward PID block output (OUT) to the AO block cascade setpomt mput
(CAS IN). Lastly, there is a link from the AO block back-calcula-
In fieldbus terminology, the block that is the source of a forward tion o~tput (BKCAL_OUT) backward to the PID block back-calcu-
pP'¢
link is said to be the "higher" or "upstream" block, and, conse- lation input (BKCAL_IN). Thus, the cascade structure between PID
·I'
'
¥!' ; quently, the block that is receiving the forward link is said to be the
"lower" or." downstream" block. The term cascade applies not only
to the classtcal control strategy where the output of a primary
and AO is the same as between two PIDs (figure 4-27).
"' 1:
' c:
1·······'·.·.··
'..·.·.·.
"
I
Chapter 4- Configuration
Alarm and Event Parameters Manufacturer-specific blocks have alarms that are implemented in
a fashion consistent with these parameters. The alarm for change
Alarms and events are collectively called "alerts" AI in "Write enable" status is only found in the resource block. The
and · . f · arms occur
rematn active or some time, after which they are clear E t two parameters have names starting with WRITE. The "Discrete"
on the other hand, only occu~. Alarms are reported both whe:~~es, alarm parameters have names starting with DISC. The "Discrete"
occur and when they clear. Smce events do not remain active theJ alarm triggers when the state equals the alarm setting. For the
are never reported as cleared. An example of an event is a "Block diagnostics" alarm there is a common status parameter for
parameter cha~ge. Alarms and events can be configured to be the latest diagnostic alarm (BLOCK_ALM). The block alarm is
detected and hme-stamped in the field devices, provided the host used by asset management software to track the health of devices.
supports the acceptance of the associated alerts reported by the
fteld devices. The parameters used to configure the alarms and The parameters for the deviation between process variable and set-
check al~rm status are the same across the range of blocks·. point have names beginning with DV_HI for process variables that
Dependmg on the block type, the type of standard alarms may exceed the setpoint and DV_LO for when the process variable is
vary. The standard blocks may have some of the followJ·n g a Iarms.. below the setpoint, regardless of control action. The parameters for
• Write enable (WRITE') the four process variable alarms have names starting with HI_HI
• Discrete (DISC") for the process variable that exceeds the critically high limit, HI for
exceeding the advisory high limit, LO_LO when the process vari-
• Process variable high-high (HI_Hl*) able is below the critically low limit, and LO for advisory low limit.
• Process variable high (HI*) The parameters are summarized in table 4-1.
• Process variable low-low (LO_LO*) The "Write enable" alarm is triggered when the write-protection
• Process variable low (LO*) status is changed and therefore does not need any adjustable trip
limit. It makes sense to enable this alarm for devices that are write
• Deviation high (DV_HI*) protected. The "Discrete" alarm trips when the associated value is
the same as the set limit. The "Process variable" and deviation
(
Chapter 4- Configuration
Field buses for Process Control
Table 4-1. Standard alarm parameter names. To enable the time stamping of alerts at the source, that is, in the
Description Trip limit Priority
field device, each device has a built-in clock that is regularly syn-
Status
chronized by a time master, which is usually in the host.
Write enable WRITE_PRI WRITE_ALM
Discrete DISC/LIM DISC_I'RI DISC_ALM
The process variable and deviation alarms have a common hyster-
Process variable high-high HI_HI_ LIM HI_HI_PRI HI_HI_ALM
esis parameter (ALARM_HYS). It is expressed as a percentage of
Process variable high HI_LIM HI_PRI HI_ALM
the range set in the process variable scale (PV_SCALE) of the block
Process variable low-low LO_LIM LO_PRI LO_ALM
but in the output scale for the AI block. The hysteresis makes sure
Process variable low LO_LO_LIM LO_LO_PRI LO_LO_ALM
that the alarm does not chatter (rapidly activate and deactivate)
Deviation high DV_HI_LIM DV_HI_PRI DV_HI_ALM
when the value is close to the alarm trip limit. It does this by mak-
Deviation low DV_LO_LIM DV_LO_PRI DV_LO_ALM
ing the deactivation value different from the activation value by
Block diagnostics BLOCK_ALM
the amount specified (figure 4-28). A high alarm is activated when
the associated value is higher than the limit and deactivated when
ala~m limit values arc configured in the same unit as the process the value is lower than the limit, minus the alarm hysteresis. Like-
van~ble. The block alarm is triggered whenever the device diag- wise, a low alarm is activated when the associated value is lower
nostics detect a fault in the block. You should configure the priority than the limit and deactivated when the value is higher than the
fo~ e~ch ala:m ~o let the host arrange the alarm reporting based on limit plus the alarm hysteresis. When the value is within the band
pnonty. Th1s Will make the job easier for the operator. It is a good set by the hysteresis, the alarm will remain in the "last state" being
1dea _to use these same priority levels throughout the system for active or inactive. The hysteresis can be set within the range of 0 to
consistency and to eliminate mistakes, that isr use them also for 50%, with 0.5% being the default value.
alarms ~ha.t are detected in a shared central controller or host. The
alert pnonty shall be configured as follows: For example, if the process variable scale is set from -50 mmH20 to
+350 mmH20, 0.5% hysteresis would correspond to 2 mmH20. If
0 Not detected the high alarm is set to trip at 300 mmH20 it will clear at 298.
con~igure individual alarms in the block to be acknowledged auto- cleared. This parameter can only be read. The alert associated with
matrcally. The operator acknowledgement status does not affect this parameter has a fixed priority of 2, which is usually configured
the operati?n of the block but is indicated in the process variable to not notify the operator. The event update parameter has ele-
status. Settmg the mode out of service acknowledges all alarms. ments that are similar to the alarm status (_ALM) parameters only
The acknowledgement of the following alarms can be configured that instead of type of alarm and value, it reports the index of the
to be automatic:
parameter that was changed as well as the static revision
(ST_REV), that is, the total number of changes made to the block.
1. Write enable/Discrete
2. Process variable high-high The block alarm status (BLOCK_ALM) parameter is associated
with diagnostic errors. The associated faults are those listed for the
3. Process variable high universal block error (BLOCK~ERR) parameter, which summarizes
the diagnostic faults that are present The information in the ele-
4. Process variable low-low ments of the block alarm status parameter is the same as the infor-
5. Process variable low mation of other alarm state (_ALM) parameters. The subcode
element informs users what fault the diagnostics detected. The
6. Deviation high alert associated with this parameter has a fixed priority of 2, which
is usually configured to not notify the operator.
7. Deviation low
(
,.,______ --
iii'
__
In most blocks, the analog parameters are associated with scalin State Templates
parameters that have names ending with SCALE C t 1 g Discrete parameters are associated with state parameters that have
calclt d t 1 - . onro,
u a e, an ou put c ass blocks generally have a process variable names ending with _STATE. The function block does not use the
scale (PV_SCALE) parameter for the input. Input control and state parameter. A discrete parameter may have 256 valid states. A
calculate class blocks typically have an output scale (OUT' SCALE) host may be configured to use the state parameter as a pointer to,
parameter for the output. Input and output class blocks h~ve a for example, a predefined table of messages and colors for each
transducer scale (XD_SCALE) parameter for the value on the 1/0 state of the associated parameter.
hardware
• .
channel.
.
1
Because the blocks operate WI"th vauesm.
engmeenng umts rather than scaled in percentages in many Parameter Status
blocks_the scaling parameters have no other functio~ than to select
th~ umt. In other_blocks, only the range values are used, and the Input and output parameters always have an associated status.
umt has no function. The scaling parameters h ave four e1ements: Contained parameters, for example, process variable (PV) and
setpoint (SP), also have status, although there are only a few that
• Upper Range Value (EU_IOO%) do. It should be noted that in most blocks the process variable (PV)
• Lower Range Value (EU_O%) parameter and setpoint (SP) parameter may be following the
• Unit primary input (IN) and cascade input (CAS_IN) parameters,
respectively. Whether parameters are actually following these
• Number of decimal places to be displayed inputs depends on the configuration and mode of the block.
The host may also be configured to use the scaling information to In the section of this chapter on device configuration we discussed
drsplay bargraphs and animate filling tanks, among other activitie the "Bad" and "Uncertain" conditions for the quality portion of the
In some blocks, the operational range has to be set using the scalins. status element. In addition to that portion, the limit part of the sta-
parameter. The most common case is to set the control range for th~ tus element indicates whether the associated value is limited or
PID block. Another case in which range has to be set is in the AI constant, or has no constraint. The following limit conditions may
block for inferred measurement applications such h . be seen:
diff r 1 ' asw enusmga
eren 1a pressure transmitter for flow measurement. • None
• Limited High
Field buses for Process Control Chapter 4- Configuration
(
( (
Fieldbuses for Process Control
Chapter 4- Configuration
----Backward cascade path: In case the input is "Bad" a control class block will optionally set
Non-specific the status option parameter and pass a status to the output class
Initialisation request block. This will force the fail-safe state to bring the loop to a grace-
Not invited
Not selected ful shutdown because control cannot continue without input Sim-
Local override ilarly, the fault state is activated if the remote setpoint input for the
Fault state active output class blocks are not being updated due to a loss of commu-
nication. The output blocks may be configured to freeze in the last
Figure 4-30. The sub-status for the "G 00d ~-;-----,-,---l
forward and backward cascade. (cascade)" quality is used in the position or go to a predefined safe value. The fault state may also
be forced from the resource block. It is a good idea to make use of
this feature of the FOUNDATION Fieldbus programming language
Along. with the value from output parameter, the status is carried because it eliminates the need to configure and verify shutdown
to the mput paramete~ of the next block. The backward path r . interlocks for the basic controls using discrete logic.
and constant mformahon is used for exam I t . ImJt
in the PID integrator. Status is als~ us P e, .o prevent wmdup
fer and initialization between blocks. ~1 t~ep~l~Vclkdhe bu,n'plldesshtrans-
Whether the shutdown functionality provided by the basic con-
outputs a "B d" d as >al e t e trols is sufficient or additional SIL-rated equipment is required
re a an are not used by other bl k L · · ' must be decided by doing a safety assessment of each loop.
t~alization information is carried from lower to ~~g~~er ~:::~~~~d ini-
~~~~~~ :~:backward path. The status of the input may change the Status Options
. block. For example, m a control class block a "Bad"
Input may ~es~tlt m manual mode. Calculate class blocks normall Most function blocks have a status options (STATUS_OPTS)
protppagathe h~ut and q~nlity information from their inpt;ts to thei[ parameter by which the block behavior can be configured in
ou ut, t at IS, from higher to lower blocks. response to different status conditions. This parameter can only be
set when the block is in OOS mode during online configuration,
When the output of an upper block reaches the limit for the set- but there is no such restriction when configuring off line. The
Control class blocks do not propagate status from higher to lmver The options "Propagate Fault Forward" and "Propagate Fault
blocks. For example, in the PID block a "Bad" input from AI block Backward" are described in detail in the sections of this chapter on
or back-calculation input does not normally become a "Bad" out- the input and output class blocks, respectively. The overall purpose
put; it just puts the PID block in manual mode. Control class blocks of these options is to report a fault in the control block they.are con-
may also be configured to set a fail-safe status on the output in the nected to rather than in the block itself. The fault propagahon
event of a "Bad" primary input (IN). This done by enabling the sta- options are ideal for control loops because they allow a loop to be
tus option "lFS if BAD IN." This will initiate fail-safe action in the monitored by looking at a single block rather than at three. Th1s .
output class block, for example, a sensor failure will close the con- reduces the amount of block information that has to be communi-
trol valve (figure 4-31). cated and consequently improves control performance.
Some control class blocks like the PID shed to an actual manual
mode if the primary input (JN) is "Bad." However, the block nor-
mally returns to the set target mode, such as automatic or cascade,
once the "Bad" input condition has cleared. This allows normal
control to resume, thereby maximizing availability. However, for
AI some applications, it may be safer for the loop to remain in manual
mode rather than return to the target mode. For this purpose, you
can enable the status option "Target to Manual if BAD IN." When
you use this option, once the primary input (e.g., from an AI block)
goes "Bad," the target mode of the PID will become manual and
Figure 4-31. Status propagation and mode shedding in response to a
sensor failure. remain there until it is changed by the operator.
Input and calculate class block outputs are normally "Good" even
It is a good idea to use this feature if the AI block and PID block are while the output is limited at one of its extremes. Alternatively,
located in different devices, which is most often the case. This will you can configure the block using the status option "Uncertain if
ensure that in the event of a loss of communication the loop can be Limited" to set the output status as "Uncertain" whenever the out-
brought to a safe state. put is limited. This would, for example, allow some c~ntrol bloc~s
to continue normal control (those configured to treat Uncertam
Similarly, you may configure control class blocks to set a fail-safe as "Good") while other control class blocks take fail-safe action.
status on the output in the event of a "Bad" cascade setpoint input Another option for the input and calculate class blocks is the status
(CAS_IN) by enabling the status option "IFS if BAD CAS_IN." It option "BAD if Limited." This would cause all control class blocks
will in turn initiate fail-safe action in the output class block. For to initiate fail-safe action. It may be a good Idea to use these
example, normally a secondary PID block would shed from Cas to options for inferred measurements where value con~ersion or cal-
Auto mode if there is no communication on the cascade setpoint culation is performed. They will ensure that controlts not done
input. If this option is enabled, IFS will be passed to the AO block if based on abnormal values that fall outside the range that has been
the link from the primary PJD is lost. defined. Similarly, the status option "Uncertain if Man mode"
makes the output quality of input and calculate class ~lod<S
You may configure the status option "Use Uncertain as Good" in "Uncertain" if the mode is set to manual. However, th1s IS rarely
control class blocks to treat "Uncertain" as either "Good" or "Bad." the case since the blocks are typically left operating in automatic.
By default, "Uncertain" is treated as "Bad." This means that minor
problems would be treated just like more serious ones (for exam- Block Mode
ple, initiating a shutdown of the loop), which is the safer option.
Alternatively, for greater availability you should enable the "Use The main purpose of the block mode (MODE_BLK) parameter is to
determine the source of the block setpoint (SP) and primary output
Uncertain as Good" option so the block continues to operate as if
the quality was "Good." (OUT). These two selections are combined into a single parameter
(figure 4-32).
( ( (
Fieldbuses for Process Control Chapter 4- Configuration
Out of Service (005): The block is not being executed-In this mode,
the setpoint and output are held at their last value, or, in the case of
output class blocks, they may go to the safe state_ This is always a
Permitted mode that is supported by all blocks_ If the resource
block mode is OOS, the Actual mode of all the blocks in the device
is 005. That is, the whole device is put in "hold_"
Traditionally, there have been two ways of setting the loop mode
from a controller faceplate. One scheme involves three individual
CAS_IN buttons for Manual, Automatic, and Cascade mode. The other
scheme uses two toggle switches: one that selects the setpoint
source as either Local or Remote and one that sets the output
source as Manual or Automatic. Although the block mode parame-
ter is geared toward the Manual-Automatic-Cascade scheme a host
can be configured to let the user control the mode by using the
Local-Remote+ Automatic-Manual scheme.
The operator sets one desired operating mode for the block at the
Target element of the block mode parameter. The set Target mode
may not be achievable during certain error conditions, for exam-
ple, a process variable sensor failure or when the manipulated
Figure 4·33. Mode commands setpoint selection in an output class block. variable does not reach the valve. The present mode is seen from
the Actual element of the block mode parameter, which can only
be read. During the error conditions the Actual mode may change
Automatic (Auto): The operator sets the setpoint (SP), and the block
Itself calculates the block output (OUT). without operator intervention. This is called "mode shedding."
{
(
Fieldbuses for Process Control
Chapter 4- Configuration
.,J
Secondary
Auto
CAS IN Cas
Core ~ - ...0 SP Core
Algorithm
IMan
I ry/' Algoothml
1.'::==:"__1 ___j ~-.J.-.--.-.--
_j
BKCAL_IN BKCAL_OUT
Once the Target mode of the secondary PID has been returned to
Cas it "':'ill pass a "Initialization Request" substatus to the pnmary
Chapter 4- Configuration
Fieldbuses for Process Control
PID block. The substatus of the output (OUT) of the primary PID since these do not support the safety and bumpless transfer fea-
will be "Initialization Acknowledge." This lets the secondary PID tures of the Fou:-;DATIO" Fieldbus programming language.
know that it may be switched back to Cas mode without causing a
bump in its setpoint because it is equal to the back-calculation The reset windup protection is propagated backward to the begin-
input. Mode cannot be switched to Cas unless the initialization in ning of a cascade. For example, if for some reason the AO block IS
the primary PID block has been acknowledged. When the primary not in cascade mode it will set "Not Invited" on its back-calcula-
PID block leaves 1mhahzat10n manual the Actual mode will return tion output. When the secondary PID sees "Not invited" on the
to the set Target mode. It is sometimes possible to briefly see the back-calculation input it goes into IMan and sets "Not invited" on
"Initialization Acknowledge" on the secondary PID cascade input its back-calculation output, which also puts the primary PID in
(CAS_IN) status and the "Initialization Request" briefly on the pri- IMan. The same backward status propagation function also pro-
mary PJD back-calculation input (BKCAL_lN) status. However, tects the primary PID from reset windup in cas: the secondary PID
they are transitional stages that pass very quickly. reaches a limit. This feature allows control to piCk up faster once
the secondarv PID lea\·es the limit condition. It is therefore a good
In this example, the operator changes the secondary PJD block idea to use the FOUXDATION blocks at all levels of the cascade to
mode by setting the Target to Auto. However, the sequence of benefit from this protection mechanism.
events for initialization would be the same in a scenario in which
the Target is set at Cas but the Actual mode sheds to some other In the event of an actuator failure the output class block will set a
mode that is not using the cascade setpoint input. Once the condi- "Bad" status on its back-calculation output. When the control class
tion that caused the shed has disappeared, the block will return to block receives this status on its back-calculation input, the block
the set Target mode as soon as the initialization of the primary PID will go into !Man mode. This ensures that control using a failed
has been acknowledged. It is not necessary to remember this actuator is not attempted and at the same time prevents reset
sequence since it is completely automatic. However, remember windup (figure 4-36). It is a good idea to use the FOUNDATION
that if the block has back-calculation input, it must be connected to blocks throughout the control strategy to benefit from this protec-
the lower block's back-calculation output, otherwise the cascade tion mechanism.
will not work. If for any reason (for example, because there is no
communication) the back-calculation input (BKCAL_IN) is "Bad"
then the mode becomes !Man.
(
(
Fieldbuses for Process Control
Chapter 4- Configuration
A~ No cascade structure
~ Required
PV SCALE.EUO ·
A0 - "10%-
Figure 4~38. The process variable scale and more constrictive limits restrict
\ Good (cascade) the setpoint.
Figure 4-37. A non-cascade output linked to the cascade setpoint input in Auto mode. The absolute setpoint limits are therefore not really
need no associated back calculation link. used.
Setpoint Limiting In addition to the absolute setpoint limits there are also rate-of-
change limits. There are separate parameters for increasing
The setpoint (SP), cascade setpoint input (CAS_IN), back- (SP_RATE_UP) and decreasing (SP _RATE_DN) rate of change. The
calculation output (BKCAL_OUT), high setpoint absolute limit engineering unit for the rate-of-change limits is the process vari-
(SP_Hl_UM), and low absolute setpoint limit (SP_LO_LIM) able unit per second. For example, if the process variable unit is oc
parameters are set in the same unit as the process variable. In other the rate-of-change limit unit is °C/s; for% it is %/s. Suppose a new
words, they are set according to the process variable scale user entry or a change in cascade setpoint input causes a sudden
(PV_SCALE). In discrete blocks the equivalent parameters have change in setpoint. In that case, the block will use an internal
names thaf end with "_D". "working setpoint" that slowly ramps to the new setpoint at a rate
determined by the rate-of-change limit (figure 4-39).
The setpoint by default can be set no more than 10 percent outside
the range imposed by the process variable scale (PV_SCALE)
parameter. More constrictive setpoint limits can be set using the
high (SP_HI_ LIM) and low (SP_LO_UM) setpoint limit parame- SP
ters. This prevents the setpoint from being set over the full scale ·····{SP_RATE_DN
(figure 4-38).
By default, the setpoint limits only apply in Auto mode. This __.::,_1~\\_\
...-t-Il
restricts the setpoint value that the operator can enter. In other
words, the setpoint value does not apply to cascade setpoint input
in Cas mode, for example. However, if in the PID block the option \ SP_RATE_UP
"Obey SP limits if Cas or RCas" has been enabled in the control
options (CONTROL_OPTS) parameter then the setpoint limits will
L-------~ time
apply in caScade and remote cascade modes too. Note that the out-
put class blocks do not have the control option and usually are not
Figure 4~39. Setpoint rate~of-change is restricted within limits.
Field buses for Process Control
Chapter 4- Configuration
For example, if the rate of change limit is 5%/s and the setpoint Table 4~3. Mode priorities.
makes a sudden change of 20%, it will take four seconds for the
Mode Description Priority Remark
internal "working setpoint" to ramp to this new value.
oos Out of Service 7 Highest
IMan Initialization ·Manual 6
The rate-of:change limiting can be disabled by setting the limits to -~
LO Local Override 5
zero, m whtch case the setpoint will be used immediately as is. For
Man Manual 4
control class blocks, rate limiting applies only in Auto mode. For
Auto Automatic 3
output class blocks, rate limiting applies in Auto, Cas, and RCas
modes. Because the PID block has no rate-of-change limit on the Cas Cascade 2
-
RCas Remote Cascade 1
output, rate limiting is instead applied on the AO block setpoint.
ROut Remote Output 0 Lowest
-- -------'--------·----
If the setpoint is limited this will be indicated in the status of the
back-calculation output as "Limited High" or "Limited Low." For If the process variable input is "Bad," the Actual mode in an input
examp1e, the output of a primary PID in a cascade is used as the class block will shed to manual. Normally, it will return to the nor-
~etpoint of the secondary PID. If the primary output increases until mal operating (Target) mode when the bad condition disappears.
It touches the high setpoint limit of the secondary, the secondary By enabling the status option (STATUS_OPTS) "Target to Manual if
:"Ill set the back-calculahon output status as "Limited High." This Bad IN," the Target mode will also be set to manual. As a result,
m tur_n will prevent the primary PID from increasing its output fur- the input block will remain in manual mode even after the bad
ther; ~n ot_he~ words, the prima~y output will stop at the secondary condition has cleared. The operator must then put it back into
setpomt hmit. However, the pnmary PID will not go into !Man operation.
mode.
If the cascade setpoint input (CAS_IN) value is "Bad"-for exam-
A "Constant" limit condition will be set on the output (OUT) in ple, because of communication problems-and the Actual mode is
Man, !Man and LO modes or on inputs which are not connected Cas then the mode will shed. If the mode is not Cas the condition
until they are changed by an operator. If the back-calculation input will be ignored because, in general, the mode is not affected by the
status (BKCAL_IN) is constant the output (OUT) value will follow status of unused inputs. If the back-calculation input (BKCAL_lN)
the back-calculation input. If the input of the PID block is constant status is "Bad" (for example, because it is not connected or there are
the PID block will stop integration. communication problems), the block mode will shed to !Man.
Mode Shedding and Retum Remote Mode Shedding
~en t~e operating conditions make the set Target mode The remote modes (RCas and ROut) are not often used, and only a
Impossible, the Actual mode will change. For example, if the few control class blocks and output class blocks support them.
cascade setpomt mput (CAS_IN) is "Bad," the value is unusable They are present to allow other applications to write the block
and the mode can no longer be Cas. If the primary input (IN) is setpoint or even the block output directly. In other words, the
"Bad," no control can continue and thus the mode should be Man. remote output mode does not really use the block functionality at
Under these and other conditions, the Actual, and optionally the all during normal operation. The remotely written value is passed
Target, mode Will change. Automatic change of mode is called on directly to the next block. However, should the "link" between
:·mode shedding." The Actual mode can only shed to a mode that the block and the remote application fail the mode of the block will
IS enabled m the Permitted mode element of the block mode shed to a higher-priority mode that allows the block to take over
parameter. When the condition that is causing the shedding the functionality. For example, a loop may be controlled using
disappears, the block will normally return to the previous mode. some advanced multiple variable and multiple constraint control
Mode always sheds to the next higher priority Permitted mode. software that writes its output to the output parameter of a PID
Out-of-service has the highest priority; remote output has the block. However, if the "link" is lost, mode will shed to Auto, and
lowest (see table 4-3). Mode never sheds to remote-cascade or regular PID control will take over. The loop will still operate in a
remote-output. less advanced way, but while maintaining high availability.
(
(
~: hcldbuses for Process Control
Chapter 4- Configuration
have access to the density or the process temperature. Another Input Status Options
example of the use of channel parameters is a device that has
By default, the status on the output parameter of the input block
tnultiple input terminals. If the sensors for some reason have been
during sensor failure is "Bad- Non Specific." Although this is
cross-wired, it is possible to correct the sensor assignment to the sufficient to make the mode in a control block shed mode, the
function blocks without having to physically rewire the sensors at reason for doing so will not be visible from a host looking only at
the terminals simply by swapping the channel parameter settings the PID block. By enabling the status option "Propagate Fault
(figure 4-40). Forward" the output status will instead be the more specific "Bad-
Sensor Failure." This makes it possible to spot the problem from
the control block without tracing back to the input block. The
status is propagated through any intermediate calculate class
blocks. No block alarm will be generated in the input block when
this option is enabled. With this primary variable input status, a
control class block will generate a block alarm on behalf of the
input block. That is, only one of the blocks issues the sensor failure
alarm. Therefore, it is a good idea to enable this option in an input
block part of a control loop that connects to a control block, but to
leave it disabled in an input block that is used for monitoring.
Figure 4-40. The CHANNEL parameter can be used to rewire the inputs in The analog input block takes the primary value
software. (PRIMARY_VALUE) from the transducer block-for example,
pressure, temperature, or flow-and makes it available to other
function blocks. It provides a number of the functions expected
Input Simulation
from a transmitter, such as simulation, linearization., filtering, and
When enabled, the scalar simulate parameter (SIMULATE) and the alarm (figure 4-41).
discrete simulate parameter (SIMULATE_D) can be used to
override the signal from the transducer for system test and trouble-
shooting purposes. By writing values or status to the Simulate
element of the parameter, it is possible to safely test the system
response to faults and process conditions that would otherwise be
difficult or dangerous to try out. The simulation parameter
Transducer element shows the value and status of the signal from
the transducer. This parameter is therefore useful for checking
whether the block is receiving the correct transducer value. A
block alarm will be issued when Simulate is active, and this can
also be seen from the block error parameter. Simulation has to be
enabled if the device has hardware protection such as a jumper.
Lastly, the simulation is activated by the Enable element in the
simulate parameter. The status of the simulation protection switch Figure 4-41. AI block schematic diagram.
can be seen from the block error parameter in the resource block.
The simulation Enable element setting in the function blocks is not The AI block implements channel, simulate, damping, and process
retained during a power loss in order to ensure that the device variable alarms. The transducer scale (XD_SCALE) parameter usu-
always powers up in the normal operating mode. ally sets the engineering unit that is used by the transducer block
to prevent any inconsistencies and subsequent errors. It is impor-
i' Fieldbuses for Process Control Chapter 4- Configuration
tant to note that the process variable alarms in the AI block act on linearization type (L_TYPE) parameter. The following standard
the output (OUT) parameter, not on the process variable (PV) Jinearization options are available:
parameter. It is therefore important to keep the AI block in auto-
• Direct
matic mode. This also means that the alarm trip limits must be set
within the range specified by the output scale (OUT _SCALE) • Indirect, linear
parameter. Hence, the output scale parameter may have to be set • Indirect, square root extraction
for the sake of the alarms, even though it is not used for scaling. If
the AI block is part of a control loop it may be a good idea to detect When the "Direct'' option is selected, the measured value from the
the alarms in the controller block instead to reduce the number of transducer essentially passes through the AI block with no further
blocks that have to be monitored. processing, apart from the damping. No re-scaling of the measure-
ment is performed. The AI block operates over the entire range
Damping that the associated sensor is capable of. As a result, there is no need
For some applications, damping has to be applied to filter out to configure the scaling parameters. In other words, neither
noise on the measurement signal, thus obtaining the process XD_SCALE nor OUT_SCALE is applicable. This is the option that
variable (PV) and output (OUT). The process variable filter time is almost always used for temperature, level, flow transmitters,
(PV_FTlME) parameter is used to set the time constant in seconds and the like, as well as for pressure transmitters used to measure
of a first-order lag, that is, the time required to reach 63 percent of pressure.
the steady-state value (figure 4-42). If the time is set to zero
seconds, the damping is disabled and the measurement is passed The two "Indirect" options are used for inferred measurements.
right through. For the indirect options, the transducer scale (XD_SCALE) and
output scale (OUT_SCALE) parameters come into play. The pri-
mary value from the transducer block is converted into a percent-
age of the range that was set in the transducer scale param~ter a_nd
shown in the field value (FIELD_VAL) parameter. The engmeenng
' unit and range of the actual measurement are set in the transducer
scale, and the engineering unit and range of the inferred measure-
ment are set in the output scale. The "Indirect, linear" option is
63% il used when, for example, a pressure transmitter is used to measure
liquid level based on the hydrostatic pressure. For the example in
It
figure 4-5, the XD_SCALE shall be configured 1.49-5.89 kPa and
63%
ll the OUT SCALE set 0-0.56 m. For level applications, operators
very ofte~ prefer a reading in percentage terms rather than in an
engineering unit. For that purpose, configure OUT_SCALE as 0-
100%.
---------- treat potentially extreme values outside the desired range as "Bad"
OUT_SCALE
.EU100%
rPV I OUT for safety reasons .
Setting the raflge should not be co/lfused with Calibratio11 done against a
standard, ·which is performed in the transducer block.
Minimum Configuratiou
The lower-range value (EUO%) of the scaling parameters can be Output Limiting
higher than the upper-range value (EU100%). This is required in By default, the output is limited to +/-10 percent outside ofthe
some le~el-~eas~remen~ applications, and is useful for correcting output scale (OUT_SCALE) parameter. For most applications, the
the readmg 1f a differential pressure transmitter has been mounted output scale will be left at its default value of 0-100%, which
the wrong way around.
represents a fully closed and open valve or a pump stopped or at
maximum speed. For this case, the output is thus limited within
When you use linearization, it may be a good idea to enable the the range of -10% to+ 110%. However, for some applications, Such
status option "Uncertain if limited." This provides the option to as the primary PID in a cascade, the output scale may be set to
another range to match the process variable scale in the receiving
( ( (
ill Fieldbusesfor Process Control
Chapter 4- Configuration
block. For most control blocks, the output can optionally be limited
to a more constrictive high limit (OUT_Hl_LIM) and low limit (OUT SCALE). However, if the block is in manual mode another
t } option "Track in Manual," must also be true m orde~ for
~~: :l~ck
(OUT_LO_LIM). The output limits may be set 10 percent outside of
the output scale. These limits may be used to avoid critical to shed to local override mode. Once in local m·ernde
conditions. By default, the output limits also apply to Manual de the limit-condition part of the status for the output becomes
mode. However, by enabling the control option mo '
"Constant," even though the output va 1ue IS · d yna micallv
< ., •
(CONTROL_ OPTS) "No OUT limits in Manual," the output limits . h k'
fo1lowmg t e trac mg va . lue The status
. of the back-calculatJOn,
"N t
do not apply in this mode. This, of course, means that it is up to the remote-cascade, and remote-output parameters bec~mes o
judgment of the operator to enter a safe value. Invited." This ensures that higher control blocks go mto !Man
mode and do not wind up because of the open l?of': T~e .
When the output reaches a limit, this is indicated as "Limited mec h amsm. ·s the same
1 •
as for the cascade mode · mthahzahon.
1 · d The
High" or "Limited Low" in the limited condition part of the output . k.
dtscrete trac mg mpu . t might be an externa 1 stgna 1 receiYe
1 block
status. In Auto, Cas, and HCas modes the limit condition will also through a discrete input (DI) block or from an ana og a arm
be indicated on the back-calculation output (BKCAL_OUT). The based on an alarm condition, and so on.
limit condition is received on the back-calculation input
(BKCAL_IN) of the higher block, for example, from the secondary By loopinr;: the PID output back into the track value input a scheme is J
PID to the primary PID in a cascade control loop. The AO block tn
achieved which lite PID output is forced to freeze at its last 'l.'aluelw zen
does not really have an output and therefore no output limits. The the discrete track input is activated, for example, from some externa
limit condition, when received, prevents the upper block from signal.
moving its output further in that direction, which thereby prevents
reset windup of the integrating action in a PID controller. In other .
If the discrete !raek mpu
. 1 g oes "Bad ' " the last usable
. .value is used.
f 1
words, the limit condition status information acts as reset windup .
If the discrete trac k.mpu t.iS "Bad" on power-up ' it will be'II set
b a se. d
protection between function blocks that are located in the same or . vaIue goes "Bad ' " the last usable value Wl 'll
If the trackmg e use
h Jd .
different devices. Note that there is no mode shedding as a result If there is no last usable tracking value, the block output WJ o
of a limit condition. The PID block has a special back-calculation at its present value.
hysteresis (BKCAL_HYS) parameter to prevent offset caused by
the noise rectification of an unstable controller output near the out- The function blocks in the FOUNDATION Fieldbus programming
put limit. There are no output rate- of-change limits, but by config- language already have several safety interlocks bmlt m to deal k
uring the setpoint rate of change limits in the receiving block, such with sensor failures~ and the like. For this reason, the output-trac -
as an analog output block, you can avoid sudden process upsets. ing feature is seldom used.
Output Tracking (Control Class Local Override) Setpoint Limiting (Control Blocks)
At times, it is desirable to drive the control output to some form of The absolute setpoint limits do not apply in Auto mode. :o';;ever,
safety value. In the event of an emergency, it can be operated from the setpoint rate-of-change limits apply only m Auto mo ~ you
some kind of simple local device. The controller could be a backup set the rate-of-change limit to zero the setpomt Will be use
usually overridden by a main controller, or otherwise you could immediately, which effectively disables the setpomt rate:of-ch~nge
override the output. Most control class blocks support this limit. When the setpoint is limited this will be mdicated m ~h: i~ut
function. For output tracking to occur, it must first be enabled from portion of the status element of the setpoint parameter an ac -
the control options (CONTROL_OPTS) parameter by activating the calculation output.
option #Track Enable:~ An external tracking value is received on
the output tracking value input (TRK_VAL). This value is scaled by Damping
the track scale parameter (TRK_SCALE). If the discrete output . . d ampmg
. has
track input (TRK_IN_D) is true, the control block Actual mode will For some apphcahons, . . to be applied to filter
. bl out
(PV)
noise on the input (IN), thus obtammg the process vana e d t.
switch to Local Override, and the scaled tracking value will be .
The process vanable f'l ·
1 ter trme (PV- FTIME) parameter· iS
. use . o
converted to the output unit based on the output scale set the time constant in seconds of a first-order lag, that IS, the time
Fieldbuses for Process Control Chapter 4- Configuration
required to reach 63 percent of the steady state, just as for the AI uring the secondary PID back-calculation output to follow the pro-
block. If the time is set to zero seconds the damping is disabled and cess variable instead of the setpoint. This can be done by usmg the
the measurement is passed right through. option "Use py for BKCAL_OUT." In !Man mode, the primary PID
will initialize its output to the secondary process vanabh~. Th1s \':'Ill
Control Options make the secondary sctpoint identical to the process vanablc, elim-
Some of the control class function blocks make use of one or more inating error and bumps.
options in the control options (CONTROL_OPTS) parameter,
which allow the block behavior to be customized. For safety PID- PID Control Function Block
reasons, this parameter is only set when the block is in OOS mode The PID (Proportional, Integral, and Derivative) control block
during online configuration, but there is no such restriction when receives a controlled variable on its input (IN) parameter. fhese
configuring off line. The options that can be set are as follows: variables (for example, pressure, temperature, or flo":) are
• Enable bypass typically received from an AI block, but it's also posstb1e for them
to be processed by another block. The PID control block provides a
• Setpoint tracking in Manual mode number of the functions expected from a controller, s~ch as
• Setpoint tracking in ROut mode filtering setpoint selection and limiting, the PID algonthm, output
selectio~ and limiting, feedforward, sc:p~int trackin~, output
• Setpoint tracking in LO and IMan modes tracking, and process variable and dev1at10n alarm (hgure 4-44).
• Retain Target SP selection You can use the PID block to build common control strategies
• Direct Action together with other blocks.
TRK IN 0
The options are best described in the context of their respective fea- OUT
BKCAL_IN
tl!res. The 'Direct Acting," "Bypass Enable," "SP-PV Track in
Man," "SP-PV Track in Rout," and "SP-PV Track in LO or !Man"
options are explained for the PID block. The "SP Track retained tar-
Figure 4-44. PID block schematic diagram.
get," "Obey SP limits if Cas or Rcas," and "No OUT limits in Man-
ual" options are described for the general block characteristics. The
"Track Enable" and "Track in Manual" are explained for the con- Tuning
trol class blocks.
At the heart of the PID function block lies a PID algorithm. To
make the tuning constants dimensionless, you must configure a
In the past, cascade control setpoint tracking in the secondary PID control range in the process variable scale (PV _SCALE) parameter.
block was accomplished by setting the primary PID output to the · The engineering unit does not matter; only the range values ar~
process variable of the secondary controller. In addition to the set- used. In other words, for the FOUNDATION Fieldbus programmmg
point tracking options already available in the blocks, you can also language the "range" is usually not set in the transrmtter (AI block)
achieve tracking in the PID block in the traditional way by config- but rather in the controller (PID block). There are three tunmg
( f I
..
Chapter 4- Configuration
Fieldbuses for Process Control
(
( ( {
. " Fieldbuses for Process Contml
Chapter 4- Configuration
Activate bypass-
Deactivate bypass-
Figure 4-47. Cascade application.
bypass should the transmitter associated with the secm1dary PID have to
be removed for maintenance or calibration.
Minimum Configuration
As a minimum, the following parameters must be set:
Even if the block is in manual, the calculated result can still be seen
from the pre-output (PRE_OUT) parameter. Once the mode is
switched back to automatic, the output (OUT) will ramp to the pre- ---c--;- · - - - - - . ---;ater flow rangeability.
Figu-;;4·:so. Stacked pressure transmitters 1or gr
output value within the balance time (llAL_T!ME). This will pre-
vent the process from being bumped.
. t adings may differ slightly
It is quite possible that the t~o mpu ;~ferential pressure. A single
AR - Arithmetic Function Block even though they measure t e same the recess variable to
S\Vitchover point would there~ore ~~usefore ~he value is gradually
The arithmetic block provides a general-purpose calculation
jump from one value to the ot er. ~r~ (RANGE LO) to a high-
capability. It may be used to perform common computations used
interpolated from a set low-range pom . t should be configured
in the process industry, such as pressure and temperature
range point (RANGE_HI). The range pom sf the lower input value.
compensation of flow, hydrostatic tank gauging, and controlled
flow setpoint in ratio control (figure 4-49). for values below but ~ear.th~ u:er ra~~=: the process variable is
When the input (IN) IS withm es~ ~a in~ut (figure 4-51). The
The process variable (PV) of the block is obtained from two inputs, interpolated between the inp~tf an th:~wer half of the range, and
status of the low mput IS use or · h h lf of the
.the status of the (high) input is udse~ f~~ t~gh~gp:i~t:should be
the main input (IN) and the low input (IN_LO). For most applica-
tions, only "the input (IN) is used to obtain the process variable. range. If the low mput IS not use ' o r
However, to achieve higher rangeability the low input (IN_LO) can
( ( ( (
Fieldbuses for Process Control
Chapter .i _ C.::.nfigu:ation
configured with values lower than the lowest expected value for
the input (IN). • IN_2 Use bad
• IN_3 Use uncertain
• IN_3 Use bad
' By enabling any of the "Use uncertain" options the resf_-2:-'~U-\"e _
input value will be used as if "G oo d" ev en if .the status·.::. E~er-
;b] _, ·~·;r the
tain." Similarly, the option "Use bad" makes It poss. hef~_-- · sta -us is
input value to be used as if it was "Good" even thoug ~ ~ ·
"Bad."
--
RANGE_ HI For maximum versatility, the b Iock suppor ts- several r:- ...--ithc.s
. ala,:
h
··~~----------------
Example:
~as flow compensation for linear transmitters, for example, tur-
bmes. Q""" =Q,.,,·[t,-t,]-K
Flow Compensation, Square Root
lleat flow computation
Example:
OUT=Pv-[;~ +t3]-GAIN+BIAS
Example:
Examples:
Q = L [JLJ K
(
(
·- Chapter 4- Configuration
Fieldbuses for Process Control
desired additive flow, which is then used as a setpoint in the PID Average
block.
PV+tl+t2+t3 ·GAIN+BIAS
OUT number_ of_ inputs _used
Traditional Summer
Fourth-order Polynomial
Example:
When a single pressure transmitter is used to me~sure liquid ~;el
•I the indication varies depending on product density be~aute t I
ressure transmitter really measures mass. To correct~ e ~ve 'a
Figure 4k53. Ratio control strategy.
~econd transmitter is used to compensate for the density. For
closed tanks, a third transmitter is added at the top to comrns~e
for the pressure of the vapor in the empty space above the tqm .
Using the" traditional multiply-divide" algorithm in the arithmetic Figure 4-54 shows a typical arrangement.
block you may implement either scheme of ratio (figure 4-53). In
the multiplying method, a wild base flow of 3600 kg/hand a ratio The following formula computes tank level compensated for
of 0.5 would give a controlled additive flow setpoint of 1800 kg/h. changes in liquid density and ullage pressure.
If done using the division method, the corresponding ratio would
be 2 to achieve the same controlled flow setpoint. In both cases, it is
important to remember to set the compensation limit values such
that the factor multiplying the process variable is not limited
within the normal operating range.
- newouses tor Process Control
Chapter 4- Configuration
In an output class block, the local override mode can have two
functions. On the one hand, it can mean that the fault-state shut-
The
·tt bottom
· transmitter connects
. to the main inpttt, the top t rans-
.
down function in the block is active. On the other, it can mean that
m~ er to mput 1, an? the mtddle transmitter to input 2. The output the output device has some form of local override switch that has
gam should be configured to the height between the bottom and
m1ddle pressure transmitter. been activated. For example, it is common for electrical valve actu-
ators to have a hand/auto lever that disengages the motor and
Limiting instead engages a hand wheel. During hand operation, the mode
would be local override. Although it is possible to put an output
The part of the equation within square brackets is limited by the class function block in automatic mode, the Target is usually set in
low-compensation limit (COMP_LO_LIM) parameter and a hi h- cascade once and for all and not changed. The mode would be
compensation limit (COMP_HI_LIM) parameter, which restricrthe Auto during local operation but Cas for remote operation. The out-
amount of correc!ion applied on the process variable. Lastly, to put function blocks do not really use the output selection. The
enable output. umt conversion and other adjustments to the mode of the control loop is usually set by the block mode parame-
output, there IS also a gain (GAIN) and bias (BIAS) f th ter in a control class block, for example, the PID block.
The bl k t (OU ' or e output.
oc ou put . T) is restricted within a high limit
(OUT_Hl_LIM) and a low limit (OUT LO LIM) Th Output Clrannel
· bl · - - · e process
vana e umt (PV _UNITS) and output unit (OUT_UNITS)
The channel (CHANNEL) parameter in each output block is used
parameters do not affect the function of the block; they are there
for mformahon purposes only. to select the transducer block to which the output goes, just as for
the input class blocks. Most output devices only have a single
Minimum Configuratiou output. In this case, the channel parameter really only has one
option: 1. However, a multivariable device such as a conventional
As a minit~um, the MODE_BLK parameter must be set. Remember signal converter may have many options. For example, if the
to set the bJas and gain for inputs and output. Left at their default output terminals for some reason have been cross-wired in a
values, mputs may not b~ taker: into account or division by zero device that has multiple outputs, it is possible to correct the output
may result For the algonthms m which compensation limiting is terminal assignment to the function blocks without having to
e~~Joyed,. you must set the limits so they do not interfere. physically rewire the outputs at the terminals. This is done simply
Stmllarly~ you must set the range for the low input auto- ranging. by swapping the channel parameter settings.
!. f ( (
Fieldbuses for Process control
.. -------------
Chapter 4- Configuration
Outptd Options
• The cascade setpoint input communication watchdog times
Most of the output class function blocks mak f out
options in the I/O-options (10 OPTS) e use o one or more
1
possible to.customize the blockbehavi~:r;::~e:e~~:~:~~e ~h· • Power-on
parameter IS only set when the block is in OOS d d . s, Is • Forced from the resource block
conf~guf~tion. ~owever, there is no such restri~~new~:~ng onlme
confJgurmg off lme. The options that can b e set are these:
There is a status option in most function blocks that sets their out-
• Invert put status as "Initiate Fault State" if a critical input parameter is
"Bad," usually because of some error or failure. When this status is
• Setpoint tracking in Manual mode
received on the cascade setpoint input (CAS_IN or CAS_IN_D)
• Setpoint tracking in LO mode parameter of an output class block it will go into LO mode. In the
• SP Track retained target event the period of time in which the commnnication of the cas-
cade input parameter is lost is longer than the fail-safe time
• Increase to close (FSTATE_TIME) parameter, the block will also go into LO mode.
• Fault State to value The fail-safe time parameter is set in seconds (figure 4-55). The
shorter the time set, the safer the loop becomes. However, too short
• Use Fault State value on restart a time may result in annoying spurious trips that reduce the avail-
• Target to Man if Fault State activated ability of the loop. Two seconds is a typical value for time-out that
strikes a good balance between safety and availability. By enabling
• Use PV for BKCAL_OUT the I/O-option "Use Fault State value on restart" the fail-safe value
is used as a known "power-up" initial output value when the
The options are best understood in th . device is switched on. Additionally, there is a fault-state set param-
features The "SP T k . e context of then respective
h { rae retamed target" option is described in this eter in the resource block that may be used to instantly force all
c apter or the general block characteristics. The "U . PV f output class function blocks into their preconfigured Fault State,
BKCAL_OUT" and "Increase to close" . se . or. ignoring the fault state time.
this chapter for the AO block The "F oltpShons are explamed m
Fault State value on restart " ·and "T. au tate to ,value" '
"U
se
vated" are discussed. th"' h arget to Man tf Fault State acti- By default, the setpoint will freeze at its last value when Fault State
function block d~arac~:ris:~c~. apter on the common output class is activated. This allows the process to continue in its Jast position
but without any further manipulation of the output. This option
provides availability since the process is not interrupted. Depend-
Fault State Shutdown (Output Class Local Override) ing on the process and the actuator equipment that you have, a
When devices or comm · t" f .1 . safer option may be to shut the loop down by bringing it to a
. umca IOn at their associated controls
known safe value. If the I/O-option "Fault State to value" is
~a;not c~~tmue. Most often, you should shut down the affected
enabled, the fault-state value (FSTATE_VAL parameter in case of
sta~ ?,r;. east ~ot attempt control. This function is called "fault
. ~agnostics performed all the way fronl the analog, FSTATE_VAL_D in case of discrete) will become the set-
respo nsi"bl e f or d etectmg
. faults. Ultima tel l sensor
.. are point of the output block. Typically, the fail-safe value is something
futput class blocks that go into local over{;d:o;~~:r;~t:~~~~h that means "closed" or "off." The "freeze last value" option may
Readback
SP
FSTATE_TIME The actual status of the output hardware can be seen at the
t----·+: readback parameter (READBACK in case of analog,
1---+---i CAS_IN READBACK_D in case of discrete). This makes it possible to see,
for example, the actual position of a control valve or the actual
state of an on/ off valve. The readback value is taken backward
through the transducer scale (or state, in the case of discrete),
action type, and process variable scaling (or state, in the case of
discrete) to obtain the process variable (PV in case of analog, PV__ D
FSTATE_VAL in case of discrete). There is an option to use this actual value for
~--*~---~:~---Time cascade initialization to provide true bump less transfer and reset
Communications Loss windup protection.
'
:';-
{ ( (
k
.Ill. Fleidbuses for Process Control
Chapter 4- Configuration
simply,:ooking at the PID block. Instead, by enabling the status When the fault state is active, the fault-state value becomes the set~
option Propagate Fault Backward" the back-calculation out ut point and will also be seen on the back-calculation output
~tatus ~Ill be the more specific "Bad- Device failure." This !akes (BKCAL_OUT). This makes the upstream block initialize its output
1t poss1ble to spot the problem from the control block without using the standard cascade initialization mechanism so as to pro-
tracmg down to the output block. No block alarm will be vide bumpless transfer out of the fault state.
generated m the output block when this option is enabled. With
th1s back-cakulahon mput status, a control class block will Setpoint Limiting (Output Blocks)
generate a block alarm on behalf of the output block That·1
1
one of the blocks issues the output failure alarm. Lik~wise, :h~n Y The absolute setpoint limits do not apply in Auto mode. The
output blocks do not normally propagate the fact that the fail-safe setpoint rate-of-change limits apply only in Auto, Cas, and RCas
functwn or local override mode (operation by hand) is active ba k modes. By setting the rate-of-change limit to zero the setpoint will
to the upstream blocks. c be used immediately, which effectively disables the setpoint rate-
of-change limit.
AO -Analog Output
Action
TI1e analog output block receives an input from another function
block and may process the value before passing the signal through The process variable scale (PV_SCALE) and transducer scale
a hardware channel to a transducer block. This may be, lor (XD_SCALE) parameters are used to transform the setpoint to a
examp~e, the demanded valve position from a control class block value that is accepted by the transducer block. The engineering
It P:~vtdes a nurnb~r ~f.funct.ions that are expected from a · unit lor the process variable scale does not affect the block
post honer, ~uch a~ hmtting, signal reversing, actual position operation. The transducer scale unit usually sets the engineering
feedback, Simttlatwn, and fail-safe function. unit of the associated transducer block to eliminate any
inconsistencies and subsequent block errors. Control valve
positioners normally operate in 0 tolOO percent, which represents
the closed and open endpoints of the valve travel. However,
converters for current or pneumatic signal output need to have
their transducer scale set to the appropriate operating range and
unit. For example, in a fieldbus-to-pneumatic signal converter the
PV_SCALE may be configured 0-100 percent and XD_SCALE set to
3-15 psi.
percent always means tile valve is open-independent of the actuator action prevents reset windup ii: t~e PID block in the same way that
being air-to-open or air-to-close. This is achieved by configuring the AO feedback from limit switches dtd m the past.
block according to the actuator and configuring the PID block according
to the process behavior. The "Increase-to-close" I/O-option in tlze AO The operator normally sets th e 1oop m ode Ifrom h the dblock
. thmode
PID
block is used with air-to-close actuators. The "Direct-acting" control arameter in the PID block. To stop contro ' t. e mo em e
option in the PJD block is used in processes where an increasing process block ,,·ould be set to tv1an. If the output device for some re~son
variable requires i11creasing control output, for example, for the chiller has to be operated by hand, the best way to handd-operahte t etpana;
valve in a cooling application. log output block is to put themode to Auto an enter t e se om .
The output (OUT) parameter is made available to show a copy of 1\:fhrimum Configuration
the value that the AO block passes to the transducer block over the . . the MODE - BLK' CHANNEL, and SHED_OPT
hardware channel. The output parameter is displayed in the same A sa m1mmum,
unit as the read back Villue and the same unit as used in the trans- parameters must be set
ducer block, that is, as set in the transducer scale.
Schedule
True Windup Protection and Bumpless Transfer Everv function block in the control strategy is execut~d repeadtetd ly
· , times per second. Each time
several · th e block output ts passe · o
You can see the actual valve position or true reflection of other
. f h t block The period during which the function
types of final control element output from the readback parameter the mput o t e nex : cle External function
in the transducer scale units. The actual output value is converted blocks are being executed IS called a macro cy · . t
. d th twork whereas m erna1
into a process variable (PV) by doing the transducer and process block links are commumcate on ~ n.e th. d' . E ternallinks
variable scaling in reverse while taking the action into account. The links are passed to the next bl~c~ WI.thm lo~k ~:~c~~e~ executed
back-calculation output is normally a copy of the selected setpoint, are communicated after the ongmating b Th" that all
but by enabling the I/O-option "Use PV for BKCAL_OUT" the but before the receiving b~ock is :x~cuted. f dl~ en~~esfunction
bl ks are using values with a mimmum o e ay. e .
actual output, for example, the true valve position, is instead used
for the back-calculation output for the normal cascade
bl~~k link communication is called "operati?na~ traffic." To achieve
. and commumcation, the t'
the correct order o f execu tIon f the
initialization. This means that if the cascade has been broken it can
configuration tool synchronizes in a schedule the exe~u 10~ ~e
be returned to normal operation without jerking the actual valve
function blocks in the different devices on the networ an
position. In other words, it could achieve a truly bump less mode
transfer in the same way as an additional feedback position communication of the external links.
transmitter achieved it in the past but without the additional
instruments and wiring. To benefit from this feature it is a good Scheduling is the most common way to coordinate. function block
idea to implement the entire control loop using FOUNDATION execution. It is selected u~ing the c.ycle ty~t s~l~~~~ is one sched-
Fieldbus function blocks. (CYCLE SEL) parameter m the resource oc ·. h
ule for e~ch Hl network in the system. It takes ~to acco~nt t e
The actual valve position is not available as a block output from which a execution time of every functio~ block ~~d:~r:~~:~ih~r~~~~:
link can be made. However, it is not really required. The user does not communicating each externallmk, ~~d ~ :hrough the strategy. The
have to configure any interlocks with the PID to achieve fmc bumpless
transfer based on actual valve position because such transfer is a standard
:~~=~~l~~~=~~~~::t~i~~~:; ~:~:~~~:db~ the configuration tool and
function built into the blocks. downloaded to the devices as part of the control strate1y. rh:nd
I tells the device when to execute tts function b oc s
sch ed u e · f f the exter-
If the control valve reaches either its fully opened or fully closed tells the LAS how to synchronize the commumca ton o ether
nallinks. Every device has its own microprocessor, whtch t~~unc-
endpoint the AO block will set the corresponding limit in the sta-
tus element of the back-calculation output parameter. This tells the fo rm a multitasking multiprocessor sys.tern m whichh seve:a
PID block to not push its output further in that direction. This tion blocks are being execute d at th e same time inI t . e usually
vanous not
devices according to the schedule. The macro eye e IS
j~{
.1.~
l
. .'I.~..'.:
. (
(
-_,- ~--
-----------
Alternate Alternate
2 External Links 3 External Links
Figure 4·58. Distributing concurrent tasks in separate devices. time as all external links are broadcast on the network for all
devices to use.
actuation in the loop rather than a separate device. The blocks shall Optimizing Background Traffic
be allocated in devices in such a way that links become internal
rather than external. For example, the PID block in a simple PID The larger the window that is left for background traffic, the longer
loop can be executed in the positioner, transmitter, or in a central the macro cycle will be. By reducing the window for background
controller, resulting in one, two, or three external links, traffic you improve the control performance. Generally, the host
respectively (figure 4-59). The greater part of the macro cycle allows the background time to be configured individually for each
consists of function block links, which improves the performance network. However, a smaller window for background
by reducing the number of external links. In other words, for loop communication means that fewer parameters can be
performance it is good to allocate the PJD close to the final control communicated to the host each macro cycle. This therefore slows
element to minimize the number of external links, since these have the update time for the operator screens on the host. A balance
to be communicated. must be struck between good loop performance and good host
screen updated time. If a lot of time is allocated for backgro:md
An internal link may be made from one function block input to traffic, the screen update will be fast, but the macro cycl~ w11l be
another within the same device. A configuration tool automatically longer. Hosts generally use sev~r~l mec~anisn:s for makmg the
uses this capability to make internal links instead of multiple links background communication effiCient. VIew objects are groufs of
between the same two devices. This reduces the number of links to parameters in each function block. There are :o~r types ~f v1ew .
be communicated and consequently the macro cycle. For example, objects, which make up the static and dynamic 1~form~twn that Js
if the output of one block is connected to two or more function displayed in faceplates and a detail screen. The view object~ en~ure
block inputs in another device, only one external link is communi- that more information can be received in a single commumcahon,
cated from that output to the first input. The second and subse- thus reducing communication overhead. The four views are as
quent inputs are linked from the first input. follows:
Even if a function block output is linked to function blocks in more 1. Some dynamic parameters- suitable for faceplates
than one other device, it is still only communicated once. This is
2. Some static parameters- suitable for faceplates
because all devices will receive that communication at the same
(
( (
ill' Field buses for Process Control Chapter 4- Configuration
3. All dynamic parameters - suitable for a configuration tool 4.10 In which parameter in a standard FOUNDATION transducer
block can the detailed diagnostics be found?
4. The rest of the static parameters- suitable for a detail screen
4.11 In which parameter in a transducer block can the main
A Multiple Variable Container (MVC) object aggregates requests sensor measurement be seen?
for parameters from all blocks in the device and can therefore
4.12 To which parameter in the PROFIBUS PA AO block is the
reduce the communication overhead even further. The host auto-
matically defines the MVC based on the information that will be manipulated variable passed?
retr~eved from the devi~e. MVC it is a mechanism used only with 4.13 What do you call the capability to freely create multiple,
devJCes that support thts feature. It is a good idea to use MVC differently tagged copies of a function block type?
when retrieving information from many different blocks in a
device. 4.14 To minimize the number of communicated links in a simple
loop that consists only of AI, P!D, and AO, should the PJD
As far as engineering the system is concerned it is a good idea to block be located in the transmitter, in a shared central
operate the control Joop only from a single function block. This will controller, or in the positioner?
minimize ~he number of view objects the host must request in 4.15 What is the difference between an alarm and an event?
order t~ d1splay loop status. For example, a simple loop should be
supervised to access all the data from the PID block alone, rather 4.16 What is the setting of XD_SCALE in kPa that is required to
than some from the Al block and some from the AO block. convert the hydrostatic pressure reading in a 10 m tall tank
with water (density 1000 kg/m3) when the transmitter is
EXERCISES mounted half a meter below the tank?
4.1 What is the device called that passes data from one HI 4.17 What are the two types of "Good"?
network to another? 4.18 Does the fault-state option shut the loop down in the event
4.2 If the LRV is -200 and the URV is 500, what is the span? of power loss?
4.3 If the LRV is -200, the URV is 500, the applied input is 50, 4.19 Which parameter is used to configure "uncertain" so it can
and the button for setting the LRV to the applied input is be used as "good"?
pressed, what will the URV be? 4.20 Which is the fail-safe mode in the FOUNDATION Fieldbus
4.4 In which kinds of blocks are FOUNDATION Fieldbus and AO block and which parameter does the fault-state value
PROFIBUS PA devices configured (as opposed to set?
configuration of control strategy)? 4.21 What mode should the block be in so as to write the input/
4.5 Are the SP and OUT function block parameters static, output option (!O_OPTS) parameter?
dynamic, or nonvolatile? 4.22 What mode in the PID block ensures bump less transfer
4.6 How is it possible to determine remotely whether when the cascade structure is broken?
simulation is enabled in a FOUNDATION device? 4.23 Do the setpoint limits apply to the setpoint value that the
4.7 In which parameter is the desired mode set for operator enters in automatic mode?
FOUNDATION and PROF!BUS PA devices, respectively? 4.24 If the mode must remain in manual after a problem has
4.8 What are the three parts of the status parameter? cleared, what configuration must then be made?
4.9 Can a function block in one device be linked to a transducer 4.25 What setting is required lor the AI block so pressure can be
block in another? measured with a pressure transmitter?
4.26 Which output limit is more constrictive, OUT_SCALE our
OUT_*_LIM?
,,2
Fie!dbuses for Process Control
5
4.27 In the PJD block local override mode h. h
the tracking value set? w IC parameter does
4.28 Where is the PID control loop acfIon conf.1gured?
4.29
Does the_ simulation function in the output block h
the physical output? s c ange
4.30 Is the default fault-state option in the AO bl k
or safety?
. ..
oc avaiJabihty
Integrate and
BIBLIOGRAPHY
1.
Migrate
PROFIBUS,_ Draft, PIWFIBUS Profile, PROFIBU<;-PA p. .
for Process ~onlrol Devices, versim~ 3.0, April199L9 ' IOjllr
PROFIBUS PROFILE, Order No. 3_042 _ '
2.
~NS!/ISA-88.01-1995, Batch Control Partl: Models and
1ermmology. ·
3.
~~r~~o;;:~9NOSpecificatian, Function Black Application Process It will be some time before every conceivable type of device is
• , reviSIOn 1.4, 29 June 1999. available with FOUNDATION Fieldbus, PROFIBUS PA, and HART.
4.
~OLIN DATION Specification, Function Black Application p Until then, systems will have to be hybrid in nature, capable of
art2, FF-891 revision 1.4, 29 June 1999. rocess accepting both fieldbus and conventional signals.
5.
~OllNDATtON Specification, Function Block Application p In many plants, the existing control system has reached the end of
art3, FF-892 revision 1.4, 29 June 291999. rocess
its useful life, and must therefore be reinstrumented. It is difficult
6.
~01L~N-~ATION Specification, Transducer Block Application to gradually change an existing DCS into fieldbus. Changing just a
n <C» Partl, FF-902 revision PS 3.0, 21 Aprill998. single transmitter is not possible. The first step is to build a new
7. infrastructure of networking and software. This is a large and
~OLIN_DATION Specification, Transducer Block Application somewhat disruptive step, but from this point on the migration can
race>< Part2, FF-903 revision PS 3.0, 21 April1998.
8.
continue in smaller steps. The ficldbus technologies and the prod-
ANSI/ISA-181-1979 (R1992) A · ucts designed around them have features to make such migration
.· . .
5pcciftcatums, · ' nnuncwtor Sequences and
Research Triangle Park NC !SA ISB steps possible and relatively easy. When a ficldbus is added to an
0-87664-346-2, 1992. ' . ' N existing system that does not inherently support any fieldbus tech·
no logy the functions not supported by the existing control system
can be performed from a separate workstation, although this
results in two "dashboards." Just adding a field-level network
interface module to a legacy system docs not make it fieldbus. The
host needs supporting software and a high-bandwidth host net-
work to benefit from new functionality like configuration and asset
management. Using the process 1/0 alone is not enough. Lastly,
the process control system must be integra table with other systems
around the plant.
Hybrid 110
For many years now, several manufacturers have made available
all the main process control instruments like valves and tempera-
279
(
(
Fieldbuses for Process Control
Chapter 5 -Integrate and Migrate
There are two basic ways that conventional devices can be inte-
grated with fieldbus devices within the same system. One way is
to have a traditional I/0 subsystem for conventional signals situ-
ated at a central location within the system. Another way is to use
field-mounted converters that are connected to the fieldbus net-
work and interfacing conventional devices (figure 5-1).
L..--:-:--:-:~~-:;:-::;::::::--
Figure 5-2. Linking device with conventional I/O mo d u1es. (C o urtesy of
Smar)
Figure 5-4. Conventional I/O mounted remotely on field-level networ~ 1~1king into account future developments, consider ~o:V long an
(Courtesy of Smar)
old system can continue to be upgraded or ':het~er 1t IS bette~ to
reinstrument to new technology now. Keep m mmd that t~e first
Simple serial communication devices such as weighing scales, flow step of plants that have already migrated to fieldb~s was ~tmp!y to
computers, or other remote terminal units (RTU) often provide get familiar with the field bus technology. They typically dtd thts by
process variables that have to be part of the control strategy. This is installing a small system in an autonomous unit of the plant,. where
a typical application in which, for example, a Mod bus protocol it did not disturb the main part of the ex),sting control system.
gateway can be used to map input and output registers into FOUN-
DATION Fieldbus or PROFIBUS block parameters. Reinstrumentation
To make the system homogeneous and the configuration of control Reinstrumenting an existing plant to fieldbus invo!ves chansU:'g
strategy easy it is a good idea to use conventional I/O that makes the field instruments, or just parts of them, to the heldbus eqmva-
lent. Subsequently, changes also have to be made toward the host
the analog and discrete inputs and outputs-and even those from
·serial protocols-available as if they were fieldbusl/0. In this end. A complete reinstrumentation, includmg works~ahons and
software, makes it possible to benefit fully from the heldbus tech-
way, control loops can be implemented consistently regardless of
nologies, just as if a new system had been installed.
( ( ( {
Field buses for Process Control
Chapter 5 -Integrate and Migrate
Many smart devices sold since the early 1990s can be upgraded to This worked well for simple protocols used only for process I/0
a field bus technology by changing the main circuit board but leav- points and basic loop operation. However, fieldbus technolog1es
ing the rest of the device und1anged. This solution is easier and like HART, FOUNDATION Fieldbus, and PROFIB US l'A carry such a
cheaper than replacing an entire device. If the device is operating large volume of asset management data and other information that
in a hazard~us area this upgrade may have to be made by a spe- it becomes unrealistic to map the data through a gate:"ay. .
Cially qualified person. One way to minimize the costs today and Mapping hundreds of pieces of information for each m~trument IS
prepare best for the future would be to adopt a policy in which any tedious and conducive to error. Moreover, the networkmg,
conventional devices purchased from now on must be field bus database, and software in the old system most likely do not
"ready" through a simple upgrade path. This will keep migration support the several magnitudes of increase in the amount of
costs down and make future transition to field bus easier. instrument information.
Fieldbus control valve positioners can replace their analog counter- As part of a modernizing solution for existing systems that cannot
parts and typically any position feedback transmitter or limit be replaced yet, the l/0 part of fieldbus can be channeled to the
~witches as well since these functions are generally incorporated central controller. On the other hand, the asset management and
mto a fieldbus positioner. The valve package is converted to field- device configuration should be handled by dedicated fieldbus
bus without having to purchase a new valve body or actuator. In hardware and software in parallel. The central controller will
many cases, the retrofitting can be done without even removing remain in use, and operation can continue to be performed from
the valve from the process line. Similarly, primary sensing ele- the existing consoles. Essentially all control systems support the.
ments like temperature sensors and orifice assemblies can be left as Mod bus protocol. Modbus can therefore be used as an mtermedi-
is by simply replacing only the transmitter. ate protocol to gateway only the 1/0 parameters through the l/0
subsystem (figure 5-5).
The fieldbus technologies were all designed to work using the
same type of wires that are used by conventional instrumentation.
Some of the system's existing wiring can therefore most likely be
reused in a tree topology when the plant is reinstrumented. There
is consequently no need to purchase or run new wiring. Even exist-
ing DC power supplies can be used to power the new instruments.
All that is required are De-powered impedance modules. As link-
ing devices take the place of 1/0 subsystems and controllers some
of the old panels can be utilized as well.
controller
Host-level _1'~::::':".. ____ Remote-I/O
Upgrade network network
I/O-subsystem
When a plant has a large investment in an existing system and with Modbus
expands with field bus instruments for the additional lines it may
be hard to justify a complete reinstrumentation of the existing con-
trols. In such cases, the best option may be to upgrade the host to
handle fieldbus. Integrating a modern technology into legacy
architectures is not as easy as implementing a purpose-built field-
bus system, but it can be done. Such integration is ideal for evalu-
ating one or more fieldbus technologies on a small scale on a site
that already has a control system before going all out for one of the
fieldbus technologies.
Figure SMS. Gateway fieldbus 1/0 ~o an existing system over Modbus.
The traditional solution for enabling ad.ditional communications
protocols in traditional system architecture is by using a gateway.
Chapter 5- Integrate and Migrate
Fieldbuses for Process Control
(
( (
Fieldbuses for Process Control Chapter 5 -Integrate and Migrate
: OPC
!Server
\
Network
P.·nm M, .ua- •n·
w-
..---:;:
,....IQL.!!l
Linking
ferent.systems are integrated they form a larger system that
Device
includes some proprietary communications and programming lan-
guages, in which data has different meaning. You must therefore
take care to interpret data correctly. For example, every system
Figure 5-6. Systems linked at the host-level network. may have a different method, parameter, and code for putting a
control loop into manual mode. Ideally, the different subsystems
Workstations that are OPC clients access the data from the servers should all use the same programming language and networking. If
of the different systems and present them together. The OPe server they don't, the process visualization application has to be config:
takes care of the data type, device address, memory register, and ured in such a way that, depending on the source of the data, 1t 1s
other hardware characteristics in order to furnish the parameterS to properly converted before display.
applications in a simple format.
Several of the systems that control the plant may have Ethernet
You can use OPC bridging software to pass some data from one connectivity, which makes it easy to physically interconnect the
system to the other, for example, from a new fieldbus system to an systems. However, remember that neither Ethernet nor TCP /IP are
existing oes. OPe bridging software reads a parameter value in sufficient to enable interoperability. Many times, a proprietary pro-
one server and writes it to a parameter in another server (figure tocol is used on Ethernet. OPe will therefore ultimately be needed
5-7). By passing data through OPe directly to the workstations, the if you want to consolidate information from the different sources
controller is not loaded unnecessarily. However, to do this the OPC in case more than one protocol is used.
server must be up and running at all times. If you are using redun-
dant host-level networking, it may be a good idea to use redundant Another important aspect of an Ethernet-based host-level network
OPC servers as well. platform is that many legacy devices can simply use Ethernet as a
medium for communicating their data without havmg to worry
OPC works between software applications in a workstation but about the complexity of adding networking hardware. Rather than
also between computers on TeP /IP over Ethernet. It is therefore a having several dedicated RS232, RS485, RS422: and proprietary
good idea to use Ethernet as a platform for the host-level network media networks the devices can connect to a smgle plantw1de
since the Ethernet media can be shared by OPe, the host-level Ethernet through a device server (figure 5-8). The device server
fieldbus, and other protocols. Preferably, the networking shall sup- handles hardware handshake signals as well as software functions.
port both 10 Mbit/s and 100 Mbit/s because this will enable all The data and hardware signals are tunneled to the host end where
kinds of Ethernet devices to be connected. a second device server converts them back to the original signal.
This makes the Ethernet communication transparent; that is, it
It is important to remember that although OPe is great for bring- does not necessitate any modification of the software.
ing data from all kinds of hardware into all kinds of software, it
does not standardize the semantics of the data. When several dif-
Fieldbuses for ProcesS Control
Chapter 5 -Integrate and Migrate
(
Chapter 5- Integrate and Migrate
Fieldbuses for Process Control
As in the past, the APC connects with the basic process control sys~ Other Systems
tern to form an integrated environment. The APC does not need There is more to running a plant than process control. O~er impor-
dedicated field instruments; rather, the APC is able to utilize the tant functions that need to tie in with the control system mclude
information from the transmitters in the basic control system. Sim- production planning, materials mana?ement, quahty management,
ilarly, the APC actuates by using valves and other final control ele- plant maintenance, financial accountmg, and human resources:
ments connected to the basic control system. In other words, in a among others. These are handled by enterprise resource planmng
system with field bus the APC system uses fie!dbus networking (ERP) systems. As in the past, the ERP is separate from the process
and devices to perform the measurements and provide the actua- controls, but it now often ties in with the fieldbus sys:em. Other
tion. Traditionally, the APC had a custom irtterface to the particular typical systems include historians and plant mformatwn.
type of proprietary DCS used in the plant. Alternatively, the APC
had an interface to the plant historian software, which in turn had EXERCISES
a custom interface to the DCS. These custom interfaces were
5.1 Can conventional DC power supplies be used for IEC
expensive, and a historian interface usually necessitated parameter
mapping, which resulted in duplicated database,s. Using direct 61158-2 networks?
OPC interfaces between the APC and field bus control systems is 52 Does OPC specify the semantics of the data?
both inexpensive and eliminates mapping, resulting in a single
integrated database. Many APC systems no~ support OPC. 5.3 Is using OPC with shutdown systems permitted?
For more details about shutdown systems refer to the book Control
Systems Safety Evaluation and Reliability by William M. Goble (2d
ed., !SA, 1998).
- -·---
- . -· ~- -··- ----
. -.
· - - --
6
Troubleshooting
Device
If the network is OK then communication is possible and software
can be a great help in detecting faults and troubleshooting. To fully
benefit from the fieldbus technologies plants should permanently
connect the engineering tool to the field devices. In other words,
plantS should not only use the communication for process 1/0 like
measurement and desired valve position, but also to continuously
monitor device health. It is also a good idea to have the engineer-
ing tool running at all times so any troubled device in the plant can
be checked quickly.
·-
~----:m; T ------------------ - - -'
llill ··
~
HART Devices
display it. It is primarily intended for use by a host (primary mas-
General Field Device Status ter) to detect that a handheld (secondary master) has changed the
device configuration. This stahis prompts the host to update its
Whe:'ever the field device communicates with the handheld or database to the device configuration to ensure that the device con-
host It always reports back its status. In installations that have er- figuration file is synchronized with the actual device.
manently connected communications interfaces checks are con~n~
uous, a:'d any J?roblems are reported immediately. However, Cold Start
HART mstallations a_re predominantly using only the 4-20 rnA si~ Cold Start is an indication that power was removed from the
nal. and a handheld IS only connected occasionally for short time0 device and that it is once again powered up. It means that the
In these cases, the associated controller must monitor the 4-20 rnA device may have been removed and reconfigured separately. It
to detect faults and prompt the user to connect a handheld tenni- may also mean that the device does not have enough power sup-
nal. A current below 4 rnA or exceeding 20 rnA ll ·
indication of a fault. usua YIS a general ply to operate properly and is therefore switching off and on.
cally also measures the temperature of the sensor module in order I TRANSFERU r::-:==;:-, !CURRENT
RANGE FUNCTION! t CURRENT lf-1--~-----j-+
to perform temperature correction. The Nonprimary Variable Out CALIBRA· \
TION
of Limits status indicates that one of these auxiliary sensors has JsiMULATEP
reached its limits-the value is outside the compensation range of
the device and the primary value may therefore not be completely
accurate. It may also mean that the device is exposed to ambient
stresses beyond its limits, which could damage the instrument. Figure 6-2. HART transmitter block diagram.
prietary, and you should verify the problems they report against Enter Current Value: 1.... ......... mA
the device manual.
@!) ~ ~
Simulation
Figure 6-3. Usmg loop test to s1mulate process vanab les from a handheld.
The 4-20 rnA loop current represents 0 to 100 percent of the range
set in the transmitter. Any device that receives the signal has to be
You can also use the loop test to safely simulate process co_nditions
scaled accordingly to give an engineering unit readout. For exam-
in order to test alarm trips, controller action, and automahc shut-
ple, if the transmitter range is set to -200 to +850'C the same range
must be set in the receiving devices. Inconsistent ranging will downs1 among other actions.
result in operational problems and potentially dangerous situa-
tions. HART transmitters have a loop test function that is used to PROFIBUS PA Devices
remotely set the output current independently of the applied input A large number of the parameters in the physical, transducer, and
(figure 6-2). The loop test makes it very easy to verify readings in function blocks are there for the specific purpose of troubleshoot-
indicators, recorders, and controllers, thus simplifying the trouble- ing·. These parameters are powerful troubleshooting tools.
shooting of scaling.
(
Chapter 6 _Troubleshooting
Field buses for Process Control
Physical Block
Standard diagnostics for the device as a whole is shown in the
diagnostics (DIAGNOSIS) parameter, and additional self-diagnos-
tic checks continue in the manufacturer~specific diagnostics ex ten~
sion (DIAGNOSIS_EXTENSION) parameter in the physical block.
The short diagnostic messages give a pretty good general idea
about the fault. The device's manual would typically give specific
clues about the nature of the problem that the various diagnostics
messages indicate for the specific device.
devices on a particular network? Most importantly, what was done PROFIBUS PA and FOUNDATION Field bus
before the communications problems started? If a particular device
appears to be causing the communications trouble, connect just When a communications fault is detected use the configuration
that one device on a separate network and try to establish tool to determine if it affects the entire network or just a single
commtmication. device (figure 6-5). If you are using repeaters or repeating safety
barriers there is also the possibility that one of the network seg-
HART Communication ments is affected while the others are OK.
The most common HART communication problem is that the The engineering tool usually has a "live list" that shows all the
handheld battery is too low and needs changing or charging. communicating devices. Ideally, you should confirm that all the
Another possible problem is that the handheld is not connected at devices have been connected at commissioning. Should any device
the right place. For example, the handheld may have been con- fail to communicate it drops out of the list. For installation prob-
nected on the power-supply side of the resistor rather than on the lems, the communication is often not working, and software may
device side.
therefore not be much help. There are a number of checks that can
be carried out using traditional tools such as a multimeter. Check
Multidrop Addressing
continuity, sufficient voltage, and noise. Measure the resistances to
For a HART device in a multidrop mode you should set the polling detect short circuit: conductor-conductor, conductor-shield, con-
address manually from the handheld. There is a chance that two ductor-ground, and shield-ground. It may even be a good idea to
devices have accidentally been given the same address, causing a verify the cable capacitance.
communications problem. Verify the address of the device by con-
necting only a single device to the handheld. Usually, the handheld Device Power
has a function that checks all polling addresses from 0 to 15 to ver- If the supply voltage at the device terminals is lower than 9 VDC
ify if a device is present for any address. the device may not operate properly. Some devices may need even
more than 9 VDC. Low voltage is primarily a problem in intrinsi-
Masters
cally safe installations or even in regular installations in which
A not~so-common problem is master conflict. A network can have long, thin wires are used. Another potential source of trouble is
one primary and one secondary master. The central controller or a devices that have high current consumption. Lastly, voltage drop
RTU is usually the primary master, while the handheld is usually a may also be caused by poor connections in intermediate junction
secondary master. Some interfaces can be configured as either pri- boxes.
mary or secondary master. Two of the same could therefore occur.
Verify that only a single primary and a single secondary master is Make sure that the voltage at the device terminals is a minimum of
present on the network. If necessary reconfigure any duplicate 9 VDC, preferably more. Ensure that the power supply provides
masters. sufficient power for the combined current consumption of all the
(
~----------------~-
Fieldbuses for Process Control Chapter 6- Troubleshooting
devices on the network. Check for voltage drop at the entrance and
exit of junctions.
Check that the network topology follows the basic rules for spurs, Verify the address setting of the devices. It is a good id~a to keep a
length, device, and so on.
cross-reference list of the addresses for each of the devices on each
network.
Earth
Heavy-load equipment must not share earth wiring with instru- lnteroperability
mentation since this may cause communication problems when the The configuration tool generally has a "live list" or equivale~t that
loads are switched on and off. Separate earth wires should be shows the communication status of the devices. When a ~evtce 1s
routed for instruments, although eventually you should earth connected the linking device or interface will first detect It and .
(ground) them at the same point as all loads in the plant. then establish communication with it. After detection the devtce IS
typically shown in the configuration tool's live list differently from
Addressing
fully operational devices until the comrnuntca:I~:m IS fully estab-
FOUNDATION Fieldbus hosts detect new devices on the network by lished (figure 6-8). If there are any interoperablhty problems
constantly polling the different network addresses to see which between the host and the field device the cornmwucatwn may not
addresses correspond to an actual device. The devices that have be fully established, as the live list indicates.
been detected are displayed in the live list of the configuration tool
or by other means. Because a network has no more than thirty-two
devices, the host skips several addresses to detect the devices more
efficiently. For most plants, this will never pose a problem because
a system will not assign an address it does not poll. However, if a
plant has two different types of systems and a device is moved
from one to the other there is a slight chance that one of the sys-
tems is configured to not poll the particular address that the device Figure 6-8. Establishing communication.
coming from the other system occupies. If a device connected to a
network does not appear in the live list, it could be that it has an If there are any ways to reset the device to its original factory con-
address that is not being polled.
figuration it may be a good idea to do so because t:ersonnel ~ay
have set incompatible communication parameters m the dev1ce for
In the event the poll sequence setting has to be changed this can be some other application. If that does not work look for specific tips
done in the system management part of the configuration tool at in the users' manual for the host.
the DlmeLinkSettings parameter. This parameter is where the ele-
ment FirstUnpolledNodeid determines the first address to be Advanced Communication Troubleshooting
skipped and NumConsecUnpolledNodeld determines the number
of addresses being skipped. Addresses 0 through 15 are never A fieldbus network analyzer passively monitors the network co~
polled. For example, if FirstUnpolledNodeid = 48 and NumConse- munication and allows it to be analyzed in detail (figure 6-9). It lS
cUnpolledNodeld = 184 then the addresses 16-47 and 232-255 are not a tool that most people would use. In fact, it is rarely re~Ulred.
polled. The bus analyzer is a tool for advanced users wh~ ha~e an m-
depth knowledge of the fieldbus technology that IS bemg used.
For PROFIBUS PA devices the polling address is set manually on However, most bus analyzers allow a nonexpert to ~asily sa~ple
the device or set from the configuration tool connected on a net- snippets of communications, which are saved to a f.de. Th~ ftle can
work that has a single device. It is also possible for it to be set using !f
then be sent to a communications expert for analysis. this . .
DIP switches. There is a chance that the communication problem is advanced communication troubleshooting technique IS used, 1t ~s
the result of two devices having been accidentally given the same only during the commissioning phase of a plant when communica-
address. tion problems are encountered. Once the communi~ation problems
have been fixed, they don't reoccur unless key devices are
changed.
(
Chapter 6- Troubleshooting
Fieldbuses for Process Control
..
flltProlle-
""
PNProb<M<><Io cess visualization software.
Pll'uslotni
ono... - '""
~
S..,f~fl;
m-...r.ua
I'N ""'~eHodo
PlPuoT-
Dotff-'
Dot_F_<I
Advanced users can use Ethernet protocol ana~yzers t? see the
Rllla\ur>oloi:ea-
messages that are being exchanged. However, m a swit~hed net-
~-
PT-Tom
RTRotllmTotei.
PN Pto~e Node
work architecture often only the information that pertams to ~nc
PTPuoTal'o~
01! Dolll de-vice travels on any one cable, and corrupted messages arc fil-
RTRotu'"hb>R
flltp,;,boNode tered out by the switch. Complex problems will not be- revealed by
connecting an analyzer. Often these complex problems can be
overcome by configuring the switch to copy messages to the port
where the analyzer is connected.
trol the mode of a block; that i::., the input status may make the • Some parameter has an invalid selection or a value out of range.
mode shed. For example, a "B::d" quality usually sets Man or IMan Check the block error (BLOCK_ERR) parameter for a clue.
mode. A "Not Invited" subst2.:us also sets "IMan" mode.
It is common to forget to configure the CHANNEL, SHED_OPT,
Jfblock input is "Bad" or "Ur:.::ertain/' trace the signal back to its and BYPASS parameters, which results in a block error .and OOS
source and check what is goin~ on in the originating block. The mode. To eliminate these simple pitfalls, it is a good idea to use
substatus usually pro\·idcs a c:ue about what the problem is. Most strategy templates insofar as if these are provided with the config-
substatuses need no further ex:-,Ianation. For the back-calculation uration tool.
input (BKCAL_IN), it is possible to see if the lower block is forcing
the block you are looking at to IMan mode. The configuration tool Initialization Manual
will typically show which bloc~ and parameter is the source for the
input. This makes it easier to t:-~lce the signal backward and also • Back-calculation input status is "Bad," for example, bC'cause of a
indicate value and status dirL~c:l~-' in the control strategy (figure missing link or no communication.
6-10). • Back-calculation input status is "Fault State Active."
• Back-calculation input status is "Not Invited;' for example,
because the lower block is in the wrong mode or fault state or
because there is no communication between the output and cas-
cade setpoint input.
( (
{ (
(
~lc Js fo rc ss on~ Jl
Cascade
• The update for RCAS_IN or RCAS__OUT has timed out because
there is no communication, exceeding SHED_RCAS and
B··PV
LSTATUS
\ VALUE
8 OUT
'··STATUS
: VALUE
Good NonCI.lscade.:NonS pecific.Notlimited
440000
Good_NonC.:.tcade··NonSpec~lc:NotLimited
440.000
J
SHED_ROUT, respectively.
315
(
r][J' / I ( I
- r-reldbuses for Process Control Chapter 7- Operation
1 3ooool~.
->'·';3Q$.88_(f-'
The process visualization software that the operators interface with
45.001~
should be configured in such a way that it makes full use of the
fieldbus features. This will increase the operators' confidence level
as well as the ease of use, availability, and safety of the system.
Figure 7·1. Controller faceplate for easy operation. Note the status
Confidence Level indication adjacent to the values.
The operator workstation should display not only the process val- played as invalid to the operator. A special character such as an
ues, but also the quality of the value and whether there is any limit as~erisk or other reserved symbol will flag non-" Good" OPC val-
imposed on it. Once the quality "Good" is displayed the operator
u~s. Numerical values must not be used because they may b~ ~Is
wiiJ have greater confidence in the value he or she sees. The opera- taken for valid values. Freezing a value that may not be true IS
tor knows whether an abnormal value is a process problem or a
dangerous.
measurement problem and need not be in doubt. The status imme-
diately gets the operator's attention if something is not right (figure
7-1). When parameters deviate from tht~ir normal value, the opera- Ease of Use
tor must be alerted. It is more important to show the operator what In addition to the usual Cascade, Auto, and Manual mode ~,:I~o~s
is not expected than what is expected. The abnormal information is it rna be helpful for the control loops to include a "Norma L~ -
more valuable. ton. {he normal mode button sets the Target. mode for the loop m
the PID block to the mode that is configured m the Normal element
Safety of the block mode (MODE_BLK) parameter.
Make sure to configure displays to show the quality "Bad" and
"Uncertain" adjacent to the values in addition to the limit condi- Availability
tions "High," "Low," and "Constant". This will let the operator Status display allows operators to spot problems faster and pin-
spot abnormal conditions and take appropriate action. The block point them more precisely. Problems can be fi.xed sooner .s~ ~re
error alarm status from the alarm summary can be displayed duction can back on line. That is, the "m_ean hm~ to repair IS
alongside the regular process variable alarms. ·One important reduced.
safety aspect is that when communication fails the values are dis-
- • oo;;;•uuu::.e~ ror t'rocess Control
Chapter 7- Operation
licensing
. ,• . ") ore technology is using the client/server concept.
One of the main benefits of fieldbus is that more information can tmsswnmg
The hardware· manufacturer prondes
. . an OPC server.for the inter-
.d
be displayed. Traditionally, the process visualization software is facc on the host-level netvvork. The softwa. re companfies pro:'lbe 'It
sizcd and priced according to the number of parameters that can the
c OPC client for the software, or, even be tter' the so tware
b IS m
be mapped into the database. Such a pricing scheme will be very entirely around an OPC platform. No third partf hast~· ed
costly since tht~ number of parameters can easily double. For a involved, so hardware and soft\.varc can be free y com me .
data-intense ficldbus system it is more economical to use a licens-
ing scheme in \Vhich the number of points communicated at any OPC client/server technology bnngs · th e f ~~ Idbus data intoIathe
b d's edMS
one time arc charged. For example, a system may have thousands Windows environment where the information can ~ I P y tall
of parameters that can be displayed at one time or another, but . virtuall an recess visualization software, s.mce ~lm?s
usually only a few related to one loop detail or to a section of the usmg y t OY!f'C In other words the process visualizatiOn
of them suppor · ' , th f eldbus
plant are dispbyed on the screen. The other parameters are not f . , OPC client. The ser\'er software accesses e .I . -
so tware IS an k tl d ta avallable 111
communicated. Jn such a lkensing scheme the point count is lower, devices using the fieldbus protocol and ma 'CS 1CII ad . ' 1 the
and usually the price is too. · ' . · ed for .a ev1ces
·, reqlllr
OPC format. Only a smglc server IS ore01client
host-level fieldbus network. The server works with ~nyt. drr'vers
Asset Management
software, ehmmatmg t en~~ or bl- ms that were common in the
. . . h d f custom commumca wn -
Information about calibration, identification, and materials of con- and associated interoperabihty pro fc OPC server directly
t An OPC client can access data rom any
struction; detailed diagnostics; and other asset management data-
all arc too numerous and complex to custom-configure onto
~~~hout intermediate drivers. OPC thus ft~nctions lik~
a :oftware
backplane where clients and servers plug m to sharell at I d s
screens. For that reason, asset management functions should be
(figure 7-2). The process visualiza:ion softw~re usual y 17~ u e
carried out from a dedicated asset tool or be integrated into the
configuration tool. applications for displaying graphrcs, capt~rmg a~~go~~d ~o on.
alarms, performing histoncal trendmg an repor I ~
;y~,:
b ( I
Chapter 7- Operation
Tag Based
ore servers make up a single integrated database, withmtt dupli-
?PC t?chn?logy is tag based. This makes it particular} eas r to us cations. All applications utilize the same single integrated data-
m conjunctwn with the FOUNDATION Field bus, I'ROFI~US.~A aJ~~ base. All OPC clients will show the same \'alues \dthout
HAI\T smcc they are all based on user-defined ta s and stan ' inconsistencies.
parameter names such as SP and PV Th ~ ~ · g ~ ~ard
. · ere 1s no need to configure
mem. ory registers, device addresses data types or s ,. . To further integrate applications you can use the function block
oth th · 1 II 0 ' ·' ca mg, among
er mgs. n a PC client applications the desired data fro settings for ranges and limits in the process visualization software
the server appears automatically and uses the exact same tag t~t to restrict the operator entry range and to scale bar graphs, among
was entered once and for all in the configuration to I M other things. Any change from the engineering tool will be
eve . o · oreover,
ry parameter can be pKked using an OPC T B (I' reflected in the operator software and vice \·ersa.
7-3) F 1 ag rowser 1gure
. .. . o~ examp e,_ whe~ a user-defined tag such as "LT-123" is -
figured m the engmeenng tool it also appe'l.rs in tJ . . . con Networking
ization soft\van.'. c lC process VJsual-
;,vel~ asbthe paframeters in the blocks. No duplicate input~~g ;~~:;: Unk1ng Devices
as o e per ormed~ whiCh saves time and reduces t . Loca! Panel
Parameters are cKccssed throughout the entire network using the tate operation include automatic loop tuning and the linking of
same name. OPC offers the additional capability of allowing multi- data to I\1icrosoft@ Excel. A modern control system needs nwrc
ple ~oftware app!ications in th~ operator workstations, engineering than just configuration and monitoring software. Softv.'are f~_n·.
statmns, and rnamtenance stations to access the data at the same advanced control, simulation, inferential measurement; statlstlcal
time. process control (SPC), and plant information do not d~rec~ly sup-
port fieldbus protocols. However, these softvv~re apphca~wns are
Semantics available as OPC clients, which makes it poss1ble for a wtde range
of software to be used in a fieldbus-based system. In other words,
OPC servers are now available for most hardware and protocols.
software applications can be freely selected and interfaced with
Thus, it is possiblt.~ to mix several different protocols in a system
and make all the data available in OPC format. However, OPC fieldbus devices.
does not handle the semantics of the data. Different protocols
BeC/1l/SC softwarf i::; playing all ever more ini~JOJ:tant role in plant
present data in m,my different formats, using different parameter
opcrafitm for such tasks as mllo··funf11g, statiSt teal process C011frol, .
names and diffen~nt codes. For example, OPC docs not specify
advtllJccicontrol and opti111izalhm, it is a good idcn to use OPC so datn1s
how to put a control loop in manual or how to indicate that a
dissemi11t1ted sea111less/y.
flange of a pressure transmitter is made from stainless steel. In one
protocol, you may have to write a one to register 10069, whereas in
another protocol, device, or application you have to do something Interpreting the Data
else to put the loop in manual. Most operation-related values from the field.bus devices are in
floating-point format and in engineering umt:, and they can ?e
ore essentially communicates numbers from the field device to displayed "as is" without any further pr~cessu~g sue~ as seal mg.
the software application<; and vice versa. As a result, an OPC client Because there is little or no risk of range mconststencies the value
such as process \·isualization software must be configured to dis- will always be identical to the value in the ~ield device. However,
play the correct meaning of the codes. If several different protocols many parameters in the fieldbus technologtes that are relevant to
are mixed in the system, this configuration is still possible, but it operation are enumerated or bit-enumerated. "~numera:ed"
becomes more complex. The different protocols do not talk to each means that the parameter contains one piece of mf~rmatwn, that
other; instead, en:-ryprotocol has its own ore server application every value of the parameter has a particular meanmg, and that
handling the characteristics of the protocol and interface. An OPC only one value is possible at any one time. For example, for the" ,
client can access data from any one of them in a standard way, FOUNDATION discrete tracking input parameter (TRK_lN_D) a 0
unaware of the underlying protocol. By using an ore bridge means not tracking, whereas a "1" means that outp~t trackmg w1ll
between two SCITers, data may be passed from one network proto- be acti\·atcd. "Bit-enumerated" means that each b1t m the parame-
col to another. One important reason to select one single standard ter has a meaning, and several options can be indicated at any one
protocol like FOL\'DATIOr-o Fieldbus, PROFIBUS PA, or HART is time.
that these protocols specify the semantics of the data. This makes
the meaning consistent throughout all devices, irrespective of man- Typically, each bit corresponds to one pi~cc of information~ F~~
ufacturer. This makes it possible to use templates created by the example, a feature is either enabled or disabled, or somethmg IS
sofhvare manufacturer according to the standard parameters, dras- true or false. The FOUNDATION and PROF!BUS PA block mode .
tically reducing the need for custom configuration. If suitable tem- parameter is an example of a bit-enumerated param:ter. You will
plates are not a\'ailable they can usually be created. have to configure process visualization software designed to han-
dle any protocol in order to handle the parameter values _correctly,
Software lnteroperability either parameter by parameter or using templat:s. :ropnetary
operator software may not require such customtzahon.
When you use OrC technology software, your choices are not Iim-
it~d to a single manufacturer. Basically, you can choose any process
VIsualization application that gives you the look and feel that is
comfortable for you. Other OPC client applications that can facili-
.. (
Field buses for Process Control
Chapter 7- Operation
Status
Table 7~2. Limit condition enumeration
Many parameters that are essential for operation, such as process Value Display Description
variable (PV), sdpoint (SP), and output (OUT), have an associated I ---~----+-__:__-+---------;;;;;-,;;;--·----·-···
f--- 0 No limit
status element in addition to the value. This status is usually shown
1 L Low
on line alongside the value in faceplates and in detail screens. The
status consists of three parts: quality, limit condition, and substatus. f----·---o2c----f··-· ---.H-o--=1=----=H=-'ig;::h-::;------j
Usually, only the quality and limit parts are displayed in the pro- f------ "'3:-----+----;C~- Constant
L--------L----------'------··-----·-
cess visualization software, since the substatus has a level of detail
that operators usually don't need. Once a "Bad" or "Uncertain"
Block Mode
condition has been detected, engineers or technicians can investi-
gate the cause in detail from the engineering tool. It is therefore a The block mode parameter consists of four elements: Target,
good idea to configure the host to shmv the status adjacent to the Actual, Permitted, and NormaL The tv·.'O rnost important o_ncs f?r
value. The status element used in many parameters is rc<~lly a com- plant operation <Ire Actual and Target: In a control loop bmlt usmg
bination of enumerated and bit-enumerated. the FOUNDATJON fieldbus programmmg language the mode of the
control loop is usually set in the PID function block. The mode of
Quality Status other blocks is usually not used. Writing to the Target element of
The two most significant bits of the status byte indicate the quality. the block mode parameter sets the desired operating mode for ~he
For that reason, you should do a bitwise AND with Oxll 000000 control loop. The present mode of the loop is displayed by readmg
(192 decimal) in order to mask out the limit and substatus bits. the Actual element of the block mode parameter.
Depending on the result of the masking, the quality can be dis-
played as an enumerated state with a value and state string for the There arc many vvays to design the user interface f?r the mode of
four qualities (table 7-1). the loop. For the Fou~DATION Fieldbus programmmg language,
the most straightforward way is to use three buttons for the Target
modes and a separate indication of Actual mode.
16 Manual
Limit Status 8 Automatic
..
The two least significant bits of the status byte indicate the limit 12 Cascade
------
condition. You should therefore do a bit-wise AND with
OxOOOOOOll (3 decimal) in order to mask out the quality and substa-
It is even possible to make a fourth button in order to set the "nor-
tus bits. Depending on the result of the masking, the limit condi-
mal" operating mode of the loop, provided the button has been
tion can be displayed as an enumerated state with a value and state
string forthe four limit conditions (table 7-2). configured in the block at the Normal element of the block mode
parameter. When the normal mode button is pres_sed, or p~rhaps
activated through some script for batch control, S!mply wnte the
value at the Normal element to the Target element. This feature
• Fieldbuses for Process Control Chapter 7- Operation
may prove a useful feature since it provides a simple way to return To reduce clutter on the display it may be a good idea to avoid dis-
a loop to normal mode after service or load change, when the oper- playing any text in case the alarm is not active.
ator may have forgotten which mode the loop was in originally.
Using Scaling Information
The d.evice itself checks that the requested mode is enabled in the
Permitted clement of the block mode parameter. A lot of information is stored in the function blocks, for example,
scaling and limit information. You can use the scaling information
Display Actual when you need to create animation for the value, for example, ani-
mation of a faceplate bar graph or animation to mimic the tank
The actual mode will be read from the Actual element of the block level of the actual process.
mode (MODE_BLK) parameter. The mode can be displayed as an
enumerated state With a value and state string for the eight m 0 d The scaling of the bar graph in the process visualization sofhvare
(table 7-4). · es must match the scaling of the device in order for the b<1r graph
indication to correctly represent the percentage value. To eliminate
Table 7-4. Actual mode enumeration. the chance of any inconsistencies the range values of the bar graph
Display Description should access the scaling value from the field device. In this case,
~·oos ··-~ -- -··-----·outorserVICe--·--- any change that occurs to the range in the field device is taken into
'nitianzation Manual
account when the bar graph is displayed, that is, a single inte-
Local Override
grated database located in the field device is achieved \Vhere a
----·Ma·nua~,~~ __ __j range change in the configuration tool automatically updates the
AutomatiC
process visualization software. Use the EU_O and EU_lOO elements
·--·---·cascade-- of the appropriate scale parameter for 0 percent and 100 percent,
Remote Cascade
respectively. The related scale parameters are as follows:
-~--- - i__ _ _ _ _ ,L_ _ ~moteDutput -
PVand SP: PV_SCALE
8 LL Low-Low
4 H High -- Using Limit Information
2 HH High-High
.·- ·It isn't essential to check setpoint and output values at entry
t--· because the field device itself keeps the written value within the
1 D Discrete
~recess Control
..
• >,oldbuses tor
----------------
Chapter 7- Operation
The user entry limits that are set in the process visualization soft-
I.
ware should match the limits in the field device. To eliminate the
Text PPT /DE J
chance of any inconsistencies, the process visualization software
can access these limit values from the field device. In this case, the
Data Source: r Lir-3(;/iJr,~·;.' D.:/" - ,·:"'
software takes into account any change to the limits in the field
rSmor DliOI'S"'" 0\ TC-123HI_HI_LIH OPC!ags-... I device when the operator enters a value, that is, a single integrated
Tag$M.f<nu... J database where data is stored in the field instrument and the same
!-Point Type
P Updo!lte
.l Data Type: /DOUBLE iJ value is used both for alarm detection and operator display and
) FOf!Th:!t Jx~xxx.xx :::J where a change from the configuration tool automatically updated
P DataEntr;~
the operator display too.
r Confirm ' r rnitiatvatue: rc--
,:
r Keypad Ill 1
Homogeneous Operation Environment
p- '""'' "'""' . - -----l
for setpoint: Some steps can be taken to minimize the screen refresh time.
Reduce Views
By reducing the number of view objects that have to be accessed to
display a screen you can reduce the communication needed to
retrieve the informiltion. It is therefore a good idea to restrict the
information shown in a "faceplate" type display to the parameters
in VIEW ..J and VIEW __ 2. A "detail screen" can also display the
parameters in VJE\V__4. To gain additional information from the
block it is better to usc the configuration tool.
is usually a bar graph scaled according to the process variable scale BIBLIOGRAPHY
values. Simii<lrly, the setpoint is displayed \Vith quality and limit
conditions together with a bar graph that uses the same scale. M .II p I W Fulldn/1/CJI!als of Process CoJltrol Theory, 3d
1. urn ' au ., · SBN 1-55617-
Additionally, the se-tpoint may be restricted by more stringent lim- ed. Research Triangle Park, NC: !SA, 2000, I .
its. The sctpoint of the secondary controller cannot be written in 297-4.
cascade mode. The output is also shown with quality and limit
conditions together with a bar graph scaled according to the out-
put scale parameter in the device. Additionally, the output may be
restricted by more stringent limits. The output cannot be \Vritten in
automatic or case;:1de mode.
Tuning
Alarms
Generally, the operators are allowed to set alarm limits too. These
limits have to be set within the range determined by the process
variable scale and in the same units. Alarm hysteresis is configured
in percentage terms.
EXERCISES
335
( (
Chapter 8 ~Engineering and Design
sen. Choose a small segment of the plant as a pilot project to evalu- When developing a functional speC!·r·Jcatlon
· for t11e Ioops make
ate standards and documentation and get hands-on experience. sure to use ficldbus terminology.
for less than twel\'e for the initial system to allow for expansion. As tralizing blocks in a central controller as this makes the systent
far as possible, locate all devices that participate in the same loop more vulnerable.
on the same network. This will improve performance by avoiding
the need to use bridge functionality between networks. Using Deep inside the plumbing of the FOUNDATION Fieldbus protocol
good c,1hlc, the IEC 61158-2 wiring can run for a very long dis- there is something called a VCR (Virtual Communication Relation-
tance, far exceeding what is normal in most plants. For most net- ship). VCRs are difficult for people \Vithout expertise in fieldbus to
works, there is therefore no need to calculate the length and understand, cmd it is therefore important that the complexity of
voltage drop at each device since it is usually much shorter than VCRs be hidden from the user to make configuration easy. For you
the maximum allmved. Hcn.vever, if there is some network that propeller heads, VCRs arc explained in chapter 11, "How Field bus
runs to a remote~ unit such as waste treatment or nitrogen produc- Works." In each device, one VCR is required for each communi-
tion the wire run may be longer than it would be within a building. cated link as well as additional ones for other communication func-
Calculating the length in this case may be a good idea. For intrinsi- tions. Function blocks should be allocated into devices in such a
cally S<lfe netvvorks, you should complek an entity parameter way as to reduce th0 number of con1municated links. This vvill
sheet for each intrinsically safe segment. If you choose the FlSCO improve control performance, with the <'ldded benefit that the
concept for intrinsic safety the engineering work is reduced in number of VCRs required is reduced. for a device that supports
comparison to the troditione1l entity concept. very few VCRs, it may be prudent at the time of engineering to
check that it has sufficient VCRs for the application. Devices that
It may be very elegant to dedicate linking devices so they are not have few function blocks and few VCRs can be constrictive, \Vhich
shared between process cells. However, if you do, more linking makes the allocation of blocks to devices an iterative process. It is a
devices may be required, which will increase cost. As in many good idea to use devices that support a large number of VCRs.
other cases~ strike the right balance between simplicity and econ- Doing so, eliminates the need to calculate a VCR requirement bud-
omy. For simplicity, it may also be a good idea to usc a linking get, which is simply too much work. As a last instance, the config-
device with built-in field device power. Decide which field-level uration tool checks that the number of VCRs has not been
networks require redundant interfaces to ensure that there is ade- exceeded. Therefore, the sooner the configuration entry starts, the
quate availability for the communication. better. Waiting until all devices arrive on site may be too late.
For the host-level network, decide if redundancy is required and if When you design the control strategy work as far as possible with
there are any long stretches where fiber optics is necessary. the standard FOUNDATION Fieldbus blocks. This will make it easier
Depending on the system size consider using some switching hubs to repbce the device in the future without having to replace any
or even routers. manufacturer-specific blocks, and it gives you greater flexibility to
assign the blocks for execution in different devices. In case the
Control Strategy standard blocks don't suffice, use extended or specific blocks. It is a
good idea to usc a configuration tool that supports profiles for
When designing the control strategy rnake sure you make full use identifying blocks. With profile support it is possible to build a
of the status capability of both FOUNDATION Fieldbus and PROFI- control strategy that is completely independent of the particular
BUS PA. In other words, use the status bytes throughout the con- dE?vice that will eventually be used. That is, the process engineers
trol strategy to provide fail-safe action, reset windup protection, can build the control strategy without really knowing the devices
and bumpless transfer. In a system that uses the FOUNDATION and can let the instrument engineers assign the blocks to devices
Fieldbus protocol this is easiest done simply by using the FOUNDA-
without really caring about the strategy.
TION function blocks in all devices without involving proprietary
languages, including any central controllers. For PROFIBUS PA,
Operator Interface
make sure you select a central controller that supports the use of
the status bytes, preferably as an integral part of the language. Select the number of workstations required. Even for a small sys-
tem, it may be a good idea to use at least two to provide redun-
For FOUNDATION Fieldbus, select blocks, link them, and parameter- dancy. In a small system, the operation, engineering, and
ize. Then allocate function blocks in the field devices. Avoid cen- maintenance can be carried out from a single station, but in a larger
(
Chapter 8 _ Engineering and Design
system these functions may have dedicated stations. In a small sys- blocks meaning that theY haYe a library of many bloc~ types and
tem, server for OPC data access, alarms and events, and historical many ~opies of each bloCk type can be us~d in t~e devi_ce. ~ou
trending can be in one workstation. HowPver, for larger systems should use field devices thnt have dynmmcally msta_ntJable fun:-
such functions are best done in a separate server. tion blocks to eliminate this C"onstraint, tl~ereby_ makm? the engt-
neerin process straightforward. Dynamically mstantiable blocks
gi\;e y~u maximum flexibility vvhen building the control strategy.
Selecting Vendors and Parts
The process of selecting the host, field device, and sofhvare is fairly The number of dedces you can have on a network segment and
straightforward because devices from different manufacturers are the length of the network segment bo~h dcP_end on the volta~~
interoperable. The painful process of selecting just a single vendor drop along the wire. By choosing devices With ]ow power co
is therefore eliminated. In other words, you don't have to make the sumption these constraints greatly diminish. Consequent~y~ for
difficult compromise of having to choose either the best transmitter, most of the nchvorks in the plant there is no r:ec? to speCif:c~l.ly ,
the best valve, or the best software, and so on. Although fieldbus calculntc \vhdher the network will operate wtthm th~ const: amts.
technologies are standards, there is plenty of differentiation in the Low power consumption has the <Jdded adv~nt~g~ ot_en~bltng f
capability devices offer, in diagnostic coverage, and so on. The more devices to be connected per safety barner m mtnnsically sa e
required functionality must be specified. installations.
The differences between fieldbus and conventional devices should The existing plant standard specification for transmitters, position-
not be overdramatized. Engineering and specification is not very ers and other field instruments can be used with an add~d clau~e
different since the basic principle of measurement remains the co~taining some points for fieldbus requirements. Es~~nt~al!/' t e
same. The device spC'cification sheets should just say what type of existin JSA-20-1981 specification sheets can b~ used as IS. Just
fieldbus it shall be in place of the usua14-20 rnA signal. The rest is indicat~ that the signal shall be FOUNDATION Fteldbus HI, ~ROF!~
the same. The specification sheet docs not have to indude features BUS PA or 4-20 rnA with HART. The individual data sheet oreac
that are implicit to the fieldbus technology chosen. For example, tag sho~ld not go into details about the device type sp~n.ftcatJon.
for a controlling device it is only necessary to specify that it shall You should put the performance and feature ch~ractenshc.s that
use the FOUNDATION Field bus PlD function block, without having are common to all the required devices of a ~arhcu~ar devJ~e type
to go into details about reset windup protection, bump less transfer .. . E 1 of pomts to mclude m sepa-
into a separate speohcahon. xamp es.
and safety, and so on. This means that system specifications rate detail specifications are the followmg:
become simplified. Similarly, don't define detailed requirements . k PID A 'thmPtic Sio-nnl \hnrnc-
repeatedly for each loop or device tag. Instead, specify the com- • *Required functiOn bloC" typps: ' n _ '· y d
terizer, Integrator, Analog Alarm, Input Selector, Ttmer, an
mon reguirPments for each devict·lype and apply them consis-
tently throughout the entire plant. The engineering burden is Lead-Lag.
increased if you use devices with many restrictions such as high • *Dynamically instantiablc blocks: Yes
current consumption, limited or fixed set of function blocks, few • *Maximum execution time for each block type: 70 ms for the
VCRs, and the like. If very capable de\'ices are used much work
blocks just mentioned
can be eliminated.
• *Block quantity: more than 12
Field Instrument Specifications • Bus pm.ver consumption: 12 rnA or less
If you used devices with a fixed or Hmited set of function blocks, • Intrinsic safety: Exia l!C, F!SCO
selecting the transmitters and positioners appropriate for the
application may be an iterative process. For example, a device cho- • *VCR: more than 40
sen for the application in the first round may be found to lack a • *Link master capability
sufficient number of blocks. This may force you to choose another
• Registered as intero~erabl€
device, which in turn has to be checked against the process require-
tnents. Some devices have dynamically instantiating function
Fieldbuses for Process Control
Chapter 8- Engineedng and Design ~~~
Note: tlw_ point.s indicated by asterisks are only applicable to
FOUi\lDAl!ON Fte!dbus devices. • *Com·entional I/0 represented by regular input and output
function blocks: Analog Input, Discrete Input, Analog Output,
Host Device Specification and Discrete Output.
The l.1ost includes interface hardware such as a linking device and Note: the points with an asterisk are only applicable to FOUi\DA-
poss~bly a centra~ contr~ller. A.lso required are operator and engi- TJON Fieldbus devices.
nccnng workstations w1th theu respective software as well as a
host-J:vel nctw~rk. For FOUNDATION Fieldbus hosts it may be a Engineering Software Specification
good tdea to r.CVlCW the Host Interoperability Support Test (HlST)
report to conflrm the capabilities. Building a fieldbus system is not as simple as installing a fieldbus
interface like another module in the J/Oof an old system. The host
luteJjnce Hardware Specification must also have the software to support all the nevv functionality; it
cannot just use the process 1/0. for a small pilot system, a stand-
To achieve high av;1ilability, you should usc a redundant host-level alone fleldbus configuration tool mily work. However, for a full-
network and interface modules so as to ensure two paths to the fledged system the best solution is an integrated engineering tool
operator. To simplify both engineering and construction, the field- for field bus device, control strategy, and net\vork configuration.
~1US devic.c po~er supply subsystem should be integrated with the The reason for this is that if the control strategy and device config-
~ntcrf~ce.m a smgle device (figure 3-28). To simplify commission- urations are made in different tools \Vith different databases a lot of
mg, ehmmate human error, and reduce the number of cross-refer- l'Xtra work will be created, raising the risk of inconsistencies and
ence list documents the assignment of addresses for the field-level thus a nonfunctioning strategy. For example, suppose the range is
network shall be automatic. configured as 0-200 in the device but 0-500 in the controller or
operating screen. The alarms will not trip as they should, and con-
You can usc the existing plant standard specification for the host trols will not work, so operators will be misled.
hard war~ with an add~d clause containing some points for field-
bus reqmrcmcnts. Ind1cate that the host-level protocol shall be On the other hand, errors are eliminated if all the configuration is
FOUNDATION Ficldbus HSE or PROF!BUS PROFlnet. The following done from a single tool with a single database, so that the data is
are some examples of pomts to include in a detail specification for entered only once in a single place. This is particularly true when
a linking device: future changes need to be made because the risk that personnel
will forget to enter data in c1 second or third place is greater. To ben-
• Redundant field-level network interfoce (in different back-
phmes) efit from asset management, J'OU should design the system so the
tool is permanently on line. This will facilitate easy access to the
• Redundant host-level networks Jive list, maintenance, and calibration information when the plant
is operating.
• *VCR: more than 50 per port
• *Automatic address assignment on field-level network For the host to be truly interoperable and able to configure any
device regardless of manufacturer it should only require the stan-
• OPC server diltn access version 2.0 compli<lnce-tested
dard de\·icc support files associated with the protocol used. If the
• Integrated redundant power supply and impedance (in differ- host requires additional device support files from the host manu-
ent backplanes) facturer, no independent institutes will test these files to "certify"
each version of every device made. The host manufacturer will
• Field-level ports: minimum 4
consequently have to test these files to make sure the proprietary
• *Publisher /subscriber communication of process I/0 files are OK. The use of proprietary files reduces interoperability to
just a small shortlist of devices.
• *FOUNDATION Fieldbus language function block execution: PID,
· Arithmetic, Signal Characterizer, Integrator, Analog Alarm, Network drawings and P&l diagrams show devices and function
Input Selector, T1mer, and Lead-Lag · blocks, respectively, but not how blocks are allocated to devices.
(
The configuration tool should therefore automatically generate You can use th(' existing plant standard specification for the pro-
such a. cross-r~fcrencc list. Other useful engineering documents arc cess visualization softvvare with an added clause containing some
those tllustratmg block parameterization and the allocation of points for field bus and OPC The following are examples of useful
devices to the networks (figure 8-10). features and characteristics explained in the earlier chapters that
you should consider including in a detail specification:
Field instru~~ents and other devices used in large quantities are not
off-t~1e-she.lt Items. Therefore, to minimize engineering time the OPC client
con6guratmn must begin long before these devices have been • Direct OPC access
manufactured and installed. The engineering tool should therefore
be able to build control strategy and to configure devices off line • Non-Good OPC values are flagged by a special character such
without any field instruments or controllers being connected. as an asterisk or other reserved symboL Numerical \·alues must
Because FOLNDATION Field bus and PROFIBUS PA have function not be used.
bloc.ks in the fiel~i de:' ices the boundary between configuring • Display quality and limit conditions next to value:>
devices and configurmg control strategy becomes blurred. lt's a
good idea to use a configuration tool that allows the control strat- • *Use FOUNDATION alarm priority levels throughout the system
egy to be configured independently of the device where it will be • Support the 32-character TAG_DESC, function block tag, physi-
executed. The block can be allocated to devices later that is the cal device tag, and parameter names used in FOUNDATION and
device issues and control strategy can be kept separ~te. ' PROFIBUS PA.
You :an use the exjsting .Plant standard specification for the engi- Package Units
I:eenng softv~are by addmg a clause containing some points for
fteldbus reqmrements. The following list gives examples of useful The basic control system usually has to be integra table with pack-
features and characteristics explained in the earlier chapters that aged units for boiler control, compressor controls, and other func-
you should consider including in a detail specification: tions around the plant. Package units are equipment that come
with their own preinstalled instruments and controls. To simplify
• *No propriet~ry devic: s:tpport files should be required, just engineering and integration work make sure to specify that all
standard devtce descnpt10n and capabilities files. package units must have a connection for the same host-level net-
• Automatic generation of documentation work utilized by the basic control system.
• Display of live list
System Configuration Entry
• Offline configuration
Typically, the control strategy, network architecture, and field
• Dynamic block instantiation device configurations are built in the offline mode from the config-
uration tool once the control strategy and deYice requirements
• Permanent online access to instruments have been decided. This work can be completed before the devices
• Auto-generate OPC tag list have been manufactured or connected. Downloading is done dur-
ing the commissioning stage. Generally, this configuration is made
• Support of profiles in order to identify block capability from a single tool that allows function blocks to be assigned to
devices and devices to be assigned to networks by simply drag-
Process Visualization Software Specification ging and dropping their icons. Before you begin configuration you
A prerequisite for easy engineering is that there is no duplication must load the device support files for the relevant device types on
of databases. Therefore, it is a good idea to use process visualiza- the computer unless they were preinstalled. By starting configura-
tion software in the operator consoles that accesses data directly tion when the project is launched, you can reduce the engineering
from the OPC server without needing to map into intermediate and start-up time. The configuration of device and control strategy
databases. · is prepared in advance from any location. The configuration is
stored as a file, brought on site, and downloaded once the devices
- are_ in _Place: 1_'he engineering tool continuously checks the configu~
r~t10n s valid1ty to prevent users from making illegal configura~
··---·---- ------------------·- ----1
Chapter 8- Engineering and Design
It is a good idea to use a single configuration tool that treats field- base, such as commonly usPd office tools, \Vhere it can be sorted
bus and conventional I/0 the same way. This will make it easier to and filtered (figure 8-2).
implement a hybrid configuration consistently.
Documentation m
• -~\-.l\'"""'., J. .;:...:~:,..;...., \•o.,•.( ~;.;.,.M·J,...;_t•~~:'±_L~~ -~.'C~~}, _______ .~!.~!t
M..,.
TI_1e docume~1tation process for a fieldbus system requires only
slight alterat~ons from past practices. Usually, the configuration Figure 8-2. Blo~k execution allocation exported to Microsoft® Excel.
tool automatJcally generates part of the documentation as the con-
figuration is entered, for example, lists of networks, instruments,
blocks_and parameters, and the like. These listings make ideal P&l Diagram
d~cck!Jsts to usc when doing 1-<AT (factory acceptance test) and SAT P&l diagrams ust!illly follow the ANSl/lSA-5.1-1984 (Rl992) stan-
(s1te acceptance test) verification. dard, which states that a P&ID is used for symbolizing the key
functions of an instrument whereas other details are covered else-
\Vhen several devices are multidropped it is more suitable to use a where. The fieldbus technologies do not change this, that is, the
network diagram with all devices on the us than the traditional spparation of hardware from control functionality. Just as in the
loop diagram. Jn f\1UNIJATION Fieldbus and PROFIBUS PA the past, the P&ID shows neither wiring aspects nor which device a
boundary between devices and control strategy can becom~ con- function block is being executed in. It is possible to indicate vvhere
fused. To keep the design process simple, do not let the P&J dia- control is done by placing the control bubble next to the bubble of
gram and network diagram, which replace the loop diagrams, the device where it h; executed, for example, next to the valve bub-
have overlapping information because duplicated data results in ble. Use consistent tagging regardless of whether the blocks are of
inconst~ncies. The physical wiring is best shown only in the net- a proprietary nature in a central controller, in PROFIBUS PA, or in
work L:Jagr~m ~nd the control scheme functionality only in the FOUNDATION blocks in a field device because control is indepen-
P&ID,. JU:t hke m the past. Devices and the physical device tag dent of the physical location. Function blocks perform the same job
(PD _1AG) are best shown m the network diagram. Function blocks regardless of where they are located. Thus, there is no need to indi-
and function block tags (FB_TAG) are most suitable for the P&ID. cate which device the block is in on the P&ID; this is done in a sep-
The configuration toolusuaJly generates a cross-reference between arate document. Keeping the transducer blocks and resource
theP&ID and network diagram that lists which block goes into (physical) blocks that are related to device configuration out of the
wh1ch dev1ce an~ w~at loops the blocks in a device belong to. To P&l diagram ensures that the documents are not cluttered.
correlate the devrces 111 the nehvork drawing to the function in the
~&I di~gram it may be a good idea to print these cross-reference Signal linking between fieldbus devices as shown On P&ID's and
hsts. Ltsts can typically be exported to any ODBC-compliant data- other system documentation needs to be depicted differently from
Fitlldbuses for Process Control Chapter 8- Engineering and Design
signal linking for conventional analog electronic signals. At the ·were used technicians could be misled into belie\·ing that discon-
time of this \Vriting, the only symbol available for usc that comes m•cting \VOuld only affect the single loop.
close to being appropriate in ANSI/!SA 5.1 (1984) R-1992 is the
data link symbol typically used for DCS applications. To the end ---------I
that this symbol is not specific enough, the committee for that stan-
dard is addressing the need for a specific symbol as part of their ~:Cc<";C, ':=['"'-Q,,;,cCc '-l=~=~' '~ j . l
current revision work. It is anticipated that the revised standard r - r , - - f , H r·'-7.
will be issued by the end of 2001 or early 2002. ln the meantime, it .
'I
~+t3J~-n- ~~·j :
is recommended that the current data link symbol be used.
I i·(••y H I I
Il
I
®~_
•._•_~.·._·. •.J._:
-----{}----- 0---
L w--
l . ~ ' '
__
( _______ _ _ _ _ _/·~-~- -
Figure 8-3. P&ID detail using data link symbol for fieldbus interconnections.
, I
Network Drawing
(
Fieldbuses for Process Control
Chapter 8- Engineering and Design
device number and port number: FN-ii-pp. Use the network tag It is a good idea to use the fieldbus configuration tool to maintain
name in the network drawing as well as in the configuration tool electronic documentation in a paperless system.
for easy cross-rcferc'ncing. Use consistent tags for field bus and con-
ventional de\· ices. D.:m't include network numbers in the device Control Strategy Documentation
tag as it is not always clear which network a device V\-'ill eventually
be on. FOUNDATIO\: fjeldbus specifies a graphical programming lan-
guage, and consequently most configuration tools are able to print
Represent fieldbus and nonfieldbus devices consistently in net- out the function block diagram as part of the configuration docu-
\Vork diagrams and conventional loop diagrams. These documents mentation (figure 8-7).
are used for trouble~hooting dt"'Vices, and fieldbus devices have the
same basic function as conventional devices.
-~--~-~--~--------·-"!·,..;,..
"''"'i"""'""''"""'"r:::t:=------=--
hl""' ~" ,_, """"' >g- >, Cl><• · - 0!<'0
::%:t'• ~~
-l
liilt!i>~~t..:~ • . ,, 11I\!I!f'9''l!lm$"•:.~.~,.,!"-·!o·tt.·.
A' •' • :.. .·,,
"
i~"
:f
iii
"
if:
'
""
=
"'
?f
~· ~
t.D.:!L\_I'riii'f"~.n~J~-=.ui~:L~~-"J...~""·t~l·l __ ---···-···- I!III.!Jr Figure 8-7. Control strategy.
1'.o>dj ''"--·--~-- --·---~---··-··-·-·-:----;-
the blocks have been allocated. The tag of the device in \Vhich a
block is executed is shmvn next to the block itself. 1~1 tt ·-!i 1 tt.. ll '·~0!_~!:''>'. ~l'.l
cl':.JE'< ~d< ~ ..... , - l""' " " ' ' - ~ ..Jft:JlfJ
(;l<lf:l,lq;:,I:~>"'' •l'l•Bii!'iiO'ti"'l'l:!!j$%,:,Z.'l~~-·!).·A.•.
---l
r
,---~ ~-------- ~~:""r~,: t·.,:~T::.~'" " ·h.,,;./,~·:b~~-,-E - F >! __ '
:l ll1 l '"[E 8L lq
3 LT 122 Ch 1
J Ll I ' L ''P'
5 Ll 12 sl~T 0 f ~
6 LT ' T , [C~
l~~gJLZ~:~~~_~,~~.M~.r_L"'*'"-' ''-~c~~~Ll~L--
~ ~~-:;; ~;:t",\, . _ :~;:;,, ....,,, ,_, .,.,""'
2l:f•>lll .. ,., ,,._, •'•l
ii'r.:.m f<l-ll,;; •m
(
Fieldbuses for Process Control Chapter 8- Engineering and Design
ufactured before the test could begin and vvould require fewer Site Acceptance Test (SAT)
staging resources.
Site acceptance tests (SAT) are an essential quality assurance dwt+
Decide at an early stage of the project vvhich form of J.AT should be to verify that the correct devices are in place and that they arc con-
performed. During the FAT, the complete host, including all link- figured and working properly.
ing devices, controllers, and conventional I/O subsystems, as well
as the host-level network should be subjected to both hardware SAT Test Plan Additions
and software functional tests. The conventional part of the system The buyer and supplier usually work out an SAT test schedule
should be tested the same way it was before. Many of the checks document together. If the configuration has not been down!oadl'd
performed during conventional FAT also apply to the fieldbus and tested during the FAT it should be during the SAT. There arc a
part, for example, testing the quality of terminations, and so on. number of new points to be tested in the field:
FAT Test Plan Additions • Make sure all field devices appear in the live list for the relevant
network.
Together, the buyer and supplier usually vvork out a FAT test
schedule document. For the fieldbus part of the system, ~here is no • Ensure that the correct device is in the right place by verifying
l/0 calibration and scaling to check and no point mapping to data- that the physical readings from sensors and to actuators an.·
base to verify. However, there are a number of new points that coming through.
must be performed:
• Ping all the host-level network nodes.
• Test all field-level network communication ports against a
known good device. Simply make sure the device appears in
loopCu.-.: ~,9.9.9 ............... mA
the live list.
PV: ?.9,.$.Q.Q ............ inH20
• Test interoperability with one field-level device of each type. SV: n. .?.~.Q. ............ deg_f
TV: t!l~ ................. N/A
• Test switchover from the primary to secondary field-level com-
QV:N/.f! ................ NIA
munications interface'.
• Test switchover from the primJry to the :;ccondory host-level
network.
EXERCISES
8.1
8.2
Is it necessary to make a VCR calculation at the time of
engineering?
How many device support files are provided with
9
FOUNDATION devices to make it possible for the
engineering tool to configure them?
Maintenance and
8.3 During the purchasing process, should the function block
requirement he specified on a per-tag basis? Asset
8.4 Should physical device details be indicated in the P&I
8.5
diagram or in the network diagram?
Can preengincered FOUNDATION control strategy templates
Management
be used with any device?
BIBLIOGRAPHY
l\1aintenance and asset management for fieldbus concerns the
1. ANSI/ISA-5.1-1984 (R1992), Jnstrumrntation Symbols and
health of the instrumentation and to some extent the networking
Identification, Research Triangle Park, NC: !SA, ISBN
hardware, but does not involve the control strategy. However,
0-87664-844-8, 1992.
asset management indirectly improves control because it can be
2. ISA-20-1981, Specification Forms for Process Measurement a11d used to ensure that the devices are in a better condition to perform
Control Instwmcnts, Primary Elements and Control Valves, control. Troubleshooting installation problems and debugging con-
Research Triangle Park, NC: !SA, ISBN 0-87664-347-0, 1981. trol strategy is covered in chapter 6, "Troubleshooting."
359
Fieldbuses for Process Control Chapter 9- Maintenance and Asset Management
When your plant embarks on the first project involving fil'ldbus Pronctive lllnintcnnncc is a scheme in \Vhich service is targeted
technologies work with the quality assurance department. Define toward the instruments that really need it, that is, based on the
how the maintenance tool shall be used and how to make it an condition of the device. Resources are not wasted on devices that
integral part of the calibration and st~rvice procedures. need no maintenance. This scheme requires a minimum of
resources, has the lowest possible cost, and offers the most efficient
Reactive nwintcnn/lce is a scheme in which a device is only fixed usC of manpower. Use fieldbus technologies in addition to diag-
after it is broken, or rather only after it has been found to be bro- nostics to continuously monitor "leading indicators" of wear and
ken. This kind of maintenance can be very dangerous since, tear, stress, extreme ambient conditions, and the number of opera-
depending on the application of the device, the plant may not be tions to predict future faults without the need for manu.al data col-
safe while the device is not operating properly. A failed device lection and entry. Network-enabled asset management IS f.astcr
may, again depending on its application, cause production to stop and easier than manual data collection and entry as there JS no
or reduce the product quality below an acceptable level. The lmv delav bC'lween the time the diagnostic data is created and the
availability means loss of production time. Shutdowns due to fail- mon;ent when it reaches the asset management software.
ures are normally very expc•nsive as whole batches of products
often are destroyed and production capacity may be reduced for a
long time. Stopping and restarting the process every time there is a
Asset Management-enabled Systems
failure is also frustrating. Time, raw materials, energy, and other Just adding a fieldbus interface module to the system h~rdware
resources are wasted. H the process goes wrong it can be very time does not open up the great potential of these technologtes. Asset
consuming to clean up the mess. Although reactive maintenance is management is a software-centric ap~roach to mainten~nce and
far from the preferred maintenance scheme, use the fieldbus tech- calibration. To fully benefit from the heldbus technologtes make
nologies to improve the situation. Rely on the field instruments' sure the engineering tool or dedicated asset management sof~ware
ability to report faults to the host through standard means. This is permanently connected to all field-level networks so there IS
will make it possible for maintenance technicians to take quicker continuous online overview and monitoring of the devices even
action. while the plant is operating. Diagnostics, configuration, identifica-
tion, and the like can be done any time. Although a stand-alone or
Preventive llzaintcnance is a scheme in which devices are serviced at temporarily attached configuration tool may work for a small pilot
~chosen interval whether they need it or not. This approach plant, it prohibits effective utilization of the tool for asset manage-
Improves saftc>ty and availability since surprise slops are in many ment in a larger plant. Inconsistencies between the control and
cases avoided. However, this scheme is also costly because device databases often may result. It may be inconvenient to have
resources like time and spare parts are wasted on many devices to move between different workstations. It is a good idea to leave
that actually need no attention, that is, unnecessary maintenance. your maintenance application runni~g continuously on th~,sam~
The preventive maintenance is disruptive since production may workstation as the process visualization software. When a Ba~
not be able to run normally while the maintenance is carriPd out. status, block error, or abnormal mode is indicated in the operation
Although availability is not at its optimal level use the field bus screen, staff can check the maintenance tool to sec what is going on
technologies to store and retrieve information about the last cali- without having to leave the station (figure 9-1).
bration or service in the field device.
Asset management deals with devices. For that reas~n, it is the
Predictive mninfennnce is also a scheme in which service is per- resource (physical) block and the transducer blocks m
formed on a periodic basis whether the device needs it or not. FOUNDATION or PROFIBUS PA devices that are accessed. The
However, the service interval is optimized using failure rate and details of the parameters in these blocks are covered in chapter 4,
drift statistics gathered for each device type over long periods of "Configuration."
time. There is still some waste of resources, but less ofit since
unnecessary maintenance is reduced. Use the fieldbus technologies
to more accurately determine when devices fail and how much
they drift.
- 1·1eldbuses for Process Control Chapter 9- Maintenance and Asset Management
------~~-- - - -~--- ----- was pe-rformed using the same set of potentiometers. Therefore,
the terms calibration and range 5Cftings have been confused. To sepa-
rate the two functions the true calibration in HART is called
"trim." In FOUNDATION Fieldbus and PRO FIB US PA true calibra-
tion is indeed called "calibration," whereas range setting is called
'
"·"'"''"'
'<! """~'''''
' "scale." For example, transducer block calibration is not used to
- :<S'"-'''
• f1 "c, .,_.,_,_.,, . . ""'"'"'-~'
. n -'-'··'"""'~~ :.
' n, _(r_ ' ' ''"~" (OH'~'-''~ r
cancel pressure from a "vvet leg" in, for example, level or flmv mea-
giijjf#!ili!Utog !!It+!
0 ~;''-~"
surement. Rather, this is done vdth the transducer scale in the ana-
log input function block. Range setting can be done remotely, but
calibration cannot because it by definition requires connection of
standard reference input. Calibration must occur at the device in
order to apply different known input values one by one to calibrate
agc1inst. Since HART transmitters and positioners have 4-20 mJ\
output and input, respectively, the loop current can odso be ci1li-
brated, though this is very rarely done. Therefore, HART devices
also have a "current trim."
Figure 9~1. Engineering tool sees all devices in the plant.
Calibratioll is the correction of sensor reading and physical outputs
so they match a standard. Therefore, calibration means that a
Calibrating Fieldbus Devices known external standard input has to be applied when performing
input calibration and that the output has to be measured for output
Calibration is typically done on the workbench in the instrument calibration.ln other words, calibration cannot be performed
workshop. Some simple calibration that does not require bulky ref- remotely because it requires someone to connect the external stan-
erence standard equipment can be carried out in the field. Since dard. Use calibration when the primary value reading (in engineer-
detailed diagnostics and calibration require communication with ing units) does not match the applied input. Since the primary
the device communications facilities should be available in the value reading is later scaled to obtain the percentage reading (and
instrument workshop. For a large installation, you can justify a 4-20 rnA output of a HART transmitter), sensor calibration indi-
small stand-alone maintenance station consisting of a workstation rectly affects the percentage reading too.
and a simple interface ¥vith power supply. This is easiest done
using a linking device that h<1s integrated power (figure 3-11). Rn11gc setting for HART transmitters ls done primarily to tell the
transmitter the values at which the output shall be 4 rnA and 20
for a small installation a dedicnted system for the workshop m.:1y rnA. For FOL..\iDATJON and PROFIBUS PA transmitters, range set-
not be justified. In this case, an altern<Jtive is to run one field-level ting is typically only done for applications of inferred measure-
network from the main system into the instrument shop for the ments. Range can be set remotely without applying any input or
sole purpose of calibration and maintenance. Similarly, the host- measuring the output. Use range setting when the percentage
level network can also run into the shop to a workstation dedi- reading is not correct. Range setting does not affect the primary
cated to maintenance tasks. It is a good idea to have the mainte- value reading.
nance station connected to the host-level network so any
configuration changes and calibration record entries are stored in Note that for HART transmitters it is possible to correct a calibra-
the same single database. tion error by changing the range-and this is often the practice.
The engineering unit reading is wrong, but the 4-20 rnA output
Calibration versus Range Setting will still be correct
The field bus technologies do not change the concept of calibration.
Do not confuse calibration with range setting; they are two differ-
ent things. For analog transmitters, calibration and range setting
!
Fie1dbuses for Process Control
Chapter 9- Maintenance and Asset Management
Performing Calibration
A special case of sensor calibration is zeroing the transmitter,
~alibra.ti()l: i~ a device function. For a FOUNDATJON or PROFIBU \vhich is commonly done for some measurements. A zero input is
I A deviCe It JS therefore done from the corresponding transduc S achieved to simulate the input without having to connect any stan-
blo~~.l~l~weve~, range setting is a control strategy function ande; dard. This is done simply by venting the pressure, shutting off the
5 flow, or emptying the tank, as appropriate for the measurement
therefme done Ill the corresponding function block.
being done. The calibration can then also be performed without
Although the ficldbus specifications standardt"ze how tl having to key in any calibration point value (figure 9-3).
· t ·1 •• ·· 1e user
m era_ cts Wit 1 tlw devices the exact proced f f. .
b t. i"ff ' - ure or per ormmg COlli
I r~ IOn may t J er depending on the configuration software-ha~d-
le d_land the device. Refer to the relevant product manuals for -
j
tC~lS. '
~omctimes the primary value reJding mav differ from the appl" d Value: 050tlinH20
mput. The reason may bt~ that for cxamF-,1~ th t. . ~ IC
· .. . ' ' , e tansmtttet mount-
mg posthon or the readmg shifted because of o
t ' , verpressure, over-
empera.ture, ~r long-term drift. Calibration is performed to match
the readmg \Vtth the ~pplied input. Applying a value from a
~nown ~,:andard and_mforming the transmitter what that value is
te~ch~s the trans.mJtter the correct value. The correct read in is Figure 9-3. Zero calibration of HART transmitter.
keyed mto the device through the engineering tool which us!an
a,lso shmvs the pr~sent value as seen by the transmi~ter (fi }-ure
1he correct value IS referred to as the "calibraf
9-!
. t "g h ).
"t . . t" . h JOn pom ' or t e
Typically, calibration is done in two points as close as possible to
~. nm pom m t e case of HART. Calibration for FOUNDATION the expected measurement range. These two points are referred to
Fieldbus and PROFIBUS PA transmitters is performed by writin as the low and high calibration points. For most modern transmit-
the applied mput to the low calibration point (CAL_POfNT LO)g ters, the calibration of these two points is noni.nteractive. This
and h1gh calibratiOn pomt (CAL POINT Hf) . h d - means that one can be calibrated without affecting the other, so an
bl k I l"b - - m t e trans uccr
(~C • nput ca I ration changes the process value that may cause iterative process is not necessary. All transmitters, whetht:~r they
pro~ess up~ets. Therefore, it is prudC'nt to either calibrate the stntc it or not, have a finite measurement resolution, and a mea-
deviCe
·
off hne or with the control loop in m'I1LI'l
u n .
Many con r·lgura- surement over a small span would therefore result in poor accu-
tmn tools prompt the user to check mode. racy in percentage terms. For most transmitters, there must
therefore be a minimum span between the upper and lower cali-
bration points. Attempts to calibrate with smaller spans are
rejected. For FOUNDATION Fieldbus and PROFIBUS PA devices, the
minimum span (CAL_MIN_SPAN) can be reviewed from the
transducer block.
Output Calibration
Output calibration mainly applies to signal converters that have
analog output such as 20-100 kPa (3-15 psi} or 4-20 mA. To cali-
brate the output signal, you first force the transducer block to out-
put a signal of a set leveL The actual physical output may deviate
Figure 9-2. Calibration of a PRO FIB US PA transmitter.
from the desired level that has been set. If it doesn't, calibration is
not required. The actual physical output value as measured exter-
Fieldbuses for Process Control Chapter 9- Maintenance and Asset Management
nally is then written back into the device from the software-hand- tion record to determine the calibration status of the device. For
held, which will then correct its output accordingly. Typically, the example, HART has a parameter for a date that can be used to
low and high calibration points arc non interactive, which elimi- record the time of the last calibration or the time scheduled for the
nates the need for an iterative process. next one, based on the manufacturer's recommendation or plant
experience. PROFIBUS PA dC'vices have <ln installation date
Control valve positioners that are able to calibrate themselves arc a parameter in the physical block that you can perhaps be used to
special case of output calibration. With a simple click from the store the date of the last or next calibration instead. In addition to
engineering tool, the positioner will stroke the valve over its entire date and time, the FOUNDATION Fieldbus transducer blocks also
range of travel and automaticaJly calibrate itself for the open and store who did it, where it was done, the method used, and the like.
closed end points. This process m<ly take a minute or a few, and Both the FOU~DATION and PROF! BUS PA transducer blocks have
once calibrated the user is informed. Obviously, stroking the valve the calibration point p<H<Hneters. From these, you can review the
upsets any process fluid flowing through it, and therefore last calibration vJlues to determine if the calibration performed is
calibration should only be done off line or while the process is not suitable for the application. Because the information is stored in
operating. The PI\OFlBUS PA actuator transducer block has a the device itself it stays with the device at all times and is not lost.
standard parameter to invoke this function, SELF_CALIB_CMD.
Use the calibration record capability in the calibration manage-
Current Loop Calibration (Current Trim) ment scheme. Use the networking to get an overview of the cali-
bration status of the devices around the plant. Target the resources
HART transmitters have a 4-20 rnA output. Because there are no
toward the devices for which calibration is due. It is a good idea to
mechanical parts not much drift is associated with the 4-20 mA.
update the calibration record information each time a calibration
Therefore, there is no real need for current loop calibration. Never-
has been performed. Include device record-keeping as part of the
theless, it is possible to calibrate it in two points, which are ca1led
plant procedures.
current zero trim and current span trim for the 4 rnA and 20 rnA
points, respectively. When the output calibration is invoked the
software-handheld forces the current output to the relevant value Information Pertinent to Calibration
and the user is prompted to measure and key in the actual output Calibration can only be performed at points within the limits for
(figure 9-4). the sensor, and the two points of calibration must be separated by
at least the minimum span limit. These limits arc stored in HART,
FOUNDXI'ION Field bus, and PROF! BUS PA devices along with
other pertinent information, such as sensor type (figure 9-5). Usc
this information to assist you in the calibration.
Please, Select Desired Point::
Current Trim:~
~ Diagnosing Fieldbus Devices
Please, Ent:er loop Current::
Network-enabled diagnostics can help you troubleshoot when you
loop <urrent::j.& .......... rnA
arc maintaining devices that have already failed right from the
engineering tool. HART, Fou:-.:DATION Fieldbus, and PROFIBUS
PA devices have several parameters that are dedicated to diagnos-
tics that simplify troubleshooting, as explained in chapter 6, "Trou-
bleshooting." Use the diagnostics capability to spot device failures
Figure 94. Loop current calibration. faster and therefore rectify them earlier. In other words, early
detection enables you to n:tinimize breakdown times, thus avoid-
Calibration Record-keeping ing unnecessary process downtime. For example, it is a good idea
to configure the process visualization software to display the
A field device also stores the information that is pertinent to the parameter status and notify the operator when faults in the field
calibration. From the engineering tool, you can review the calibra- devices are detected, as explained in chapter 7, "Operation."
(
( (
liil Fieldbuses for Process Control
Chapter 9- Maintenance and Asset Management
Ub!tfjditf+iM.Irq&ijlfj! _Jolx!
Reducing Repair Time
Make it a point to always use the engineering tool to pinpo_int the
8 PRIMARY_W<LU€
. SlAHJS
instrument that has failed and to determine in greater detml what
GMd_N.:.nr.. sc•do Non$p•dte Nc<lln'!itW
VALUE
f±l PRiMA.fll"_VALUE_HANGE
230S22 the problem is before you go into the field (figure 9·6).
;~~98
: U.l_PQIIH_HI
, (AL_PD•Nl_LO
; CAL_M:N_SPMJ ;,r
. D.L_wm
: SENSQA_TYf'f
mtnH20 !l'<€'ff)
[.op~lon.o~
j
8 SU60R_RANG£
· EU_lOO
, EU_O
, UNIT5JCW£X "'"
.sooo
rotnl-120 !f-BI')
DECIMAL
• SEIISOFl_SII '
15670t;
: ~~~~g~=~:i{~~HOO
· S~f~50F:_tALJJAH
· SEIISOR_Cftl_Wf-10
Devices based on fieldbus technologies have wide diagnostic cov- Figure 9-6. Diagnostics.
erage and use additional sensors, other electronics, and self-diag-
nostics firmware algorithms that can detect faults based on
manufacturers' experience with failure modes. The transmitter Armed with this information, you can carry the right spares and
detects the failure of external sensors such as a thermocouple or tools into the field and perhaps fix the problem on the spot rather
even faulty or poor wiring. Ambient conditions like temperature than bring the instrument back to the workshop. For FOUNDATION
that exceeds operating limits may also be reported. When the oper- Fieldbus, the block error (BLOCK_ERR) parameter IS Ideal for
ator i~ notified of the fault, he or she can immediately attend to it, gaining a diagnostic overview and is used by asset ~anagement
which will ensure good transmitter performance. Use asset man- software to check device health.
agement features to do as much of the maintenance tasks as possi-
ble from the control room. Doing so will lower your exposure to Predicting Failures in Fieldbus Devices
dangerous plant environment and minimize the number of work
permits you will require. 10 a much larger extent than diagnostics can, co~tinuo~s opera-
tional statistics enable plants to move to a proactive n:amtenance
Reducing Unnecessary Maintenance scheme. Diagnostics tell you if a device .has already f~tled, but
leading indicators collected in the field_J~struments hke wear~and
Perhaps the biggest advantage of continuous device diagnostics is tear data and exceeded operating cond1hons ca:r: ~e used t_o tnp
not that it tells you a device has failed but that it tells you that it maintenance alarms before the device fails. Stahs_tics predl~t
has not failed. In other words, the diagnostics provided by the degrading device performance, which can cau~e ~naccuracies an?
field bus devices can help you to make an assessment confirming faults. Plants can therefore use operational stah~hcs to target n:am-
that no troubleshooting is required. By ruling out the devices that tenance resources on d evtces
. tha t m ay soon be m need of repa1r.
are functioning, you can target troubleshooting to other devices or
to the process. Review the results of the self-diagnostics to deter- Operational Statistics
mine if you have a device problem or a process problem. This will
reduce the number of times a device from the field is taken unnec- Operational statistics are stored in the transducer blocks. Control
essarily to the shop, only to be tested and found to be OK. .
valve posihoners are a good examp1e of a device. that
f h collectst a
.
large amount of operahona · t"tcs. Examples o t ese are ota1
1 statts
valve travel (odometer) and the numb~r of reversals. Plants can
Fieldbuses for Process Control
1 Chapter 9- Maintenance and Asset Management
I
use such information to predict the time of failure by comparing For example, if the manufacturer recommends that you replace the
these statistics to the life expectancy data for critical parts as pro- valve stem packing after a certain number of reversals, key this
vided by the manufacturer. Plants can use operational statistics to number into the positioner as an alarm limit. When the limit is
more accurately predict when maintenance is due since wear and exceeded, the alarm alerts the h.-.'chnicians that replacement is due
tear is measured rather th,tn estimated on an average. For example, (figure 9-8). In this way, you can drastically reduce the number of
the PROFIBUS PA valve transducer has standard parameters for unscheduled shutdowns caused by unforeseen failures. Knmving
total travel in the equivalent number of full strokes and a total about imminent failure in advance helps you reduce the chances of
travel limit at which maintenance should be performed. a surprise shutdown, and spares can be ordered beforehand. Main-
tenance can be proactively scheduled at a convenient time, when
Devices that trigger an alarm when a set limit for the operational all the devices on a unit can be serviced together.
statistics has been exceeded provide early warning. As part of your
new maintenance procedures, make sure you use these tools to tap
into the information of the instrwnents. This will give you inst~mt
access to the status of any device at any time and thus a complete
picture of the entire plant. Obtain information from the equipment
manufacturers on the recommended number of cycles before
replacement is needed and configure that number into the device's
wear-and-tear alarm (figure 9-7).
---~-----------------------.
P•
·-ORDERiNG_ CODE f'YJ02·1Hl53
• TR.:.VEL_HI-C..BLE
• TRAV£l_I)EADBAND '•
2
• rR,:.V'El_LIMIT HmOO
• TRAVEl 19382
· AE\'E~SAL_ENABLE
' Rf·lfRSAL DEADBA/'1[·
· R€VEA$Al-UMIT
'"
2
wm
, REVERSAL-
' DEVIATIOri_HlA6L£
· [>f_VlAIIml DE.".DBAND
'2
y~,
- O~W.Tim(TIME Figure 9-8. A field bus valve positioner diagnoses the valve and keeps
, STRO>'ES operational statistics. (Courtesy of Smar)
T,MfJLOSINC;
· T!ME_OPENING
)
• kiGI-lEST_TH.!PfRATUME
· LG'WES r _TEMPfflAT'JP,t
(J,~:;~;OSf'>_STATU~
Spot Process Variability
Another major benefit of operational statistics is that it gives you
the ability to spot poorly tuned control loops. A rapid increase in
the number of reversals is a clear indication that the loop is oscillat-
Figure 9M7. Operational statistics are easily reviewed and trigger al~
--~------
ing. Operational statistics can thus help you not only in mainte-
notifying valve is due for service. nance but also in optimizing the process by indicating that it's time
for tuning or a different control strategy. It is therefore a good idea
Make sure you configure the host to enunciate maintenance alarms to review the operational statistics from time to time in order to
to the operators. Using the engineering tool, it is easy to determine spot unstable behavior and thus reduce process variability.
when several de\rices may be relatively close to needing service.
Include as part of the maintenance procedures steps for keeping a
record of the .number of reversals performed between service and
to reset the statistics counters after repair.
I
(
i Fieldbuses for Process Contr~l Chapter 9- Maintenance and Asset Management
--------·--··-------------
Figure 9~9. Basic information from a HART device.
Materials of Construction
From fieldbus devices it is possible to retrieve other useful infor-
mation like materials of construction for the parts wetted by the
process in a pressure transmitter. You can then use this information
to order identical devices or to assess its suitability for a certain
application. Standard parameters in FOUNDATION Fieldbus and Replacing Fieldbus Devices
PROFIBUS PA include the material for the sensor diaphragm and
the fill fluid. Specific parameters are used in the HART protocol as Field instruments do fail from time to time and will eventually
well as for other parts (figure 9-10). · need to be replaced. Once you have connect~d ~ ne': device_ you
must download the configuration to it. In th1s SltuatJ~n, y~u can
download the configuration just for the replaced device Without
~~ Fieldbuses for Process Control Chapter 9- Maintenance and Asset Management
1
having to download it into all the devices on the network. Since the
I the new device supports the blocks used in the old device. This is
device's entire configuration is downloaded in one go it is quickly particularly true if the standard FOUNDATI0\.1 blocks are used.
brought on line.
EXERCISES
Jnteroperability versus Interchangeability 9.1 Is calibration performed in the function blocks or in the
When you replace a failed device with an identical model you can transducer blocks?
simply download the configuration. However, if a different device 9.2 Which parameter in the FOUNDATIO:\' function block
type or even another version takes the place of the failed device contains diagnostics?
you will have to consider the portability of the configuration. For
HART devices, most of the essential pammc'ters governing the 9.3 liow can operational statistics be used to spot process
operation are covered by universal and common practice com- variability?
mands that will work with any device without interoperability Are blocks interchangeable?
9.4
problems.
BIBLIOGRAPHY
For FOUNDATION Field bus and PROF!BlJS PA, basically C\'cry kind
of device has a specific extension to the standard set of parameters 1. ANSI/!SA-51.1-1979 (R1993), Process lnstrumcntatimz
in the transducer blocks. If a new type of device replaces an exist- Tcclznology, Research Triangle Park, NC: !SA, ISBN
ing one you will have to create a new transducer block in the con- 0-87664-390-4, 1993.
figuration but it is easy as only very few parameters have to be set,
often only the mode. The resource (physical) block usually has no
extensions and is supported by all devices. Thus, it wiiJ m~st likely
not cause any interoperabi!ity problems. However, many devices
have enhanced function blocks that have their own specific param-
eters in addition to the standard parameters. A device may also
have' completely proprietary blocks for special functions. If you
have to replace a device in which a manufacturer-specific block is
being used with a device that does not have such a block, you can
allocate the function block to another device.
• (
( ••
10
Availability and
Safety
Goals
People often mistakenly use the term safety when they are really
referring to availability. A system without redundancy can be com-
pletely safe. For example, if the network fails it is still safe as long
as the affected loops are shut down, stopping the process. Redun-
377
Field buses for Process Control
Chapter 10- Availability and Safety
dancy is a measure for increasing availability, not saft:'ty. For more can use the fieldbus technologies to provide safety beyond that
information, see the book Co11trol System Safety Evaluatio11 and Reli- found in basic control systems using conventional technologies.
ability, by W. M. Goble (2d ed., !SA, 1998, ISBN 1-55617-636-8).
An important feature of safe networks is that they do not require
Safety Goals redundancy. For example, the PROfiSafe technology is targeted to
To minimize the risk of harming people, the environment, property SIL 3 without redundancy, and so are several nonredundant pro-
and the like, some control loops must be shut down if the process prietary networks. For safety, the devices have a wide diagnostic
experiences a problem or if the system fails. In other words, there coverage on the communications, which detects any error and if it
are two safety aspects: process problems and instrument failures. finds it brings the process to a safe state.
A process-problem shutdown is part of the interlocks in the pro-
cess control system or in a dedicated safety-related system. Some For example, using either FOUNDATION Fieldbus or to some extent
loops are more risky or hazardous than others/ necessitr1ting l'ROFIBUS PA the loop will be shut down if the fieldbus cable
grenter safety. Safety-related systems are specifically designed to breaks, is short-circuited, or if there is another fault that causes
shut down dangerous loops in the event such a problem is communication or the power supply to fail. It is therefore safe to
detected. Safety-related logic solvers and instruments are usually multidrop several devices on a network even without redundancy.
certified by independent test institutes who assign two different To enhance safety in case of failure, sites should use detailed
levels of safety, Requirement Class (RC or AK) or Safety Integrity device diagnostics for other parts of the systems such as sensors
Level (S!L). and actuators for shutdown.
Availability Goals
WARNING-Those sites that have process units that have been
assessed to have risk or hazard should provide safety protection To minimize production losses some control loops must be able to
by using an approved safety-related system of the appropriate function even in the presence of a fault. Availability is a percentage
requirement class in addition to the basic process control system measure of the time during which the loop is operating OK. In
used for the loops associated with the danger. other words, fault tolerance is required in order to achieve good
availability by minimizing downtime. Decentralization is one pop-
ular measure of fault tolerance, and redundancy is another.
In order for process problems to be detected reliably the instru-
mentation and controls must function properly. Microprocessor- System
based shutdown systems typically have built-in diagnostics or dis-
crepancy-checking capability to detect their own failures and shut For most loops, only a process control system is required. Some
down in case they are unable to function safely. Fieldbus technolo- h<:~zardousloops may require a safety-related system for shut-
gies are ideal for dealing with instrument failures, but presently down.
they can only be used in basic control systems because no safety-
approved devices are yet available. Independently safety- Process Control Systems
approved transmitters with HART exist, but they rely on the 4-20 Process control systems arc designed to handle sophisticated con-
mA signal. PROF!safe technology has received a favorable report, trol strategies for achieving optimal control. Safety-related systems
but no approved PROFIBUS PA devices that use it are in the mar- do not support FOUNDATION Fieldbus, PROF!BUS l'A, or even
ket at the time of writing. Indeed, in the interim most safety-related HART. They are therefore unable to benefit from the improved
systems are using regular field instruments that lack safety controls and asset management for condition-based maintenance
approval. that the fieldbus technologies provide. Thus, as much of the con-
trol and monitoring functionality as possible should be handled by
There are no standards that clearly state the SIL for a particular pro- the proce~s control system.
cess loop. Different loops may require S!L 3, 2, 1, or no SIL at all.
For control loops that need no SIL-rated shutdown interlocks sites
Field buses for Process Control
Chapter 10- Availability and Safety
Network Decentralization
It is a good idea to partition large plants into areas, such that each
one has a separate subnet for the host-level network. Should a fault
occur, you would need to switch only the relevant subnet to a safe
state. Subnets are tied together using routers. Use hub-based star
topology 10/IOOBase-T Ethernet with only one device connected
per network segment cable rather than the multidropped coax. Do
Figure 10-1. Process controls separate from safety sh~tdo_w_n_.- -
not let more than thirty or so control loops depend on any central
controller or linking deYice, even if redundancy has been imple-
Mic~oprocessor-based safety-related systems have extensive dia - mented.
nostJCs to make them shut down in case allr.ntern I I ., . g
det l . ' • a aJ ure IS
. ectec. However, If analog signals are used to interface with field Further, subdivide each plant area into process cells and control
~nstruments such safety-related systems are unable to ac . th modules such that each field-level network covers only one or a
mte 1 d' · . . cess e few control modules. \Vhen a failure occurs only the few loops on
t rna h tagnoshcs
.. m held instruments,, alld til ere Iore th eymtss
.
ou on t e addthon~l safety. Performing discrepancy checkin '' the field-level network would be affected. Keep the number of con-
thro~gh central votmg catches only gross failures. Analo de~ices trol loops that are dependent on a field-level network relatively
reqmre frequent o:errides so manual inspection can be p!rformed low. Generally, a field-level network can only have sixteen devices,
b ut that may also mtroduce errors. ' which translates into a maximum of eight loops, but it may be pru-
dent to keep the number of control loops even lower. As a rule of
NOTE: Non-SIL-rated field instruments can reduce the overall thumb, for networks use eight devices to make four control loops,
safety of the system to SIL 1 or lower, even though the s stern uses plus four devices for monitoring, and leave another four devices
an SIL 3-rated safety-related logic solver. y for future expansion. In other words, the field instruments in the
plant are distributed m·er several separated field-level networks.
Improving Availability Should a fault occur, only output devices on the respective net-
work need to switch to a safe position. This increases system avail-
A high degree of availability means having a high tolerance for ability since a fault in one Hl network only affects a few devices.
faults and reducmg shutdowns caused by false faults. High avail-
Field buses for Process Control Chapter 10- Availability and Safety
It is also a good idea to, wherever possible put o11 I . I a\·ailability because the failure of the controlling device, for exam-
t · 11 1 · ' Y a smg e con
ple, a \·ah·e positioner, affects only its own single loop, not thirty or
IO oop t lat r_equJres high availability on each field-level netwo -
To further increase the fault tolerance of some of the field-l 1 Confined Shutdown
works you can optionally partition a network into several::~- net~ You can also achieve better availability by distributing shutdown
rnents of, say, only four devices each. However this is r 1 ~ functions into the output devices in the field. Use the capability of
for regular installations. This practke is commo'n fo . ta:e ~ lolne
f · 11 · r m nnstca y FOUNDATION Fieldbus to allocate these functions into the field.
sa c msta ahons because isolating safety barriers that have b "It .
\Vhen the device diagnostics detect a fault it will only shut down
rp~~cater~ ar~ ~enpra11y used (figure J0-2). Jn such a configur~';io-m the few loops associated with the instrument. Typically only a sin-
a ~ ort CJrcwt m a hazardous a rea would only re11 de a ·' 1 1 n,
t s 1~ s· 1 ·. -r smg e oop gle loop, nonrelated loops will be unaffected. For example, if a
I/~ ess. mce t le repeater separates the segments from each other val\''e positioner on one network is not receiving the process vari-
a auJt on one segment does not affect another. ' able from a transmitter on the same or other network, the loop will
fail safe but not the entire network. In other words, this failure of
one loop does not cause failure in other non-related loops, which
will continue operating. Only degraded loops are shut down.
Safe Side Therefore, it is a good idea to use the FOUNDATION Fieldbus pro-
---··-- . Segment gramming language.
(
Field buses for Process Control
Chapter 10- Availability and Safety
Redundant :· Redundant
Single Port : Dual Port
Linking Device ',;;,;;:iy·;se'i:6nii;;iy , <;;;c,;;n;<;;,;Linking Device
L_______________________L_in-k~in~g-0-e~vi_ce~--~~--~~---------J
Figure 10-4. Complete Ethernet hostMievel network redundancy.
~ath to the affected device. As a result, the system can sustain nl.ul-
hple faults to th(' devices and networks and still continue. All Hot-standby Transmitter Redundancy
redundant Ethernet device pairs and the workstations are con- Several transmitters Gm be connected to the same process point.
nected to both Ethernet buses. The switchover is totally bump less The status associated with the measured values can then be used to
~nd transparent to the operator, which only sees the active de\·ice filter out "Bad" measurements and select "Good." Both FOUNDA-
tn ~he redundant pair. Every communication port has its own TIO:-J Fieldbus and PROfiBUS PAuse status bytes for each process
umque IP address, mak~ng it ~ossible to diagnose both the primary variable. HART has a status bit in the "field device status"
and.secondary of a dev1ce patr and communication port. HSE response byte that indicates the quality of the measurement as
devtces pass stand~rd diagnostics mes..c;.1.ges between each other on detected by the sell-diagnostic algorithm in the device itself. Since
both networks: Thts allows ~very ~evice to get a complete picture the diagnostics is done in the transmitter, no additional compari-
of the networks health and mtegnty so it can determine which son and alarm logic is required in the control strategy to reject bad
port to address on any device and which path to use to get the values.
message across.
Make sure that you configure the control strategy to make use of
Use ~omplete network redundancy when high availability is this valuable status to select a "Good" measurement. This is easy
re~mred. Keep the primary and secondary of redundant de\·ice using the standard selector block in the FOUNDATION Field bus pro-
patrs on separate networks. gramming language. The standard selector block handles three
inputs but can be cascaded to handle more. A transmitter failure
Nehvork and Media Redundancy will cause one of the other transmitter readings to be selected, and
Networ~ redundancy can be combined with media redundancy in a shutdown of the loop will therefore not be required. If three
a dual-rmg topology to effectively create lour paths across the ;,et- transmitters are used, all three have to fail before the selector out-
work (figure 10-5). This means that the network can sustain rnulf- put becomes "Bad," initiating a shutdown. Redundant transmit-
1 ters thus result in fewer unnecessary shutdowns.
ple faults but.still continue to function. Thus, the networkin is
extremely rehable. g
This is a classic example of fieldbus technologies making it easier
to achieve measurement redundancy in order to achieve higher
availability. In this example, three out of three (3oo3) sensors have
Workstations to be degraded in order for a shutdown to occur. Use transmitters
with Dual N!C from diverse manufacturers to reduce the number of common
cause failures. This is easy to do since the fieldbus technologies are
interoperable between multiple vendors' products. If your plant
adopts PROFIBUS PA technology, make sure to use a central con-
troller that is able to incorporate the process variable status into the
Secondary
control strategy and manually configure equivalent interlocks.
Similarly, if FOUNDATION Fieldbus devices are connected in a sys-
tem that does not use the FOUNDATION programming lang·uage in
the central controller, you must configure the logic manually.
(
(
Fieldbuses for Process Control
Chapter 10- Availability and Safety
Backup Master
An active master device is required for communications to func-
tion. Without a master, the communication halts, loops shut down,
and availability suffers. Since FOUNDATION Fieldbus typically per-
forms control in the field it has an additional option to increase Unk Link Basic Basic
Master Master
availability. The linking device on the HSE host-level network is
usually the primary Link Active Scheduler (LAS) for the Hl field-
level network, but if it fails another LAS takes over. If redundant Figure 10-7. Consider backup LAS in the field, particularly if redundant
linking devices are used, the secondary will take over the LAS role. linking devices are not available.
You can use many FOUNDATION Fieldbus field instruments as link
masters to assume the role of LAS in case the prevailing LAS fails Availability through Diagnostics
(figure 10-7). In this way, communication and therefore control can
continue without shutting down. In other words, you should Devices that are based on the fieldbus technologies have a wide
diagnostic coverage built in. This self-diagnostic capability detects
enable backup LAS in a field device on networks that require high
device failures, with different severity levels, and confirms that
availability by configuring it as a link master device~ particularly if
redundant linking devices do not exist. For networks that empha- they are indeed genuine.
size safety it may be better not to configure any backup LAS. At
design time, it may be a good idea to identify which networks ben- Reduce Mean Time to Repair (MTTR)
efit most from availability and which from safety and configure The longer a loop is not functional th~ w~r.se ~he availability will .
backup masters accordingly. be. An important way to increase availab1hty IS t~ de~e.ct problems
early and fix them quickly, that is, to increase avail~b1hty by reduc-
If the linking device has failed the operator has no visibility, but if a ing mean time to repair (MTTR). Make sure to conflgu:e the pro-
backup LAS in the field is used control still continues. Basically, the cess visualization software so that if somethmg IS not nght 1t.
loops run on blind faith. It may be prudent to implement a proce- displays status and sounds alarm to get th~ ~perator's attention:
dure that limits the period of time a loop can be run in this way. If This will prompt operators to call o.n tech~1oans to ~se ~he engi-
the communications cannot be reestablished the affected loops neering tool to carry out detailed dtagnos~ICS that ~m~omt the
may have to be shut down. problem so it can be solved. Use diagnostics ~o venfy If an abn.or-
mal condition is a process problem or an eqmpment problem. fo
Multiple Workstations use this scheme, the status must be communicated continuously to
It may be a good idea to have at least two workstations, even for a the operators, and the engineering tool must be permanently con-
small system. In the event one workstation fails, the operation car:t nected to access any device any time.
still be carried out from the second station.
(
(
(
i Fieldbuses for Process Control Chapter 10 _Availability and Safety
Reduce False Shutdowns risk of loose leads touching each other and short-circuiting the net~
It is paramount that the self-diagnostics be reliable and accurate to work.
avoid unnecessary spurious shutdowns-when what first appears
to be a device fault really isn't.lf many shutdowns occur downtime An active junction box detects whe~her a s.pur branc~ing ~ut to ~ne
goes up and the availability of the system goes down. It is a good of the devices has been short-circmted. If It has,. the JUnctwn box
idea to utilize the fine granularity diagnostics provided by FOUN- isolates it from the rest of the bus, thus preventmg a prolo~1.ged d
DATION Fieldbus and PROFIB US !'A technologies to distinguish short circuit of the entire network. In this way, not all ?evJCes an.
between serious and less severe faults and take suitable action their associated loops on the network will be affe.cted If a sh?rt CJT-
accordingly. In other words, internal fieldbus diagnostics is more cuit is caused by the improper handling o~ the Wtres. ~t des~~n
precise than external discrepancy checking in comparing values time, it may be a good idea to identify which ne~w~~ks ~eqm~e
from two transmitters. For example, when availability is a high pri- very high availability and to use active current hm1tmg runctwn
ority shutdown should be configured so it only occurs for "Bad" boxes on them.
quality, whereas for "Uncertain" just notifying the operator will
do. Such configuration becomes particularly easy if you use the Fewer Points of Failure
FOUNDATION Fieldbus function block programming language, Use the capability of FOUNDATION Fieldbus to execute contro.l in
which allows you to configure the desired behavior by using, for the field and thus eliminate the shared central control~er devJce. If
example, the status option (STATUS_OPTS) parameter. If you use ou don't use a controller for the loop, there is one pomt.less that
HART or PROFIB US PA devices, make sure to work with a central ~an fail, which means availability increases so~;ewhat. ~~r:ce there
controller that supports the indusion of status into the control l·s no "main" there is no need for a redundant backup either.. If
strategy in order to configure interlocks based on the status. ' executing the PID algont
the positioner · h m ·lS wor k·ng
~ ' control1s
.
working as well because the PID by itself cannot faJl. It IS merely a
Standby Health ieee of software running on the same electromcs and mtcropro-
Diagnostics is crucial if redundancy is to be effective. It is required ~essor that governs the rest of the device. What would stop th~ PJD
if the fault is to be detected and if the switchover from primary to execution is a complete positioner failure, but wtthout a post honer
secondary is to occur. Diagnostics also te1Is the operator if one unit a central controller, even with redundancy, would b: of no use .
in the redundant pair is not functioning, meaning that a switcho- either. In other words, since controls cannot work without a posi-
ver for a second fault could not occur. This tells the operator to tioner the controller can be put in the positioner too.
replace the faulty part of the redundant set so it is ready to take
over at the next failure. Without information indicating that one Fail Operational
failure has occurred redundancy is almost useless. In the event of sensor, communication, or some othe~ failure, you
can make an output device either fail safely by shuttmg the loop
Additional Availability Measures down or fail operationally, in which case the valv: ;vould remam
in its last position. When the valve is in its last post bon, the. process
Fieldbus systems offer plants several other options and practices is allowed to continue running, although it is not really bemg con-
for increasing the fault tolerance.
trolled since it is not moved to respond to changes.
Short-circuit Prevention
Improving Safety
A network short circuit during routine maintenance would bring
the devices down, which would make the final control elements The field bus technologies do not really change the way process
shut down to their de-energized state. Measures should be taken to roblems are detected and used to shut loops down. However,
reduce the risk of a network short circuit. It is a good idea to use ~ey can be used to increase the safety of a process control system.
polarity-keyed, plug-in industrial connectors. These make it possi- The most important feature is the diagnostJcs m the held mstru-
ble to connect and disconnect device wiring without incurring the ments, which can be an integral part of the safety mterlocks by
shutting the loop down in case of instrument failure.
Fieldbuses for Process Control Chapter 10- Availability and Safety
safe gets activated if the remote cascade setpoint input does not
WARNING The suggestions for safety and availability in this receive successful communication from the central controller for
book are meant to be used for instruments in process con trot not longer than fail-safe timeout (FSAFE_TIME). Thus, communication
for shutting down risky processes where SIL-rated equipment failure or central controller breakdown cause a shutdown.
has been deemed necessary. The plant may need both a process
control and a shutdown system. For FOUNDATION Field bus, the links between blocks in different
devices are communicated at a very precise interval according to a
Safety through Diagnostics time schedule. If anything in the chain from the tran~r:'itting .
device or field-level network fails, the intended rcceivmg device
Increased diagnostics means that more dangerous failures in the will notice it immediately because the value is not received a~
system are detected and fewer dangerous failures go undetected, scheduled. The input status will be set to "Bad- No com~umca
particularly in the field instrumC'nts. Undetected faults are very tion." The programming language for the FOUNDAT{ON. F1~ldbus
dangerous because the process is not shut down but continues function block diagram provides several options for bnngmg con-
"unprotected." Make sure that you take advantage of the sophisti- trol to manual or shutting the loop down. The status works .
cated instrument diagnostics and interlocks to improve system throughout the chain even if a bridg~ ~n~ host-lev~l net~Tor~ fails.
safety. Fieldbus detects additional shutdown scenarios, which Thus, the shutdown will occur even tf It IS not the local nc twork
makes it safer because it shuts down for failures that are not in which the valve fails but rather a value that should come from a
detected by conventional means. failed remote network over a bridge.
(_-. J (.
- - - - --
Chapter 10 _Availability and Safety
Fieldbuses for Process Control
time, long enough to rectify the faulty interface or finish the batch. Balancing Availability and Safety
For outages that last any longer the loop should be shut down. Safety· and availability are two conflicting goals. Safety mcansdthat
t p"ng productwn andre uc-
loops will have to be shut d own, s 0 P 1 h
Fieldbus valve positioners with diagnostics and feedback are ing availability. By striking the right balance fo~each loop,~ ~h
essential for safety since a loop that has a valve without diagnos- plant's productivity and risk management can e optlmtze h. e
tics is unsafe no matter how good the rest of the system is. Indeed, capacity to detect instrument failures and _have op~wns for an-
without diagnostics in the valve the loop is being operated blindly dling them gives the user the ability to stnke th~ nght ~al~n~e
because operators cannot see if the controller output comes though between safety and availability for each loop. Dtagnoshcs ts Impor-
OK. tant both for safety and availability by making systems operate
safely but with few spurious trips.
In the FOUNDATTON Field bus programming language alarms and
events are reported with priority levels 1 through 15. For consis-
tency and to eliminate confusion, the same priority levels should Uncertain
be used for alarms throughout the system. That is, for safety rea- As we have seen devices based on FOUNDATION Fieldbus and .
sons it is a good idea to use a host that homogeneously integrates : .
PROFIBUS PA dtstmgmsh . between senous
, · problems and less sen-
alarming. . d ·cat"tng "Bad" and ''Uncertain" status, respec-
ous probl ems b y m I f d
tively. This makes it possible to balance the interests of sa ety an
De-energize Safe availability. "Uncertain" quality includes conditions when the or
measured value is out of range or inaccurate for some reason. F
The shutdown strategies for any instn1ment failure or process
inputs it may additionally mean that the linking was chan1ed or
problem rely on power to function. In the event that electric, pneu-
the value entered manually. A "Bad". value cannot be used ~r con-
matic, or hydraulic power is lost the final control elements must
trol and always shuts the loop down. However, a value that IS
fail safely anyway. This means that the mechanical design has to be
"Uncertain" may still be useful, and it can theref~re be used for
such that the output returns to a safe position when power is lost.
loo s that are not hazardous. However, "Un_ce_rtam'~ shoul_d ~a use
For example, a valve must be self-opening or self-closing.
a stutdown for a loop that is hazardous. ThiS IS easily achte\ ed
~~in the function blocks in the FOUNDATJON Fieldbus pro~ram_-
WARNING-Make sure valves are selected with mechanical . gl nguagc In blocks for which status is relevant there IS a st.a-
mmg. a. (STATUS · - parameter where "U ncer tam
OPTS) · " can be .
fail-open or fail-closed as an additional level of safety. This pro- tus optiOn - .1 bT ( ly notl
vides a last line of defense in case of power failure. ' f red to be treated as "Good" for avat a 1 tty mere -
prccon tgu ) "B d" for safety This can be done for each
fying the operator or as a · . ll
individual loop. This optimizes the operation and a ows two.
Discrepancy
loops using the same value to act differently. One can be conh~~~t
The instrument diagnostics provided by field bus technologies is ured for availability (continuing to run), the other for safety (s
crucial for safety. However, detecting external problems may not ting down).
be possible, for example, those occurring in the connection to the
process. For example, there is no deterministic way for a transmit- Where dual redundancy is used for availabilit~ the status is 1"
ter to detect a blocked or damaged process connection. When it is "Good" when both are working. It is "Uncertam.sub-norma .
necessary to detect faults external to the device two transmitters when only one is working and "Bad" when neither are ."'orkmg.
must be used. If two "Good" values deviate from each other, the This allows smne loops to shut down while others contmue.
problem is most likely external, such as buildup or "caking" on a
pressure sensor diaphragm, that is, shutdown triggered by dis- The FOUNDATION function blocks also contain the status option
crepancy checking for the piping. (STATUS' OPTS) parameter, wh1c · h ·IS used to select whether a hm-
. t d r m;nual value Shall be "Uncertain" instead of the usual
~~~o~d." This enables some loops to shut down f~r safety reasons,
while other loops using the same value may contmue to operate.
Fieldbuses for Process Control
Chapter 10- Availability and Safety
In the FOUNDATION function blocks~ there is a status option 10.3 Does diagnostics improve safety?
(STATUS_OVfS) to show limited values as "Uncertain" or even Does redundancy increase safety?
"Bad" instead of the default "Good." Similarly, manually entered 10.4
values can also be shown as "Uncertain." Thus, downstream 10.5 Is a loss of communication unsafe?
blocks can optiona11y take safe action in these situations. How does the "Uncertain" make it possible to balance the
10.6
interests of safety and availability?
Summary Table
10.7 Does a backup LAS improve safety?
The various options for striking a balance between safety and
availability are summarized in table 10- J. Note that for a majority
of the options the default setting is aimed toward process control BIBLIOGRAPHY
availability rather than safety. . Proposalfior an Interim Solutien for the Use of
1. Fa II er, Ra mer, . , . · Sarficty
- rfi
N of/ :.a e ty-related Jntelli(rent Fteld !IJ5trumen.)yz
o 3 ? TUV Product
Table 10-1. Options for balancing the interests of safety and availability Applications iH the Process Industry, rev ·-·
-- Feature Safety Availability
-- Service, 7 October 1998.
STATUS_OPTS Don't (Le. as "Bad') u·se 'Uncertain" as Goble, W. M., Control System Safety Eva/uatic•ll and Reliability,
"Good"
2.
2d ed !SA- The Instrumentation, Systems. and
STAI US_OPfS 1arget to Manual if"Bad' Don't (i.e. return to normal Auto,:;,ationSociety, ISBN 1-55617-636-8,1988.
IN once OK)
STATUS_OPTS Initiate fault state if IN is Don't (i:e. merely go-~ Gruhn, Paul, and Harry L. Cheddie, Sajelli Issues Related to
3.
hBadn manual) Field Devices, volume EMC 17.01, !SA, 2000 ·
STATUS_OPI S Initiate fault state if Don'~-(~.e. merely go
CAS_JN is ~Badn automatic) ANS!/ISA-84.01-1996, Application of Safety !JIStrument~~
4.
SfATUS_OP!S Set 1arget mode to uon't (i.e. return to normal Systems for the Process Industries, Research Tnangle Pa '
manual if IN is ''Bad" once OK) NC: !SA, ISBN 1-55617-590-6,1996.
SlAfUs_OPTS Set quality as HUncertain" Don't ~~-e. cOnsider
if limited "Good")
STATUS_OPTS Set quality as "Bad" if Don't ~!:e. consider - -
limited "Good")
Sl'A'flm_OPIS Set quality aS "Uncertain~ Don't (i.e. con.sider ~~
if block is manual mode "GoodH)
10 OPTS Fault State to Value Don'~_Q.e. freeze out~
10=0~----~ 1JS8 Fault State value oil- DOrl'f{restart from P~
restart position if available)
Function block link stale Few Many
count limit.
-~
EXERCISES
10.1 Is safety and availability the same thing?
11
How Fieldbuses
Work
This chapter is for the "propeller heads" who want to know a little
bit more about how the field bus technologies work. However, you
don't have to understand how the fieldbus technologies work
internally to use them. These protocols are complex, but manufac-
turers typically implement them in systems in such a way that they
appear easy. Most readers may therefore skip this chapter or read it
merely out of curiosity. The main focus is the field-level networks,
that is, HART, FOUNDATION Hl, and PROF!BUS PA. There are
plenty of books describing how Ethernet, IP, TCP, and UDP work.
These subjects are therefore not covered here.
Primer
HART, FOUNDATION Field bus, and I'ROFIBUS are all serial com-
munication protocols. Information is converted into a stream of
ones and zeroes, which are transmitted over the media. These tech-
nologies are half-duplex, meaning that communication is bidirec-
tional-that is, a device can both transmit and receive, but not at
the same time.
OSI Model
HART, FOUNDATION Fieldbus, and PROFIBUS are all based on the
Open System Interconnection (OS!) reference model as defined in
the ISO 7498 standard. Messages are parsed through these layers,
with each layer performing a set of functions. Layer 1 includes the
physical media the message travels on, typically a wire. Above
layer 7 is either the "real" device function, such as measurement,
actuation, or control, or the operator interface in a host. A message
407
(
Fieldbuses for Process Control Chapter 11 - How Fieldbuses Work
makes its \:ray dmvn through the layers in the transmitting device, tant aspect of the HART, PROFIBUS I'A, and FOUNDATION
over the wtres,.and then up throu~h layers in the receiving device. technologies is that they specify in detail the application and user
1f th~ message 1s a request, the devtce attends to it and responds by layers that are required for interoperability. This sets them apart
passmg a message back the opposite way. from many other protocols. These fieldbus protocols specify not
only how data is transported but also its semantics, that is, what
the information means. For example, all HART devices use the
same codes for engineering units, and all FOUNDATION control
OSI FOUNDATION HSE
Reference Model PROFlNet
loops are put into manual mode the same way. Without applica-
Modbus!TCP tion-layer and user-layer standards plants will ultimately require
F:~:~:Ofij·.
"Layer 8"
custom programming and parameter mapping to make the system
Layer 7 [. A.ppl~~aii~~
Layer 6 ! Presentation , ··-;···· work.
t-Ses~i;;--·j
~ ,~,:.";" ··]l
Layer 5
Layer 4 f_T""'POrt.l Physical Layer
Layer 3 ~---;Network _j .. Network..•.··..
Layer 2 : Data Link j ala Link The physical layer defines how the signal is physically transmitted
Layer 1 jphysica!l
~·----,.-J Physi<:_~l J over media from one device to another, electrical or otherwise.
RS232 and RS485 are classical examples of physical·layer stan-
Figure 11-1. Open System Interconnect model as applied to fieldbus dards. Note, however, that these are not complete protocols. The
technologies. physical layer does not interpret the data; it just passes it to and
from the data link laver. The installation rules are described in
detail in chapter 3, "installation and Commissioning."
Typically: each layer in the transmitting device adds a piece of
mforrnahon to ~he ongmal message, which is then stripped off in
the c~rrespondmg layer of the receiving device. For example, the
HART
?ata lmk layer may add a destination address that is then removed The most important aspect of HART is that it retains the analog 4-
m the data link layer of the receiving device. 20 rnA signal. Digital communication at the rate of 1200 bit/sis
superimposed on the same two wires as the analog current loop
Most protocols do not implement all seven layers. For field·level signal without disturbing it.
protocol, usually only levels 1, 2, and 7 are implemented (figure
:1-J). For host-level protocols, levels 3 and 4 are usually also HART Encoding
mcluded. Both FOUNDATION HSE and PROFlnet use Ethernet for
HART uses frequency shift keying (FSK) according to the Bell 202
l~yers 1 and 2. The InterneU'rot~col (IP) is the protocol for layer 3.
standard to superimpose a digital signal as AC on top of the 4·20
I ROF!net and FOUNDATION HSE use the Transmission Control
rnA DC. Bits that are "0" and "1" are encoded as sine waves of the
Protocol (TCI') and User Datagram Protocol (UDP), respectively,
frequencies 2,200 Hz and 1,200 Hz, respectively. When transmit·
for layer 4. The network administrator in your company will surely
ting, the bits are converted to the corresponding frequency, and
have a book describing the function of Ethernet, IP, TCP, and UDP.
when receiving the frequencies are converted back to bits of the
Layer 7 lnteroperability corresponding state.
For devices to be able to interoperate with each other on the same The frequencies are sinusoidal and completely symmetric and
network all the seven OS! layers and the user layer must be the therefore add no DC component. Moreover, the frequencies are
same. Merely using the same physical layer does not provide any removed by low-pass filters on the inputs of analog devices in the
mt~roperabthty; 1t JUSt guarantees that devices are electrically com- current loop. Thus, digital communication can be done withoutdis-
patible. In other words, using RS232, R$485, Ethernet, and so on is turbing the analog 4·20 rnA signal. A HART communications chip
not sufficient for interoperability, nor is TCP liP. In fact, most pro- (figure 11-2) performs the signal modulation and demodulation.
tocols usmg these phystcallayers are proprietary. The most impor-
II Fieldbuses for Process Control Chapter 11- How Fieldbuses Work
HART Character
---··----·--~-~-- HART uses an asynchronous mode of communication, meaning
Figure 11·2. HART communications control!~ (CourtesY- of sm---;~ Re~;~·h
Corporation) that data is transmitted without a clock signal. To keep the trans-
mitting and receiving devices synchronized, data is transmitted
one byte at a time. It is led by a start bit "0" and followed by the
HART Signaling eight bits of the real data, one parity bit which is odd and one stop
The FSK signal is transmitted by modulating the current in the "1" (figure 114). The parity is set either "0" or "J;' which makes
loop with an amplitude of approximately 0.5 rnA (figure 11·3). Pas· the total number of 1s in the data and parity together odd. The par·
sive devices, such as most field instruments, do this essentially by ity bit provides additional data integrity within the received char-
rapidly altering their current consumption. Active devices like a acter by checking that the total number of 1s is indeed odd.
handheld do it by injecting a signaL
. ~- Parity Bit
8 0 ata B1ts
Current Start Bitt ~-~-----...... I Stop Bit
[Sll!fcilliJ:ctill Id!d Id IiliJ
The HART network must have some resistance between the The frame has a preamble that is transmitted at the beginning of
devices and the power supply. This resistance, usual! y the 250 ohm each message to "wake up" all other devices on the network and
shunt on the host input module, has two functions: it prevents the allow them to synchronize their receiver to the transmitting device.
DC power supply from short·circuiting the AC communication A start delimiter denotes the end of the preamble and the begin·
signal, and it also acts as a shunt for the communication signal. As ning of the actual message, coming to or from the data link layer,
the transmitted FSK current passes through the shunt a 0.125 VAC after which there is an end delimiter (figure 11-5).
(
-~ ~ ~· ~~ieldbuses for Proc,ess Control Chapter 11 _How Fieldbuses Work
Start
Delimiter
Preamble 1
-l Data Link layer Data
,.-----------~~~ r-
End
. .
nJLSULSlJl_f1_nJ clock
1 0 1 0 1 0 1 0
fl
[Pj_sJQLQlQJ ~.. i!>lQl!ilil DehmJter ~ ?_~_§.--7_____§'z__j; - 'y___~_r;-- Preamble
1 N+ N- 1 0 N- N+ 0
Figure 11 ~5. IEC physical layer frame. _
-Y_J~ ___ft_~-L~ Start Delimiter
1 N+ N- N+ N- 1 0 1
IEC Encoding \'_f~____r-[_ ____j-~-- End Delimiter
Figure 11-8. IEC 61158·2 chip used for both FOUNDATI?N H1 Fieldbus &
ll.ru~u-u-u-LIULJ clock PROFIBUS PA. (Courtesy of Smar Research Corporation)
The start delimiter and end delimiter arc encoded, including spe-
cial unmistakable nondata transitions (figure 11-7).
+10 mA --
-10 mA
VlJ- :o:~ated -0 5 v
Encoded
A fieldbus communication controller (figure 11-8) performs the sig-
nal encoding and decoding, as well as many other functions.
Figure 11-9. Transmitted waveform, nominal signal levels.
IEC Signaling
By modulating the current with amplitude of approximately 10 The network has an impedance module located between the ~
rnA, the Manchester signal is transmitted over the wire media (fig- devices and the power supply. This impedance prevents the DC
.ure 11-9). Passive devices, such as most field instruments, do this power supply from short-circuiting the AC commumcahon stgnal.
The network also has a 100 ohm terminator in each end that acts as
Fieldbuses for Process Control Chapter 11 - How Field buses Work
a shunt for the communication signal (figure 11-10). The parallel HART
shunts result in a 50 ohm impedance, and as the transmitter's
.t-.1anchester current passes through it creates a 0.5 VAC voltage The HART protocol is a quite simple protocol, primarily of a mas-
dro~. _All devices on the_network pick up this AC voltage and are ter I slave nature.
sensthve en?ugh to rece1ve even if there is attenuation of the signal
along the Wires. In other words, transmission is done as a current HART Device Types
reception as a voltage. ' The HART data link layer recognizes three device types:
~~~~--J----r-
ri
~-~--- ~ ---- XT
- -j-
___
J,
Network
• Master
• Slave
• Burst mode slave
( i
Fiefdbuses for Process Control Chapter 11 - How Fieldbuses Work
Slave burst mode is initiated by a command from the master ~he The start c/wrncter is a single byte that denotes the end of the pre-
slave w_ill continuously broadcast the command response un-til a amble and the beginning of the actual message. The value of the
master mstructs _it to stop. In other words, burst-mode responses start character tells if the frame is a request from a master, a
are generated Without ~orresponding request frames. Using the response from a slave, or a request from a slave in burst mode. The
burst ~ode, the data wtll be updated much faster since the slave start character also tells if polling address or unique ID is used for
transmits without waiting for a master request. addressing.
Col,Iisi~n on the network is avoided by first detecting if any other The address is five bytes when the long unique ID address is used
de\ tce IS transmtttmg before a frame is transmitted. Timers control or one byte when the polling address is used.
access sharing between primary masters, secondary masters
sl~ve~, and slaves in burst mode. The two masters have the ~arne The comma11d is a single byte that represents the HART command
pnonty ~or accessing the bus to initiate communication. A master associated with the message. No interpretation of the command is
that has JUst tr~nsmitted a message must wait longer than the other performed in the data link layer. The command and data is merely
:naster before 1t can access the bus. Thus, if both masters are access- passed through to and from the application layer.
l~lg the bus_ they will alternate. Slm·es do not initiate communica-
t~o~; the~ stmply respond to requests and must do so within a The hytc count is a single byte that indicates how momy more bytes
hm1ted time. Slaves in burst mode wait longer to transmit than there are until the end of the message, excluding the checksum.
doe~ a master, which allows the master to instruct the burst-mode Using this information, the receiver can verify \-Vhen it has reached
deviCe to stop. the end of the frame.
HART Frame Formats The response code is a single byte that is included only in response
messages. If the n1essage was not received successfully, the
Th~ HART message frame is made up of nine parts (figure 11-11), response code from the slave will indicate the form of communica-
whzc~ are descnbed later m this section. The response from the tion error it encountered. If the message was successfully received,
~lave mc~udes command response code and field device status the response code will instead indicate if the slave was able to suc-
mfor~ahon th~t is not included in a request message. Usually, cessfully execute the command. If there were any problems execut-
there 1s a short tdle period between the transmission of each char- ing the command this will be indicated.
acter.
Fieldbuses for Process Control
Chapter 11 -How Field buses Work
The field device status is a single byte that is included only in are used for instruments, 248-251 are default addresses for unini-
response messages to indicate the health of the device. Sec chapter tialized devices, and 2:J2-255 are used by temporarily connected
9, "Maintenance and Asset Management." devices such as handheld devices. The address is assigned auto~
matically by the LAS \vhen the de,·ice is connected to the network.
The data is the information in a write request or in the response to a The automatic address assignment eliminates the risk of address
read request. No interpretation of the data is performed in the data duplication.
link layer. The command and data is merely passed through to and
from the application layer. The number of bytes can be anywhere H1 Arbitration
from none up to twenty-four.
As far as the FOUNDATIO:\" data link layer is concerned there are
The clzecksui/J is a single byte of longitudinal CycHc Redundancy two types of communications:
Check (CRC). The transmitting device generates it by doing an • Scheduled conm111nication (foreground traffic)
XOR (a logic exclusive-or) of all the bytes in the message from the
start character. The same function is likewise performed in the • Unscheduled communication (background traffic)
receiving device, and the result must match. The checksum thus
Data that only has to be communicated infrequently is transmitted
provides data integrity by detecting corrupted messages.
acyclically using unscheduled communications. Unscheduled
communication includes, for example, the host reading and writ-
FOUNDATION Fieldbus H1
ing parameters in the field instruments. The LAS passes a token
In FOUNDATION Ficldbus, any device can initiate communication between the devices using the Pass Token (PT) message. Once a
as long as it holds the right to do so. Transmission on the FOUNDA- device holds the token it can send messages for up to the maxi-
TION HI network is controlled by the link active scheduler (LAS). mum token hold time or until it is finished, whichever is shorter.
The data link layer appends five to fifteen bytes of control informa-
tion at the beginning of the message and two bytes of error check Data that has to be communicated cyclically on a precise periodic
at the end when it transmits. It removes the information when basis is transmitted using scheduled communication. Scheduled
receiving. communication includes, for example, function block links
between devices. The LAS has a schedule determining when the
H1 Device Types cyclic values in the devices on the network shall be transmitted.
When a value is scheduled for transmission, the LAS transmits a
The FOUNDATION Hl data link layer recognizes three device types:
Compel Data (CD) message to the device, which subsequently
• Basic publishes the data on the network using a broadcast. Devices that
subscribe to the published value all receive it at the same time.
• Link Master
• Bridge Scheduled communication has the highest priority on the network.
After all scheduled data has been published, the time remaining
Link masters arc able to become LAS, whereas basic devices are before the next macro cycle is used for unscheduled communica-
unable to become the LAS. Field instruments like transmitters, and tion and some other functions. The LAS maintains the live list of
valve positioners are typically basic devices, whereas host inter- known devices on the network. A Probe Node (PN) message is
faces are link masters or bridges. However, many field devices can periodically sent to the unused addresses to detect if any new
also be configured as link masters and are able to take over the device has been added. When receiving such a message, a device
LAS role. sends a Probe Response (PR) message to let the LAS know it is
present, and the device gets added to the live list. The LAS then
H1 Addressing broadcasts the updated live list to all devices on the network. The
LAS also ensures that the clocks in the devices on the network are
The FOUNDATION HI data link layer uses a sirigle-byte network
precisely synchronized by periodically broadcasting a Time Distri-
address. Addresses O-I5 are reserved for internal functions, I6-247
bution (TD) message. The time distribution ensures that function
(
Field buses for Process Control Chapter 11 -How Fieldbuses Work
blocks to be executed and messages to be published are synchro- the token to make a complete circle to all masters is called token
nized among all devices on the network. rotation time. The master that holds the token can poll slave
devices, which will respond. The token-passing mechanism
The LAS schedule and token-passing mechanism ensures that only ensures that only one device at the time is granted permission to
one device at a time is granted permission to access the bus, access the bus. This prevents collisions.
thereby avoiding collisions. The LAS ensures that the scheduled
data is published and that all devices have a chance to communi-
cate. The tirni~g of scheduled communications is precisely defined
and therefore mherently deterministic.
H1 Error Detection
Communication errors are detected by transmission of a Fr<~mc
~heck S~quence (FCS) in the message generated by the transmit-
tmg device. In the receiving device the received FCS is checked
against internal1y computed FCS.
PROFIBUS PA
In PROFJBUS PA, only a master device can initiate communication. S!ave Slave
The data link layer ensures that only one device at a time accesses
the bus. The data link layer also handles addressing and error Figure 11-12. Masters pass token from one to the next in a logical ring.
check.
PA Device Types The token mechanism is free running, meaning that there is no syn-
chronization between the communication and the user layer func-
The PROFIBUS data link layer recognizes two device types: tions. For that reason, the token rotation time should be targeted as
• Master low as possible to ensure that inputs and outputs arc updated with
minimal delay. The token-passing procedure ensures that each
• Slave
master wi!l have enough time to fulfill its communication tasks if a
sufficient token rotation time is configured.
Masters include central controllers and a host configuration tool. A
slave is some form of field instrument, such as a transmitter or
valve positioner. Master devices initiate the communications, Application Layer
whereas the slaves merely respond.
The application layer is where simple data types and :nore sophis-
PA Addressing ticated objects are defined. Several functions are provtded for
accessing these. Because interoperability is not just transferring
All addresses up to 125 are individual addresses that are available bits and bytes from one place to another, the application layer is
for devices. Address 126 is a default address. The lower the essential to making devices interoperable.
address, the higher the priority. Therefore, the lower addresses are
typically occupied by masters. The HART application layer differs from the FOUNDATION applica-
tion layer in that HART provides very direct commands that are
PA Arbitration specifically targeted toward a function like calibration or reset. .
FOUNDATION and PROFIBUS PA, on the other hand, have genenc
The masters pass a token between themselves in a logical ring in
services that read and write all kinds of parameters, some of which
address sequence, using a special message (figure 11-12). Once a
master receives the token, it can send messages. The time it takes invoke functions like calibration and reset.
Fieldbuses for Process Control Chapter 11 -How Fiefdbuses Work
PROF! BUS PA does not specify an application layer. However, the accessed using the device-specific commands. A master transmits
functions performed by the PROFIBUS DP communications profile a request to read or write values to a slave, which will return a
upon which PAis based are very similar to those of an application response.
layer and are therefore included in this section.
The universal commands arc used to identify the device in order
HART to establish communication. Universal commands can be used to
monitor and read basic device configuration. The universal com-
The HART application layer is based on a set of commands for mands are as follows:
accessing functions and data in Held instruments.
• Read Unique Identifier
HART Data Types • Read Primary Variable
HART supports a few basic data types: IEEE 754 float for valm's • Read Primary VZiriablc Current and Percent of Range
that are analog in nature; ASCII and packed ASCII for strings; and • Read Dynamic Variables and PV Current
unsigned integers of up to 1, 2, or 3 bytes used, for example, for
enumerated options. The options that are associated with universal • Write Polling Address
and common practice commands as well as some others are stan- • Read Unique Identifier Associated with Tag
dardized in common tables. These include, for example, engineer-
ing unit codes. • Read Message
• Read Tag, Descriptor, Date
HART Variables • Read Primary Variable Sensor Information
Measured and calculated variables in the device are referred to as • Read Primary Variable Output Information
dynamic variables. Four of these are fixed or can be assigned as
dynamic variables: primary variables, secondary variables, tertiary • Read Final Assembly Number
variables, and fourth variables. The primary variable corresponds • Write Message
to analog output number 1. If additional outputs exist these corre- • Write Tag, Descriptor, Date
spond to the secondary variable and so on.
• Write Final Assembly Number
HART Commands
The common practice conmzmzds write the basic device configuration,
Masters read and write information in slave devices and invoke and some essential functions can be performed as welL Some com-
functions using commands. Every command has a different func- mon practice commands are the following:
tion and different amount of data associated with it. There are
three classes of HART commands: • Read Transmitter Variables
• Universal • Write Damping Value
• Common practice • Write Range Values
• Device-specific • Set Lower Range Value
• Set Upper Range Value
The universal and common practice commands are part of the
HART standard. The universal commands are mandatory and sup- • Loop Test
ported by all HART devices. On the other hand, the common prac- • Perform Self-test
tice commands are optional, and each device typically only
supports a few of them as applicable. Most functionality in a • Reset
device is accessed using the universal and common practice com- • Input Zero Trim (Calibration)
mands. Additional less common functions in the device are
(
Fieldbuses for Process Control
Chapter 11 - How Fieldbuses Work
• \Nrite PV Units
• Current Zero Trim (Calibration) Protocol
Control ~---
;~"''~ r ~~·_:r::~=:J].[Q~l~J
Sequence
r
1_ Physical I
L-------··--·--.J
T~e FOUNDATION application layer consists of two sublayers: the The report distribution VCR (QUW is used for the acyclic transmis-
F1eldbus Access Sublayer (FAS) and Fieldbus Message Specifica- sion of trends, alarms, and event notifications to the host. Report
tion (FMS). As the message makes its way from the function blocks distribution is queued, meaning that when the function block gen-
each layer adds_ control i~formatio~ t? it, which is stripped away at erates an alert it is sent in an order determined by priority and time
the correspondmg layer m the rece1vmg device (figure 11-14). of occurrence and does not overwrite earlier alerts. Report distri-
butions are unscheduled and one-to-many, meaning the value is
FOUNDATION Data Types broadcast to many subscribers simultaneously (figure 11-16).
Thi:teen differ~nt simple d.a!a types are defined: Boolean, integer,
unstg~ed, ~oatmg pomt, VISible string, octet string, date, time of
The client/server VCR (QUB) is used, for e)\ample, for acyclic read-
day, timedifference, bit string, time value, null, and packed. These ing and writing of device parameters, downloading configura-
are combmed to form the more complex data objects. tions, and other activities from the host. Client/ server
communication is queued, meaning that requests are sent in an
Fieldbuses for Process Control Chapter 11 -How FieJdbuses Work
Subscriber
Subscriber Publisher i
FOUNDATION Object Dictionary (00) VFD support services are used to manage virtual field devices. They
do the following:
The FOUNDA T!ON Field bus protocol is object oriented. The infor-
mation m the de~1ces is accessed in the form of objects. In Fou;..;-oA- • Read a device/user status
TION FMS: the obJects for configuring device and strategy in a node • Report an unsolicited status
arehsted in an object dictionary (OD). Each object is identified by • Read vendor, type, and version
an mdex. For example, every function block and every parameter
• FMS reject of improper confirmed service
Chapter 11 - How Fieldbuses Work
Field buses for Process Control
(
Field buses for Process Control
Chapter 11 - How Fieldbuses Work
• Master class 1 reads data from slave Every FOUNDATION device has a 32-byte unique identifier, which is
a hardware address that consists of a 6-byte manufacturer code,
• Master class 1 writes data to slave 4-byte device type code, and a serial number. These uniquely dis-
• Indicate diagnostics tinguish the device from all others in the world. The manufacturer
code is universally administered by the field bus Fom~dation,
• Set slave address which eliminates the potential for duplication. The manufacturer
assigns the device type code and sequential number.
?nly one r:'aster is allowed to write outputs. It is therefore a good
1dea to venfy that the redundancy scheme employed in the system The LAS periodically polls network addresses to detect new
correctly swttches over m the event of primary failure. devices. LAS identifies new devices and assigns them an operating
address in case the original address was in the default range or a
System Management and Network Management duplicate address is being used by a device already on the net-
work. Network address conflicts are automatically resolved
HART and PROFIBUS PA do not use system and network manage- because the LAS uses the unique identifier hardware address to
ment. System and network management in the devices and the distinguish between the devices contending for the same network
ho~t work together to provide functions like automatic address address.
~sstgnment and clock synchronization. Clock synchronization is
Impo~tant because time is used to time-stamp alarms and schedule Clock Synchronization
functiOn block execution and communication.
The system management in the LAS periodically publishes the
FOUNDATION Fieldbus H1 time for the devices on the network to synchronize their internal
clocks. This time is used to ensure that the schedule in each device
The system management in a device is responsible for function is synchronized with all the others, which ensures that the blocks
block an? communica:ion scheduling, time synchronization, and are executed and the links published at exactly the right moment.
automatic address asstgnment, among other functions. The Net- The time is also used to time-stamp alarms, events, trends, and the
work Management Information Base (NMlB) and System Manage- like.
ment Information Base (SMIB) are accessed through the first VFD
lil the device. The NMIB contains the LAS communication sched- Should the primary time publisher fail a secondary will take over
ule, VCRs, communication statistics, and the like. The SMIB con- and so on.
tams the device's tag, address, function block schedule, and so on.
User Layer
Function Block Schedule
The user layer is where the real functionality of the device or soft-
!he sch~dul~ for function block execution and link communication
ware takes place. This is where transmitters measure, positioners
Is explamed m chapter 4, "Configuration." The schedule is stored
actuate, and hosts interface to the user. It is at the user-layer level
m the SM/NM VFD in the device. SM coordinates the scheduling
that the data formats and semantics are defined that allow devices
of fun~tion ~lock execution and the communication of function
to understand and act intelligently on data. Thus, real interopera-
block lmks m order to eliminate jitter. This is because a value is
bility can be achieved. Both FOUNDATION Fieldbus and PROFIBUS
Fieldbuses for Process Control
Chapter 11 - How Fie!dbuses Work
FOUNDATION Fieldbus
IResriUr.'C' _~.c '.· 1
1
71
the devices on the network. Within a device the blocks are con- DAP f
tained in a Function Block Application Process (FBAP) within a .!'._.,
VFD, Communication
Resource bl0ck is responsible for the overall management of the FOUNDATION Trend Objects
device, such as nmning it or placing it out of service, as well as
Trend objects sample block parameters for the sake of historical
forcing the output. It also contains general identification informa-
trending. Multiple samples are collected and communicated in a
tion and o\·erall device diagnostics.
single communication to the host.
Transducer blocks are responsible for interfacing the sensor, actuator,
FOUNDATION Alert Objects
and display hardware to the function blocks. This is where calibra-
tion is done. They also contain information about the last calibra- Alert objects report alarms and events detected in the function ,
tion and l/0 diagnostics. blocks to the host The host must confirm receipt of the alert. If 1t
does not, the alert is retransmitted.
{
(
Chapter 11 -How Fieldbuses Work
Fieldbuses for Process Control
FOUNDATION View Objects Variable describes every piece of information in the device in terms
of the following characteristics:
View objects are predefined subsets of block parameters that allow
the parameters \vithin the same block to be read using fewer com- • Input, output or contained
I
munications. There are four different views: • Dynamic or static
VJEW_l is a subset of common dynamic parameters in the block • If related to diagnostics, service, operation, alarm or tuning
that are suitable for operation from a faceplate. • Data type: integer, float, enumerated, ASCII, time, etc.
VIEW _2 is a subset of common static parameters in the block that • Significant digits and decimals
are suitable for operation from a faceplate. • Minimum I maximum value
VJE\1\1 __3 is a subset of all dynamic parameters in the block. • Scaling factor
• Text for enumerated and bit-enumerated variables
VIEW_4 is a subset of the static parameters in the block not already
included in VIEW _2. • Fixed engineering unit
• Read-only
FOUNDATION Multi-Variable Container (MVC)
• Help text for user
The Multi-Variable Container (MVC, see chapter 7) can be config- • Label identifying the variable to the user
ured to access a user-defined subset of parameters across various
blocks within a device. For example, if a device has sixteen inputs • Methods before and after editing
all of these can be accessed with a single communication. Usually, • Methods before and after reading
the host configures the MVC automatically depending on what
values from the device are displayed in the operator console. • Methods before and after writing
• Read/write timeout
FOUNDATION Device Description (DO)
• When applicable
Device Description (DD) describes all data in the device. Its practi-
cal use is explained in chapter 3, "Insta!Jation and Commission- • Error message to the user
ing." The device manufacturer writes DD using the Device
Description Language (DDL).It then compiles it and supplies it as Item Array describes a logical grouping of data in the device:
two files together with the device. The DD allows the host to inter- • Objects that are part of the item array
pret the complex data in the devices so it can be displayed in a
comprehensible way. The DD describes every object in the device. • Help text for user
Indeed, HART also has DD that is very similar to that of the FOUN- • Label identifying the item array to the user
DATION. DDL has fourteen constructs with associated attributes to
completely describe the data and even suggest how it should be Collection describes a logical grouping of data in the device:
presented to the operator. DD is used in conjunction with a capa-
bility file. The device manufacturer writes the capabilities file in • Objects that are part of the collection
the Common File Format (CFF). The capabilities file defines the • Help text for user
resources that are available in the device. This ensures that the host
• Label identifying the collection to the user
does not exceed available resources when configuring off line. The
DDL constructs of the DD file include fourteen terms, described in
Record describes data in the device grouped for communication:
the following paragraphs:
• Objects part of the record
Fieldbuses for Process Control Chapter 11 - How Fieldbuses Work
• Help text for user Menu describes how the data is organized when displayed to the
user:
• Label identifying the record to the user
• Label identifying the menu to the user
• Error message to the user
• Objects part of the menu
Array describes data in the device grouped for communication:
Edit Display describes how the data is displayed to the user tv hen
• Type editing (for example, when the user edits the range Edit Display
• Number of elements allows the range limits to also be displayed):
• Help text for user • Object to be edited
• Label identifying the array to the user • Label identifying the edit display to the user
• Error message to the user • Objects to be displayed to assist the user
• Methods before and after editing
Variable ~ist ?escribes data in the device grouped for
commumcahon: Method describes procedures for the configuration tool and the
• Objects part of the variable list user when performing functions in the device (for example, when
calibrating an output, the output may first have to be set to one
• Help text for user
extreme, the user prompted for a calibrator reading, the adjust-
• Label identifying the variable list to the user ments made, and device operation finally returned to normal, etc.):
• Input or output
Block describes every block type in the device:
• If related to diagnostics, service, operation, alarm, or tuning
• Type and execution time, etc.
• ANSI C language to execute
• Label identifying the block to the user
• Help text for user
• Parameters part of the block
• Label identifying the method to the user
• Help. text for user
• When applicable
• Variable lists part of the block
• Objects associated with the block l\clatio11 describes how data that belongs together needs to be syn-
chronized. For example, when the engineering unit is changed the
range limits may need to be refreshed because they change, even
though they are static parameters. Changing the sensor type may
also affect the range limits.
• Need to be updated when one in a group is changed etc.
• Need to be updated when the unit is changed
• Need to be written at the same time
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Fieldbuses for Process Control
Chapter 11 _ How Fieldbuses Work
These four layers are not sufficient to provide interoperability. HSE LAN Redundancy Entity (LRE)
Application layer and user layer are also required to achieve a Redundancy is used to improve the availability of the host-level
completely interoperable protocol because the formats and seman- network by providing not only redundant media but also redun-
tics of the data are defined in these higher layers. FOUNDATION dant communication ports and devices. In the device, the LAN
HSE Fieldbus and PROF!net put the existing FOUNDATION and Redundancy Entity (LRE) is responsible for redunda~cy. Redun-
PROFIBUS technologies on top of the Ethernet and IP platforms. dant devices have multiple physical network connec_t10ns but only
PROFinet on top of TCP uses the Microsoft DCOM (Distributed use one for the normal communications at any one tnne. At the .
component object model) technology for communication. same time, all other connections take part in diagnostics commum-
cation to verify the integrity of the system. Should the network,
Ethernet, IP, UDP, and TCP are discussed in many books. We there- port, or one part of the redundant device fail, thc·normal commu-
fore won't detail these technologies here. nication will take another path. There is no central redundancy
manager for the network. Instead, the LRE takes care of the ,
FOUNDATION HSE Fieldbus switchover from primary to secondary based on de~ected fault~:
The switchover is transparent to the VFD and FBAI, so no speual
FOUNDATION HSE Fieldbus supports both the TCP and UDP trans- configuration of function blocks or otherwise is required. When the
port Jayer protocols, but UDP is the default means. The same func- failed primary device is once again OK it returns on the network as
tionality provided by the FOUNDATION application and user layers
a secondary.
is also provided over the Ethernet
The LRE in the HSE devices periodically transmits to the other
HSE Application Layer devices diagnostic messages about which ~e~ices and. ports tt can
In HSE, the application layer is called the Field Device Access see on the network. Each device gathers th1s mformahon f:om the
(FDA) agent. It provides the Virtual Communication Relationship other devices in an internal network status table and uses It to
(VCR) functionality that is the equivalent of what FAS does for 1-11, determine which path it shall use to communicate vvith the other
that is, client/ server, publisher /subscriber, and report distribution. devices.
In other words, over Ethernet the blocks in the VFDs are accessed
through the FDA agent. The Ethernet data link layer does not sup- EXERCISES
port scheduling, hence publisher/subscriber data is transmitted on 11.1 Which has a sinusoidal signal, HART or IEC?
an "as soon as possible" basis.
11.2 Which signal is self-clocking, HARf or lEC?
HSE Network Management
11.3 What are the three classes of HART commands?
HSE network management is based on standard Internet technolo-
11.4 What are the two types of communication in PROFIBUS PA
gies and uses the standard Simple Network Management Protocol
(SNMP) to access a standard Management Information Base (MIB- (DPv1)?
11) with some extensions for HSE. The HSE devices also support 11.5 What entity is responsible for automatically assigning
the Dynamic Host Configuration Protocol (DHCP) for assigning IP addresses?
addresses automatically. The Simple Network Time Protocol
11.6 Which file(s) defines how many blocks of a given block
(SNTP) is used to synchronize clocks. The time received over SNTP
is used to set the clock in the HSE device, and a linking device also type a FOUNDATION device supports?
uses this time to synchronize the clocks in the devices on the Hl 11.7 Which type of block is responsible for the O\'erall operation
networks that are connected to it. Clock synchronization makes of a PROFIBUS PA device?
possible scheduled function bluck execution in HS.E devices.
11.8 Which transport protocol does HSE use?
SNMP, DHCP, and SNTP are discussed in numerous books so we 11.9 Which entity is responsible for HSE redundancy?
will not detail them here.
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Iii" Fieldbuses for Process;Control
BIBLIOGRAPHY
Chapter 1
1.1 No. For example, telephone and television systems are
networks that, at least for now, are still very analog.
1.2 Yes.
1.3 Yes.
1.4 Yes, it requires fewer transactions. Master I slave needs to
make one read transaction and then one write transaction
for each recipient, whereas publisher I subscriber only
needs a single direct transaction from originator to all
recipients.
1.5 Factory automation.
1.6 No. It is just a physical and data link layer, but nevertheless
an essential platform for many protocols.
1.7 Yes. Any fault affects a smaller part of the plant.
Chapter 2
2.1. No.
2.2. The device manufacturer.
2.3. Transducer block
2.4. Yes. For example, if the operator is unaware that a
positioner has failed, this could be a hazard. Diagnostics
tell the operator that the loop is not under controL
445
FieldJJuses for Process Control
Appendix A- Solutions to Exercises
I
I
l
Fieldbuses for Process Control
Appendix A- Solutions to Exercises
4.23. Yes.
Chapter 7
4.24. Enable option Target to manual for Bad IN in the status
option (STATUS_OPTS) parameter. 7.1. Yes. If the process value appears unreasonable but the
status is "Good," then the device must be OK, so it must
4.25. Set the linearization type (L_TYPE) parameter as Direct. therefore be a true process problem.
4.26. The OUT_*_LIM limits are more constrictive than 7.2. No. For bit-enumerated parameters multiple options are
OUT_SCALE. possible.
4.27. The output (OUT). 7.3. Yes. If several parameters are accessed from the same block
then they can be accessed using a View object in a single
4.28. In the PlD block control option (CONTROL_OPTS)
communication.
parameter.
7.4. No.
4.29. No. The physical output is not changed by the simulation.
Tt is a readback signal that is simulated.
Chapter 8
4.30. Availability. The default option for fault state in the I/O-
option (IO_OPTS) parameter is fault state to value. 8.1. No, not if you use devices that have sufficient resources.
8.2. Three: two for Device Description and one Capabilities file.
Chapter 5
8.3. No, not in the opinion of this author. A plant can simplify
5.1. Yes. However, there must be a power supply impedance engineering and purchasing by using a single standard
between the regular DC power supply and the IEC 61158-2 requirement for each device type throughout the plant.
network. The power supply impedance must be able to
8.4. Device and wiring details should all be in the network
handle any noise or instability in the DC power supply.
diagram. Only control functionality should appear in the
5.2. No. P&ID.
5.3. Yes. However, the OPC server should be safety approved. 8.5. No. Provided that the templates are created by using
Most likely, it is restricted to read-only operation. standard function blocks they can be assigned to any
device that uses standard function blocks. However, if any
devices do not support standard blocks, or templates are
• Fieldbuses for Process Control Appendix A- Solutions to~~~;~::s II
made using nonstandard blocks, the blocks cannot be 11.7. The physical block.
universally applied. 11.8. UDP.
11.9. LRE.
Chapter 9
9.1. In the transducer blocks. Range setting is performed in the
function blocks.
9.2. The block error (BLOCK_ERR) parameter.
9.3. A large number of cycles is an indication of an unstable
process.
9.4. The standard function block types defined are, but
extended function blocks and transducer blocks are not.
However, transducer blocks have few parameters to be set
and no links, so they are easy to change.
Chapter 10
10.1. No. TI1e goal of availability is to keep a system running,
whereas for safety the goa) is to shut down.
10.2. Yes. Better diagnostics reduces false trips and allows true
faults to be detected and rectified faster.
10.3. Yes. Better diagnostics detects dangerous faults.
10.4. No, not the way it is implemented in control systems.
Redundancy improves availability.
10.5. No, not if the loop is configured to shut down safely.
10.6. The same value used in a dangerous loop can shut it down,
while a nondangerous loop is allowed to continue.
10.7 No. It improves availability.
Chapter 11
11.1. HART (Bell202).
11.2. IEC (Manchester coding).
] 1.3. Universal. common practice, and device specific.
11.4. Cyclic and acyclic.
11.5. System management.
11.6. The Capabilities file.
{
Appendix B
Parameters
Index
453
Fieldbuses for Process Control
, Parameters
DD_REV 168
GAIN 181, 190,248,250,256,262, 30!1
DEADBAND 190 MAX_NOTIFY 169 I{;\ TE 181, 190-191, 233, 2..J.8
GAIN __IN_l 256
DEV_HEV 168 MAX_SENS01CVALUE 187, 189 RATED_TRAVEL 191
GATN_IN_2 250
DEV __TYPE 168 MAX_TEMPERATURE 187 RCAS_IN 193-194, 196,224,226, 2J6,
GAIN_IN_3 256
DEVICE_CALIB_DATE 192 MEMORY_SIZE 172 31?, 395
GRANT_DE0:Y 172,215
DEVICE_.CERTIFICA TION 184 MIN_CYCLE_T 170 RCAS_OUT 193,312
DEVICE_CONFIG_DATE 192 MIN_SENSOIC VALUE 187, 189 READBACK 181, 267
HARD_TYPES 168
DEV!CE_!D 183 MIN_TEMPERATURE 187 RESET 181, 184, 190,248
HARDWARE_REV!SION 183
DEVICE_MAN_ID 183 MODE_BLK 164,172,182,219,223,243, RESTART 170
HI_ALM 212
DEVICE_SER_NUM 183 254,262,271,300,317,325-326 Rj_TEMP 189
HI_HI_ALi\·1 212
DIAGNOSIS 183-184,300 MODULE __ SN 180 Rj_TYI'E 189
HCHCLIM 212
DIAGNOSIS_"EXTENSJON 183,300 I-IJ_HI_YRI 212 ROUT_IN 224, 226, 236
DIAGNOSIS_MASK 184 NV_CYCLE__T 170 RS_STATE 168,300
HI_LIM 187,212,232,244, 248, 262,328
D!AGNOSIS_MASK_FXTENSION !84 HCPRI 212
DV_HI_ALM 212 OUT 190, 193--195, 197,207,216-217, SCALE_IN 185
HW_WRITE_PROTECTTION 184
DV_HI_LIM 212 223-226,228-230,232,234,240-241,243- SECONDARY_VALUE 177,180,185,
DV_HI]RI 212 248,250-251,254,262,264,269-270,276- 187
IDENT_NU1-IBER 183
DV_.LO_ALM 212 277,312,324,327-328,331-332 SECONDARY_VALUE_! 185,187
IN 185, 193-196,207,217,221-230,232,
DV _LO__ LIM 212 OUT_CHANNEL 195 SECONDARY_VALUE_1_UNIT 187
234-237,244-247, 252,254-257,265-266
DV _LO_I'RI 212 OUT_HI_LIM 244,248,262,328 SECONDARY_VALUE_2 185, 187
268,310-312,323,395,403-404 '
IN_1 246, 256 OUT_LO_L!M 244,248,262,328 SECONDARY_VALUE_2_UNIT 187
EXTERNAL_Rj_ VALUE 189 IN_2 256-257 OUT_SCALE 190,195,216-217,240-241, SECONDARY_VALUE_UNIT 177
JN_3 256--257 243,245,250-25!,277,327 SELF_CALIB_CMD 192,366
FACTORY_RESET 184 OUT_UNIT_TEXT 194 SELF_CALIB_STATUS 193
IN_GIANNEL 195
FAULT_STATE 31! OUT_UNITS 262 SENSOR_CAL_DATE 176, 179
IN_LO 254, 256
FEATURE_SEL 171,253,264,404 SENSOR_CAL_LOC 176,179
INCREASE_CLOSE 196
FEATURES 170 POS_D 196 SENSOR_CAL_METHOD 176
INPUT_FAULT_GEN 188
FEEDBACK_vALUE 190 POSITIONING_ VALUE 189 SENSOR__ CAL_WHO 176, 179
INPUT_OPTS 256
FF_GAIN 250 PRE_OUT 254 SENSOR_CONNECTION 179, 189
fO_OPTS 196,242,264, 277,404
FF_SCALE 250 PRIMARY_ VALUE 174, 179, 184-185, SENSOR_DIAPHRAGM_MATERIAL I
FF_VAL 250 188,239 87
L_TYPE 19-l, 241,243
FIELD_ VAL 241 I'RIMARY_VALUE_RANGE 174 SENSOR_FlLL_FLUID 179, 187
LIM_NOTIFY 169
FINAL_I'OSITION_v ALUE 180, !90 PRIMARY_VALUE_TYPE 174,179,185 SENSOR_HI_LIM 187
LIN_,TYPE 188,191,194
FINAL_VALUE 177,180,190 LO_ALM 212 PRIMARY_ VALUE_ UNIT 185,188 SENSOR_JSOLATOR__ MTL 179
FlNAL_vALUE_CUTOFF_HI 180,190 PROCESS_CONNECTION_MATERIAL SENSOR_LO_LIM 187
LO_LIM 187,212,232, 244,248,262,328
FINAL_vALUE_CUTOFF__ LO !80, 190 187 SENSOR_MAX_STAT1C_PRESSURE 18
LO_LO_ALM 212
FINAL_VALUE_RANGE 177, 180 LO_LO_LIM 212 PROCESS_CONNECTION_ITPE 187 7
FLOW_UN_SQRT_POINT 186 PV 194,213,216--217,224-225,232,236, SENSOR_O_R!NG_MATERIAL 187
LO_LO_PRJ 212
FREE_SI'ACE 171 240,245-247,249,254,256,262,264-265, SENSOR_RANGE 175
LO]RI 212
FREE_TIME 171 267,269-270,320,324,327,331,423-424 SENSOR_SERIAL_NUMBER 187
LOCAL_OP_ENA 184
FSAFE_ nrE 194, 196 PV_FTIME 240, 245 SENSOR_SN 174
LOW_CUT 186,242
FSAFE_VALUE 194, 196 PV _SCALE 194,213,216-217,232,236, SENSOR_TYPE 174,179,185
LOW_FLOW_CUT_OFF 186
FSTA TE_T!ME 265,311 247,265,269,327 SENSOR_UNIT 185
LOWER_SENSOR_LIMIT 188
ESTATE_ VAL 265 PV _UNITS 262 SENSOR_¥ALUE 185, 187, 189
SERVO_GAIN 181,190
MANUFAC_!D 168
RANGE_HI 255 SERVO_RATE 181, 190
RANGE_LO 255 SERVO_RESET 181, 190
~~~ Fieldbuses for Process Control
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Field buses for Process Control