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Fieldbus Foundation™Freedom to choose. Power to integrate
2005 General Assembly
Fieldbus Commissioning benefits
Copyright Fieldbus Foundation, October 2007
Fieldbus Commissioning Benefits
• Commissioning - Device integration• Commissioning - Physical layer
Copyright Fieldbus Foundation, October 2007
Fieldbus Commissioning Benefits
• Commissioning - Device integration
Copyright Fieldbus Foundation, October 2007
Easier - Real Number Engineering Unit
• No range mismatch• Unit downloaded when device is replaced
Transmitter PositionerFF FF
BUSFF
CTRL
CPU
CPU
CPUDigital
Digital
DigitalDigital
TransmitterRange
0-800 kPa
SystemRange
0-400 kPa
8 mAProcess200 kPa
Reading100 kPa
...alarms and tripsnot working
AIA/D
D/A 4-20 mA
AOD/A
A/D4-20 mA
RangeRange
Copyright Fieldbus Foundation, October 2007
Lower Cost & Faster:- Device Commissioning
• Traditional: 2 hours / device for 2 technicians– Attach device– Verify 4-20 mA signal
• five points– Verify link to control
strategy– Check device parameters
with handheld
• Foundation fieldbus: 25 minutes / device for 1 technician– Attach device– Drag-and-drop
commissioning wizard– Compare configuration
faster on computer
•Devices are auto-recognized•Devices are auto-addressed•Devices identify themselves
Plug-n-Play
Only FF has automatic
addressing
Copyright Fieldbus Foundation, October 2007
Fieldbus Maintenance Made Easy:Device Commissioning Wizard
Copyright Fieldbus Foundation, October 2007
Fieldbus Maintenance Made Easy:Protective Decommission
• Removing device in an orderly fashion– “Safely remove
hardware”• Temporary removal
– To remove for calibration etc. with intention to put back into same place soon after
• Permanent removal– To remove for
replacement etc.
Control-in-the-field does not mean just
“simple” PID
Copyright Fieldbus Foundation, October 2007
Easier FF Device Commissioning and Replacement
• Commission or replace device without touching the software
• System automatically logs process in background
Automatic configuration reconciliation with device database
Automatic configuration
download
View details in historian and
log
Copyright Fieldbus Foundation, October 2007
Intelligent Devices via Fieldbus is a Must
• Process Industries worldwide require fieldbus based systems because of cost reduction– Reduction of wiring and cabinet costs– Less system and instrumentation hardware– Reduced commissioning time
• Intelligent devices enable Asset Optimization– Increase of maintenance effectiveness– Improves process availability– Enhances productivityAventis says: Fieldbus technology
saves costs and enables innovative applications. Future plant will be
equipped with fieldbus
Copyright Fieldbus Foundation, October 2007
Intelligent Devices Enable Asset Optimization
OK!Oops!BAD!
• Scheduled monitoring of asset health status• Smart condition reporting• Notification of key personnel independent of their location• Generation of fault reports and submission to CMMS
Copyright Fieldbus Foundation, October 2007
Fieldbus Commissioning Benefits
• Commissioning - Physical layer
Copyright Fieldbus Foundation, October 2007
The physical layer – alive and well?
– Proper termination– Water ingress– Ground faults
Copyright Fieldbus Foundation, October 2007
The physical layer – alive and well?
– Proper termination– Water ingress– Ground faults– Loose wiring – Faulty devices
Copyright Fieldbus Foundation, October 2007
The physical layer – alive and well?
– Proper termination– Water ingress– Ground faults– Loose wiring – Faulty devices– Unstable communication– Short circuits– Bulk power failure– …
Copyright Fieldbus Foundation, October 2007
Online monitoring of the physical layer
Time
Equipment Health100%
Minimum device health FAILURE
Time to respond
Warning level
Monitoring the physical layer protects you from unwanted shutdowns!
Copyright Fieldbus Foundation, October 2007
Advanced Diagnostics for physical layer
•Integrated single tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need
Copyright Fieldbus Foundation, October 2007
Advanced Diagnostics for physical layer
•A portable tool for commissioning, monitoring, and troubleshooting. Versions to suit your every need
Copyright Fieldbus Foundation, October 2007
Diagnostic Manager Software
•User interface in the control room:– Display of values – Warnings with actionable information– Color coding for easy recognition
•Value-add:– Automated commissioning
procedures and documentation– Live segment monitoring with alarms– Expert troubleshooting tools
•Embedded expert-knowledge
Copyright Fieldbus Foundation, October 2007
Asset Management Integration
•One Plant Asset Management – Includes fieldbus now as asset– Customary look and feel– Reduces required training – Reduces potential for errors
•Open Architecture Integration:– AMS Suite– PRM– FieldCare – FieldMate– PACTware– OPC Interface
Automatic Setup
Included
Copyright Fieldbus Foundation, October 2007
Open Architecture Integration
– ADM uses a simple infrastructure for data integration– ADM automates display of diagnostic information
• Benefits– No Planning:
• No planning of system resources required• Last minute decisions are possible on ADM implementation
– No Engineering: • Software configures alarm settings for segments and device tags• Commissioning wizard automatically configures ADM settings
– No Worries: • Easy to use graphical user interface and actionable information
Copyright Fieldbus Foundation, October 2007
Commissioning until now
– Always on the critical path– Manual, step-by-step procedure– Labor intensive– Requires
• Screw driver• Check sheet• Pencil• Multimeter• Oscilloscope
– Connect one device at a time– Disconnect after testing
Test Report
Copyright Fieldbus Foundation, October 2007
Simple Commissioning Steps with ADM
– Verify address setting– Wire up devices in the right location– Check shielding– Activate communication– Use automated work procedures
• Testing • Documentation
– All devices at once– Wiring remains undisturbed
Commissioning Wizard
Test Report
Copyright Fieldbus Foundation, October 2007
Commissioning Wizard
– Simple to use– Eliminates manual test procedures – Ensures compliance with
AG181 and IEC 61158-2– Creates baseline report:
• Snapshot of all measurements • Complete documentation
– Recommends warning and alarm limits for the ADM– Stores limits in non-volatile memory– Reduces pre-commissioning
time by up to 80%
Copyright Fieldbus Foundation, October 2007
Commissioning process
■ Segment Checker: design of the physical layer
Cas
h Fl
ow
Plan and purchase
■ Verify against original design■ Automated checkout procedures
Commission
Install and commission
■ Longer plant uptime■ Know before you act■ Actionable information in clear text
TroubleshootMonitor
Operate and maintain
Engineering
Copyright Fieldbus Foundation, October 2007
■ Segment Checker: design of the physical layer
Engineering
Commissioning process
Copyright Fieldbus Foundation, October 2007
■ Verify against original design
■ Automated checkout procedures
Commission
Commissioning process
Copyright Fieldbus Foundation, October 2007
Commission
■ Printable Segment report in pdf format.
■ Save in Harddisk.
Commissioning process
Copyright Fieldbus Foundation, October 2007
■ Know before you act■ Actionable information
in clear text
Troubleshoot
Commissioning process
Copyright Fieldbus Foundation, October 2007
■ Longer plant uptime■ Know before you act
Monitor
Commissioning process
Copyright Fieldbus Foundation, October 2007
■ Segment is still operaating with good preformance.■ Setting of pre-alarm.■ Warning – maintenance required.
Monitor
Commissioning process
Good valueMaintenance required
Out of specification
Copyright Fieldbus Foundation, October 2007
■ Oscilloscope function.
Troubleshoot
Commissioning process
Copyright Fieldbus Foundation, October 2007
■ Oscilloscope function.
Troubleshoot
Commissioning process
Copyright Fieldbus Foundation, October 2007
■ Oscilloscope function.■ Readable Manchester
code.■ Able to identify
device ID.
Troubleshoot
Operate and maintain
Commissioning process
Copyright Fieldbus Foundation, October 2007
Automated Pre-commissioning Saves Time
• Case Study with cost comparison for pre-commissioning: – 4…20 mA– Fieldbus– Fieldbus with Advanced Diagnostics
Case Study – SpecificationsNumber of instruments 1,200Number of segments 100Instruments per segment 12Hours per work day 8 hoursMean time to repair (MTTR) a fault
4 hours
Pre-commissioning is defined as work steps taken to install and validate the hardware configuration and the physical layer.
Source: Fieldbus Testing with Online Physical Layer DiagnosticsTechnical White Paper available from Pepperl+Fuchs Part No: 198636
Copyright Fieldbus Foundation, October 2007
Automated Pre-commissioning Saves Time
Task 1 of 2 Model 4-20 mAFieldbus without
diagnostics
Fieldbus with Advanced
Diagnostics
Constructional checks:
Time/Unit 5 min 10 min Not required
Units 1200 loops
100 segments Not required
Total Time 12½ days 2 days 0
Construction failures (1%):
Time/Unit 4 h MTTR 4 h MTTR Not required
Units 12 loops 1 Trunk, 12 Spurs Not required
Total Time 6 days 6 ½ days 0
Copyright Fieldbus Foundation, October 2007
Automated Pre-commissioning Saves Time
Tasks 2 of 2 Model 4-20 mA Fieldbus without diagnostics
Fieldbus with Advanced
Diagnostics
Pre/commissioning instrument checks:
Time/Unit 10 min 60 min 8 min
Units 1200 loops 100 segments 100 segments
Total Time 25 days 12½ days 1.6 days
Pre/commissioning failure:
Time/Unit 4h MTTR 4h MTTR 4h MTTR
Units 0.5% =6 loops
0.5% = 1 segment
1.5% = 2 segments
Total Time 24 h =3 days
4 h =½ day
8 h =1 day
Totals 46.5 days U 21.5 days U 2.6 days U
Copyright Fieldbus Foundation, October 2007
Commissioning saves time and money
– A few mouse clicks conduct automatic testing
– Reports on the actual installation with all devices connected
– Automatic setting of warning and alarm limits
Copyright Fieldbus Foundation, October 2007
Monitoring increases plant up-time
– The ADM increases the number of detectable faults
– The physical layer becomes a managable asset
– The ADM is prevention from unwanted shut downs
Copyright Fieldbus Foundation, October 2007
Accelerated Commissioning
– Actionable information guides to potential sources of faults
– ADM provides expert knowledge and advice
– For anyone working with fieldbus
– Accessible from remote for consultation with fieldbus experts
Copyright Fieldbus Foundation, October 2007
Accelerated Commissioning ( ADM makes the physical layer visible )
– Fieldbus itself becomes a managable asset
– ADM integrates into Asset Management Systems
– Available as stationary or mobile module
– Display in the safety of the control room
Copyright Fieldbus Foundation, October 2007
Accelerated Commissioning
– Rapid commissioning: Accelarates loop check
– Longer operation: Warns before failure
– Faster troubleshooting: Assists with actionable information
Copyright Fieldbus Foundation, October 2007
Conclusion
– Foundation Fieldbus Simplifies device commissioning and saves time. Device integaration into the control system environment made fool proof.
– Advanced Diagnostics tools for physical layer reduced physical layer commissiong time and provided online monitoring and reporting system that saves CAPEX and OPEX
Copyright Fieldbus Foundation, October 2007
QUESTIONS?