Integrating HART into PROFIBUS DP...
Transcript of Integrating HART into PROFIBUS DP...
Integrating HART into PROFIBUS DP
Walter Stoops, Pepperl+Fuchs
Theo Bervoets, AUMA
Jaap Westeneng, Endress+Hauser
Network Infrastructure
• How can you integrate legacy HART devices for the process industry into PROFIBUS and PROFINET networks, upgrading your existing legacy instrumentation to modern standards, getting ready for future requirements? How can you implement industrial wireless networks? How can you save energy by investing in the latest network technology, ProfiEnergy?
‘How can …’ starts here, with knowing!
What is our challenge?• How to exploit the power of HART and PROFIBUS devices in
the installed base?• What relevant information is available from a HART or
PROFIBUS device?• How to get access to HART and PROFIBUS devices over
existing (fieldbus) infrastructure?• What are the minimum requirements to be specified?• How to monitor the health status of your HART and
PROFIBUS devices?
HART has a estimated installed base of more than 30 million devices
Do we agree on the following principles?• PROFIBUS (Process Field Bus) is a standard for fieldbus
communication in automation technology and was first promoted in 1989 and is a field proven technology!
• There are two variations of PROFIBUS in use today; the most commonly used, PROFIBUS DP (Decentralised Peripherals) and the lesser used, PROFIBUS PA (Process Automation)!
• PROFIBUS DP network is the proven basis for the integration of (wireless) HART devices today…!
In excess of 38 million PROFIBUS DP and 6 million PROFIBUS PA nodes are installed.
HART and PROFIBUS an overview
• Highway Addressable Remote Transducer
• Defined by the Rosemount company, 1987
• HART Communication Foundation (HCF), 1993
• Over 300manufacturers in the HART Communication Foundation
• PROcess FIeldBUS• Founding of PROFIBUS
International, 1995• PROFIBUS Nutzer
Organisation (PNO), 1989• PROFIBUS PA, 1996• Over 1400members in
PROFIBUS International
www.hartcom.org www.PROFIBUS.com
4‐20 mA + HART > Conventional + Digital communication
SPCable
AD
16 bit
DA
16 bit
I/O
16 bitD
A
16 bit
mA (current analog)
mA (current digital)
% (Percent of range)
PV (Primary value)
SV (Secondary value)
TV (Tertiary value)
QV (Quarterly value)
+ PV units code
+ SV units code
+ TV units code
+ QV units code
PROFIBUS > Digital communication
SP
ASICASIC
DA
16 bit
I/O
16 bit
Cable
Main process value + Status code
2nd Cyclic value
Display value
3rd Cyclic value
4th Cyclic value
5th Cyclic value
6th Cyclic value
+ Status code
+ Status code
+ Status code
+ Status code
+ Status code
+ Status code
7th Cyclic value + Status code
..th Cyclic value + Status code
mA (basic current)
HART over PROFIBUS > Digital communication
PV (Primary value)
SV (Secondary value)
TV (Tertiary value)
QV (Quarterly value)
+ PV units code
+ SV units code
+ TV units code
+ QV units code
History of SMART technologies
200420031987
DevelopedBy
Rosemount
1989
OpenStandard
1993
HCF
2007
HART addedto IEC‐61158
2008
HART 7specification
1989
PNO
1995
Founding of PI
1996
PROFIBUSPA
2000
Standard Device
Profile 3.0
2004
PROFIsafeCond. StatusProfile 3.01
1994
FieldbusFoundation
1996
FOUNDATIONFieldbus H1
1999
HighSpeed
Ethernet
2005
SafetyInstrumentedFunctions (SIF)
2006
DiagnosticProfiles
Specification
2008
DiagnosticProfilesRelease
2011
RegisteredHost
Profile ‘61b’
2013
HART 7.4specificationDiag. Profiles
2008
DeviceIntegrationProfile 3.02
2012
DiagnosticProfilesFF912FDT = Field Device Tool
Normen Arbeitsgemeinschaft für Meß- Und Regeltechnik in der chemischen Industrie
Purpose
• Awareness of applicability– How can get access
• NOT Temp, Press, Flow and other values• BUT Health, Quality values
– How do we use it
How to unlock SMART information?Plant Asset ManagementDevice Configuration Management
Industrial Ethernet
HART
LI PI
LICFI
PAS PAM CMMSCM
MOV
TI
KFD2-HMM-16ON
13 14 1519 20 2116 17 18
ON
RS
485
mA mA
Param.
Status
Sec. val
Diagn.
Status
Prim. val
Prim val
Status
Prim. val
Sec. val
Status
Events
Diagn.
Param.
StatusPrim. val
How to achieve
Symphony
Ethernet
ABBHART Communication via PROFIBUS direct access from ABB AC800F or Symphony integrated in ABB engineering tool
AC800FFreelance
How to achieve
Ethernet
HART Communication via PROFIBUS direct access from Siemens S7, PCS7 using Siemens PDM engineering tool
Siemens
How to achieve
Ethernet
HART Communication via PROFIBUS using system independentclass 2 master
PACTware engineering tool ABBAllen BradleyEmersonHoneywellInvensysMitsubishiSiemensYokogawa
EthernetHub
PROFIBUSGateway
DEMO
Line Redundancy (Gateway + Bus Redundancy) one master addresses redundant slaves via Voter or 2 repeaters redundant Bus lines redundant ComUnits / Gateways power supply redundancysee Power Supply
BusStandby Bus
Redundant ComUnit
Redundant ComUnit
Redundancy
Application Redundancy (Gateway+Bus+Master Redundancy) two masters address redundant slaves via redundant Bus lines redundant ComUnits / Gateways power supply redundancy see Power Supply
BusStandby Bus
Redundant ComUnit
Redundant ComUnit
Redundancy
How to unlock SMART information?Plant Asset ManagementDevice Configuration Management
Industrial Ethernet
PROFIBUS PA
• Awareness of applicability– How can get access
• NOT just values• BUT Health, Quality values
– How do we disclose this
Simple installation and commissioning
• Small footprint• Motherboard for easy wiring• Plug‐in connectors • Your choice – any mounting direction• Redundant bulk power connection• DB9 connector for PROFIBUS DP• Redundant comm units
• Optional Advanced Diagnostics: Speeds up all fieldbus work
Advantages
• Fast commissioning• Display of values• Warnings with actionable information• Color coding for easy recognition
• Embedded expert system at work• Oscilloscope• Reporting
DEMO
Conclusion
• In‐depth information • Easy access• One platform• Uniformity in message layout – NE 107• Up‐to‐date technology• Better production performance• Controlled maintenance
Do we meet our challenge?• How to get access to HART and PROFIBUS devices over
existing (fieldbus) infrastructure?– By using bypass solution (e.g. HART Multiplexer)– By using pass through (transparent) (e.g. HART Analog In/Out)– By using wireless (e.g. WirelessHART)– By using PROFIBUS DP/PA Coupler
Do we meet our challenge?• What are the minimum requirements to be specified?
– Remote IO• Support of HART transparent channels.• Availability of certified Communication DTM or Device Driver• If required meeting HART 6 specifications (e.g. 32 characters tag, device status
for every HART values [PV, SV, TV, QV].
– PROFIBUS DP/PA Coupler• Availability of Advanced Diagnostics Module.• If required select transparent DP/PA Coupler (freedom of PROFIBUS DP
transmission speed >> application).• Approved for explosions areas if required.
Why operate valves from remote?
• More cost effective than manual operation• To automate production processes• To control and optimize product quality • To control and optimize plant availability
MOV
Proces Automation and MOV’s• PLC/DCS Outputs
– Commands• OPEN/STOP/CLOSE• SETPOINT• ESD• SAFE OPEN/CLOSE
• PLC/DCS Inputs– Feedback
• ENDPOSITION OPEN / CLOSE• FAULT (not available, torque, ... )• INTERMEDIATE POSITION• .....
Commands Feedback
Proces Automation and MOV’s
• Primairy function electric actuator
Valve operation Feedback
PLC / DCS
Proces Automation and MOV’s
• Secondary function electric actuator
StatusDiagnostics
PLC / DCSPlant‐Asset‐Management
Self‐Diagnoses
Self‐diagnosis actuator – NE107• Towards PLC / DCS
– I/O Interface (inputs/outputs)– Auxiliary voltage– Fielbus communication– Fiber optic connection
• Towards Power supply– Phase failure and – sequence– Separate 24 V DC input
• Towards Valve– Torque– Position– Running time
Self‐diagnosis actuator – NE107
• Application– Number of starts/hr– Temperature– Vibrations
• Maintenance Information– Grease– Sealings– Mechanics– Reversing contactors
Self‐diagnosis actuator – NE107
• Maintenance Information– Grease– Sealings– Mechanics– Reversing contactors
Self‐diagnosis actuator – NE107
• Out of Specification– Number of starts per hour too high– Characteristic curve Temperature – time– Characteristic curve Position – time
DEMO
Summary
• Less down time increased availability more profitability• Savings on maintenance costs more profitability
+ to avoid
=+
Do we meet our challenge?• What relevant information is available from a HART or
PROFIBUS device?– First of all relevant information is application specific!– Operator : Process values and (condensed) Status,– Maintenance : Detailed (consistent) diagnostics and events
Demo AUMA Actuator (Out of Service)Plant Asset ManagementDevice Configuration Management
Industrial Ethernet
Out of Service notification in Asset
Monitor
Out of Service notification in Process Automation System
Out of Service notification in Plant Asset Management
Demo P+F PROFIBUS PA (Advanced Diagnostic Module)
Plant Asset ManagementDevice Configuration Management
Industrial Ethernet
Demo E+H PROFIBUS PA Device (Maintenance Req.)
Plant Asset ManagementDevice Configuration Management
Industrial Ethernet
Demo Siemens RIO HART DevicePlant Asset ManagementDevice Configuration Management
Industrial Ethernet
What is our challenge?• How to monitor the health status of your HART and
PROFIBUS devices? – It is too much engineering effort to read and interpret each and
every manufacturer specific PROFIBUS Status or HART Device Status in Process Automation System for each device!
– By applying an Intelligent PROFIBUS Access Point in parallel (bypass) to Process Automation System which is able to monitor Health Status of connected HART (pass‐through) and PROFIBUS devices according to NAMUR NE107
Intelligent PROFIBUS Access Point
• Auto detection of bus settings for hassle free commissioning
• Pre collection of relevant asset information
• Active monitoring of PROFIBUS live list prepares for event based condition monitoring
• Brief overview of connected devices and communication status
DXCHG no Diag
DXCHG with Diag
DXCHG fails
Not in DXCHG
Intelligent PROFIBUS Asset Monitor
• Interpretation of listened device diagnostic telegrams based on GSD information
• Mapping of device diagnostic messages according to NE107
• Time stamped logging of diagnostics events
• Email‐notification on diagnostic event
• Overview of all connected PROFIBUS devices with NE107 status
OK Failure CheckFunction
Out ofSpecification
MaintenanceRequired