PROFIBUS & PROFINET System Design - PI UK & PROFINET Conference, June 2015 PROFIBUS & PROFINET...

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PROFIBUS and PROFINET System Design Andy Verwer, Verwer Training & Consultancy Ltd UK PITC PROFIBUS & PROFINET UK Conference, Stratford-upon-Avon 23/24 June 2015

Transcript of PROFIBUS & PROFINET System Design - PI UK & PROFINET Conference, June 2015 PROFIBUS & PROFINET...

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PROFIBUS and PROFINET 

System Design

Andy Verwer,Verwer Training & Consultancy LtdUK PITC

PROFIBUS & PROFINET UK Conference, Stratford-upon-Avon 23/24 June 2015

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System Design

What do we mean by System Design?

• We are talking here about Network Design, i.e. PROFIBUS, PROFINET, and the integration of other technologies such as standard Ethernet, AS‐i, IO‐Link etc.

• Choosing and putting together a collection of available parts to achieve the desired automation functions, performance, reliably and at the minimum cost.

It should be simple:1. Understand the desired functions.2. Understand where costs are incurred.3. Understand what makes systems reliable/unreliable.4. Select suitable parts.5. Assemble according to the specifications.

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System Costs

Most system designers and project managers look at the project procurement, installation and deployment costs when they price a job.

However, the costs of an automation system spread over the life cycle of the plant and should include maintenance, fault‐finding and health‐checking.

Perhaps most important is the cost in terms of loss of production should faults develop during the lifetime of the plant. Spending a little more at procurement time can repay many times over.

Also good fault tolerant design need not be more expensive. Sometimes fault tolerance can be achieved at no additional cost.

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Life cycle costs4

The procurement, installation and commissioning costs are only incurred at the start of the project.

Costs from device failures increase as equipment gets older.

When system overhaul is undertaken this can partially reset the increasing cost of failures.

System overhaul

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Control System Design

Control system design normally proceeds by building on the experience obtained from previous designs.

But, designs which are based on badly designed systems will be bad!Only by using experience from operations and maintenance staff can we develop good system designs.In my experience it is rare for such feedback mechanisms to be present.  Particularly when design is carried out by sub‐contractors.

Designers must know about mistakes that have been made in the past. 

Feedback from operations and maintenance is essential.The contract liability threat and accompanying blame culture is often responsible for preventing this feedback.

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System Costs

Maximising plant availability is critical in reducing the total costs of the system. It is essential that the System Designer understands:

That minimising plant down time when faults inevitably occur (i.e. maximising plant availability) is a key requirement. 

The impact of the network layout on plant reliability.

That the incorporation of network health checking and fault finding facilities are essential.

How to appropriately use features such as redundancy and network monitoring and rapid fault location and repair to improve plant availability.

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7Introduction

The parts of a control system will fail whilst in service.

The consequences of failures are often predictable, but the failures themselves are unpredictable.  

The design of a reliable control system is not simple.

… and should be accompanied by analysis of how parts fail and of the consequences of these failures.

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Minimising the failure footprint

There are three basic ways to minimise the impact of faults:• Make failures less likely – Minimise failure frequency.• Restrict the effects of any failures that will inevitably occur.• Provide for rapid fault detection or performance degradation, 

rapid location and rapid repair – Minimise failure duration.

A good network design will minimise the effect on production when inevitable failures occur.We can speak of minimising the “failure footprint”.

Fault frequency

Fault effect

Fault duration

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Minimising the failure footprint

Understand and implement the design and installation rules.

Improve reliability ‐ use of well tested (certified) and reliable devices, connectors and network components.

For PROFIBUS use the lowest possible bit rate that gives the required performance.

1. Make failures less likely – Minimise failure frequency.

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Minimising the failure footprint

2. Restrict the effects of any failures that will inevitably occur –Minimise failure extent.

Well thought out network layout and design.

Think about using: Separate networks or different masters (distributed control),

Different segments (segmentation),

Dealing with common cause failures.

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Minimising the failure footprint

3. Provide for rapid fault detection or performance degradation, rapid location and rapid repair –Minimise failure duration.

Provide facilities in the design for rapid fault diagnosis and fault location.

Provide in the design for hot device swapping without reconfiguration.

Use designs that allow for a quick fix.

Provide redundancy when appropriate. Needs to be well thought out!

Use standardised, vendor independent solutions rather than being locked into manufacturer specific solutions.

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Techniques for minimising fault impact 

Pluggable devices that can be removed/replaced without impinging on network operation.

Appropriate network design and segmentation so that physical layer faults allow critical plant operation to continue in the event of failure or device replacement.

Layout for rapid troubleshooting and fault isolation.

Use appropriate solutions for redundancy.

For PROFIBUS systems use:

connector systems and layouts that do not break the bus or loose termination when disconnected.

Termination solutions that allow devices to be removed or replaced.

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Reliability and availability

Reliability is a measure of how a component, assembly or  system will perform its intended function, without failure, for the required duration when installed and operated correctly in a specified environment.

Availability is  a measure of reliability indicating the fraction of time in which a device or system is expected to operate correctly.

It is important to remember that reliability is a statistical measure: it will not predict when a particular device will fail, only the expected failure rate based on average performance of a batch of test devices or on past performance.

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Some definitions

Mean Time Between Failures (MTBF) is the expected or average time that a device will be free of failure.

Typical MTBF for a well designed and manufactured electronic device might be 10 to 20 years.

Mean Time To Repair (MTTR), is the time taken to repair a failed device.

In an operational system, MTTR generally means time to detect the failure, diagnose and locate the problem and replace the failed part.

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Availability

Availability can be calculated from MTBF and MTTR:

MTTRMTBFMTBF ty,Availabili

A

Remember that availability is a statistical measure and represents an average probability of being in operation.

There is little point in trying to be accurate with these figures since actual failures are unpredictable.

Availability is typically specified in “nines notation”. For example 3‐nines availability corresponds to 99.9% availability. A 5‐nines availability corresponds to 99.999% availability.

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Availability, A D = (1‐A) Downtime0.9 = 90% (1‐nine) 0.1 (10‐1) 36.5 days/year0.99 = 99% (2‐nines) 0.01 (10‐2) 3.7 days/year99.9% (3‐nines) 0.001 (10‐3) 8.8 hours/year99.99% (4‐nines) 0.0001 (10‐4) 53 minutes/year99.999% (5‐nines) 0.00001 (10‐5) 5 minutes/year99.9999% (6‐nines) 0.000001 (10‐6) 5 minutes/10years99.99999% (7‐nines) 0.0000001 (10‐7) Not feasible!99.999999% (8‐nines) 0.00000001  (10‐8) Impossible!

Downtime is an alternative way of understanding the availability:

MTTRMTBFMMTRAD

)1( Downtime,

Availability and Downtime

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Availability/Downtime

Note that the availability of a device can be improved by decreasing the MTTR.

This can be accomplished in several ways:

Faster detection and location of faults. (Accomplished by diagnostic reporting facilities, availability of fault finding tools and training of maintenance personnel).

Faster repair of the fault. (Accomplished by availability of spares and all of the above).

Fault tolerant design. 

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Example

Consider a remote IO unit with a MTBF of 10 years.When the device fails, it could take several days to recognise, diagnose and locate the fault and then, if not held as a spare part, several more days to obtain a replacement. The MTTR could be one week, giving an availability of:

998.073650

3650736510

36510

MTTRMTBF

MTBFA

I.e. ~3‐nines availability, or a downtime of  about 16 hours/year.Consider the availability when the MTTR is reduced to ½ day:

0.999865.036510

36510

A

The availability is now ~4‐nines and the downtime has reduced to about 1hour/year.

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Reliability modelling and analysis

The system designer must understand the methods of modelling and analysis of reliability and availability in systems.

In particular how system availability can be predicted from the individual parts.

Also understand how standby systems, redundant solutions and common cause failures impact the overall system reliability.

We often find that redundancy is inappropriately used and sometimes results in no real improvement in system availability.

Careful network layout can have a major effect on the fault footprint and significantly improve the overall availability of the plant.

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Standby and redundant systems

Often, we see standby systems used to improve the plant availability.

Here we have two or more devices working in parallel.

Should a fault occur in the operational device then the standby device can be started.

The switch over can be manually activated or can be automatic. The switching time should be considered when estimating the overall system availability.

This scheme is called a “one out of two” (1oo2) system.

This scheme achieves high availability because the system function is maintained whilst repairing the failed device.

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Example

Consider a cooling system for a process:

The pumps can be operated as a duty/standby pair.

Should the pressure fall or the temperature go high then the standby pump can be automatically started.

The effective MTTR for the system is the expected time to detect a failure and for the standby pump to get up to speed, a fraction of the real MTTR, or perhaps even zero.

Pump B

Pump A

Cooling water

ProcessPS

Non return valves

TS

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Standby and redundant systems

We may think that the availability of such 1oo2 systems where the switchover time is negligible might be 100%, but this is not correct, since whilst one pump is failed, the redundancy is no longer provided. There is still a chance that the second device might fail.

It is important that the system designer understands how to analyse the system availability when standby or redundant solutions are considered.

Component 1Availability, A1

Component 2Availability, A2

Redundant solutions effectively have availability of the two redundant paths in parallel so that the system can function even when one path fails.

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Common Cause Failures 

Even when we have what appears to be a fully redundant system, there will always be certain failures that will cause both redundant routes to fail at the same time.

Examples of such common cause failures include:• Power supply failure, blackout, brownout etc.• Common source interference, lightning strikes etc.• Mechanical failure, drive shaft fracture, jamming etc.• Process failure, pipe burst, blockages etc.

Redundant device

Redundant device

Common cause failure

In terms of the reliability model, any common cause failure is effectively in series with the redundant paths, bypassing the redundancy.

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Multiple Master/Controller Systems

Multiple PROFIBUS masters or PROFINET controllers with automatic duty‐standby switching are available from a number of suppliers.

These can drive different networks to provide redundancy down to the field level. However, separate power supply and network cable routing are advisable to minimise common‐cause failures.

Sometimes dual slaves can be used in the field with a simple “wired‐OR” voting system driving the final actuator or connecting two redundant sensors.

However, more often we find such redundant controllers are using the same field devices and actuators.

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Redundancy solutions for PROFIBUS

Solutions for redundant PROFIBUS cabling are available from many manufacturers:

Siemens Y‐LinkPROCENTEC ProfiHubs

ABB Redundancy Link Module

Moor‐Hawke Redundancy for PA

COMbricks modules

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Slave with integrated redundancy

YSlave 4

Slave3A

Slave3B

Mechanically combined outputs

Redundant slaves

Wired OR outputs

Slave2A

Slave2B

Y

Redundant masters

Master B

Y

Redundancy solutions for PROFIBUS

Properly designed redundant solutions can provide robustness against a wide selection of faults and conditions.

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Master A

Redundant cables

PSU A

PSU B

Redundant power supplies

YSlave1

Redundant links or hubs

Y

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PROFINET system layout

PROFINET systems can be laid out in a number of ways:

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Star and tree topologies using switches:

Line topology using two‐port devices:

Or a combination of both.

Switches

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PROFINET system layout

There is a clear advantage of the star topology in terms of system availability in that any device can be replaced without affecting the other devices.

However, the system cost will be significantly greater because of the number of switches required.

The line topology is much lower cost, because separate switches are not required.

But removal or replacement of any device will cause all downstream devices to fail.

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PROFINET and Redundancy

One of the big advantages of PROFINET is that it incorporates a specification for media redundancy.

The standardised Media Redundancy Protocol (MRP) provides manufacturer independent redundancy which can be used over copper or fibre cables.

PROFINET redundancy can provide:• Controller redundancy.• Transmission media and switch redundancy.• IO device redundancy.

Redundant PROFINET systems are relatively easy to implementand can be used across different manufacturers.

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PROFINET redundancy solutions30

Standardised Media Redundancy Protocol (MRP) can be used on PROFINET systems to give media redundancy.

IO Controller with MRP

IO Devices with MRP

Switch with MRP

IO Device without MRP

But the system must still be properly designed, considering all possible failures and their likelihood. Common cause failures must be properly dealt with.

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Other ways to improve availability

The careful design of networked systems can improve their availability.In particular by organising the system so that selected parts of the system can be independently shut down for maintenance without affecting the remaining production.A simple example of this is seen with streamed production. 

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A stream can be taken out of service without affecting the other stream.But only if the system design allows this. 

Process 1 Process 2 Process 3Stream A

Process 1 Process 2 Process 3Stream B

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Automation Islands or Units

The concept of dividing the plant into Automation Islands or Automation Units is well established.

Each automation unit is considered as being functionally separated from the rest of the plant so allowing it to operate (and to be shut down) independently.

A good network design will facilitate the isolation of these automation units using:

• Different controllers;• Different networks or subnetworks;• Segmentation.

Careful choice of various architectures for automation units is a key stage in the design process which can impact on the overall reliability and maintainability of the control system.

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Who needs training and why?

People who are involved with network installation

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Commissioning and maintenance personnela) Need to know the wiring/layout rules and 

reasons for them.

b) Need to know how to use diagnostic tools to identify faults and locate problems.

c) Need to be able to health check systems and verify network quality.

a) Need to know the wiring/layout rules and reasons for them.

b) Need to be able to make up and test cables, connectors and devices.

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Who needs training and why?

System designers and people involved in the specification, procurement and management of a control system project

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Device developers and designersa) Need to know the wiring/layout rules 

and reasons for them.b) Need to understand the protocol and 

profiles and what these offer.

a) Need to know the wiring/layout rules and reasons for them.

b) Need to understand the impact of design decisions on the reliability and availability of the plant.

c) Must be familiar with drawing and documentation standards.

d) Need to understand the whole life cycle costs involved in a project.

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PI Certified training

PI Certified training currently incorporates the following internationally accredited courses:

• Certified PROFIBUS Installer course (1‐day)• Certified PROFIBUS Engineer course (3½‐days)• Certified PROFINET Installer course (1‐day)• Certified PROFINET Engineer course (3½‐day)

The Certified Installer is widely accepted as the minimum standard for anyone involved at a technical level with PROFIBUS or PROFINET.

The Engineer course provides in‐depth treatment of the protocol and profiles. Useful for developers and for more difficult problems.

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Certified System Design courses

This year we started to run certified PROFIBUS System design courses in the UK. These courses are currently accredited within the UK by the UK PROFIBUS Group.The objectives and learning outcomes for these courses have been developed by an international team of experienced trainers and consultants over a period of three years.The UK water industry in particular has been asking for this certified designer training so that they can ensure that sub‐contract design is carried out by suitably trained staff.The courses have been run by VTC and will soon also be available from MMU.The course has been accepted in principle by PI and it is expected that international accreditation will be approved within a few months.Certified PROFINET system design courses are also planned.

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