Yokogawa Update on Fieldbus Offering
Transcript of Yokogawa Update on Fieldbus Offering
Yokogawa Electric Corporation
Copyright © Yokogawa Electric CorporationYokogawa User Group 2003
Yokogawa Fieldbus Update
2003-08-25
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Today’s Items
Introduction of FieldbusInteroperabilityIntrinsic SafetyFieldbus Products by YokogawaFieldbus Systems by Yokogawa Plant Asset Management for the 21st CenturyJOB Information
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Fieldbus
P
T
L
F
Process
DCS
Control & Monitoring
A Fieldbus is a digital, two way, multi-drop communication system for instruments and other plant automation equipment
Definition:
What is Fieldbus ?
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IEC 10 protocols
IECPROFIBUS (PA & DP)P-NetWorldFIPFOUNDATION fieldbus High Speed EthernetControlNetInterbus SSwiftNetFOUNDATION fieldbus H1ProfiNet
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H1 ... Low Speed• 31.25 kbps• 2 - 32 Devices• Two-wired• I.S. capability• 1900 m
(max)
H1 ... Low Speed• 31.25 kbps• 2 - 32 Devices• Two-wired• I.S. capability• 1900 m
(max)
PLCPLC
PLC Analyzer LinkingDevice
Controller
Control System
High Speed Ethernet• 100 Mbps• Redundancy
High Speed Ethernet• 100 Mbps• Redundancy
oooooo
H1 Fieldbus and HSE Fieldbus
SwitchesSwitches
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Expected Benefits From Foundation Fieldbus Technology
Typical Benefits of Foundation Fieldbus:– Necessity of Fewer Devices (Muliti Sensing)– Reduction of Wiring (50 – 70 % Saving)– Interoperability : Integrate Best Products– Reduction of Control Room Space (No Marshalling)– Reduction of Startup Time
– Easy Integration with Resource Management Software– Saving in Maintenance & Calibration (Diagnostics)– Greater Accuracy (Tracability/Fully Digital)– Faster & More Accurate Control
Fieldbus Technology is expected to save more than 9% on overall installation costs and more than 20% on maintenance cost (by ARC Report)
CAPEX
OPEX
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Reduction of Wiring & Control Room Space
Wiring & RackCable CostJunction BoxCable ConduitProcessing of CableMarshallingBarrierProcess I/O Card
ConventionalSystem
Fieldbus System
Cabinet Cable
Case of 350 I/O points
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Cost Saving in Fieldbus System Installation (ARC Report)
Reduction of Installation Cost – Cable and Construction fee– Cost of DCS, Device Instrument, Marshalling Rack etc
Item Conventional Loop Fieldbus Reduce RateInstrument $92,800 $102,800 -10.7%
Wiring & Rack $3,400 $2,200 35.3%Cable cost $8,500 $4,000 52.9%
Junction box $3,000 $3,000 0.0%Cable Conduit $32,500 $32,500 0.0%
Processing of cable $10,300 $4,250 58.7%Marshalling $1,900 $0 100.0%
Barrier $13,700 $3,100 77.4%Total $166,100 $151,850 8.6%
Note) Cost of PJT management and design & engineering are not included.
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Evolution of Maintenance Work From Corrective Maintenance to Preventative Maintenance
Relative Maintenance Cost
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Cost Saving in Maintenance by Plant Asset Management Software (ARC Report)
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Working Worldwide
EuropeAfrica
AsiaOceania
Japan
South America
North America
0500
100015002000250030003500400045005000
1997 1998 1999 2000 2001 2002 2003
Fieldbus System Installation Trend
Fieldbus Installations Are Growing ! – Over 200,000 Fieldbus Devices Shipped – Over 4,000 Fieldbus Systems Shipped
FF Report, as of 30 June 2002
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Today’s Items
Introduction of Fieldbus
InteroperabilityIntrinsic SafetyFieldbus Products by YokogawaFieldbus Systems by Yokogawa Plant Asset Management for the 21st CenturyJOB Information
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What Is Interoperability?
Interoperability DefinitionInteroperability Is The Capability For A Device From One Manufacturer To Interact With That Of Another Manufacturer On A Fieldbus Network Without Loss Of Functionality.In Other Words Interoperability Ensures That Users Can Select Devices From Various Suppliers To Build An Integrated Fieldbus System With Full Functionality.
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How To Achieve Interoperability?
Interoperability Test(IT) For DevicesTo Verify Interoperability Of Fieldbus Devices, FF Requires Testing As Per The Interoperability Test Kit (ITK). The Latest Version Is ITK4.51 Devices are registered to FF.
Host Interoperability Support Test(HIST)After Device Interoperability, Users Requested FF To Do Something Similar For The Hosts. FF Issued A Guideline named HIST To Test The Interoperability Between Host And Devices.The Host Systems Providing The Test Procedure Conforming To The Guideline Are Acknowledged By FF. There Is No “Certificate” Or “Tick Mark” For Host Systems.
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n Yokogawa transmitters, the First unit to be FF- Registered in the world in 1998. uDifferential Pressure Transmitter EJAuVortex Flow Meter YEWFLO*E
n FF-Registered Yokogawa devicesuValve Positioner
n Yokogawa System (CENTUM) Acknowledged as HIST ready 1st
upH and Conductivity AnalyzeruMagnetic Flow Meter ADMAG AEuTemperature Transmitter YTAuDAQ Station, etc.
Yokogawa Equipment #1 in the Interoperability
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Device(EJA) on WEB site
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HIST Exhibit of CENTUM
CT0003FFTest Camp. Number
FF-IF-PCAT-H1 v1.20Revision
Softing GmbHManufacturer
Stack
21pskvc+22+23+24Comm. Profile Class
N/ASerial No
R3.10Revision
SSSSM01-C1 FOUNDATION
fieldbus toolType
CENTUM CS/CS1000/CS3000Modeln
Yokogawa Electric Corporation
Manufacturer
Host System Under Test
For more information, contact host vendor
YesDD Menu
YesCapability Files
YesDD Method Execution
YesDevice Description Services
YesFunction Block Linkage Configuration
YesCustom Blocks
YesEnhanced Blocks
YesStandard Blocks
YesBlock Tag Configuration
YesConfiguration of Link Master Devices
YesDevice Address Assignment
YesDevice Tag Assignment
YesAlert
YesAlert Configuration
Host Feature Supported
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Today’s Items
Introduction of FieldbusInteroperability
Intrinsic SafetyFieldbus Products by YokogawaFieldbus Systems by Yokogawa Plant Asset Management for the 21st CenturyJOB Information
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Efforts in Hazardous Area Installation
Intrinsic Safety– Entity model
• Assumes cable as the lump capacitance and inductance• Thus calculate it as energy source to accelerate ignition• Sufficient for a 4-20mA device• 4 devices per segment
– FISCO model• Assume cable as distributed impedance• Thus calculate it as blocking factor of energy transfer• Enlarges energy allowance in hazardous area• Required in multi-drop Fieldbus systems• 6 devices per segment
– Barrior with Repeater• Multiplies number of device per logical H1 segment
Non-incendive– Enp– Ene
Distributed barrior– Power limitting element in Junction Box
Exd
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What is FISCO?
Fieldbus Intrinsically Safe Concept– FISCO was proposed by PTB
Entity model– Assumes cable as the lump capacitance and inductance– Thus calculate it as energy source to accelerate ignition– Sufficient for a 4-20mA device
FISCO model– Assume cable as distributed impedance– Thus calculate it as blocking factor of energy transfer– Enlarges energy allowance in hazardous area– Required in multi-drop Fieldbus systems
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Fieldbus System Configuration(Example)
CS3000 R3HIS
V-NET
ALF111
Field Control Station
Dual-Redundant
ValvePositioner
PressureTransmitter
Terminal
TemperatureTransmitter
Terminator
FISCO ModelIS Barrier (Max.100mA)
SegmentNo.3
TerminalTerminator
Terminator
Terminal
AEF9D
4PortsSegmentNo.2
SegmentNo.1
SegmentNo.4
Max.1000m
Max.30m
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Today’s Items
Introduction of FieldbusInteroperabilityIntrinsic Safety
Fieldbus Products by YokogawaFieldbus Systems by Yokogawa Plant Asset Management for the 21st CenturyJOB Information
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Field Devices from Yokogawa
LINKMASTERAIx1, PIDx1YEWFLOStyle EVortex flowmeter
LINKMASTERAIx8, MAIx1, MAOx1DAQSTATIONPaperless recorder
BASICAIx3EXA SC202/ISC202Conductivity transmitter
BASICAIx3EXA PH202pH transmitter
LINKMASTERAOx1, DIx2, PIDx1, OSx1YVP110Positioner
LINKMASTERAIx1, PIDx1ADMAG AEMagnetic flowmeter
LINKMASTERAIx2, PIDx1,DIx2Digital YEWFLOVortex flowmeter
LINKMASTERAIx4, DIx4, PIDx2YTA SeriesTemperature transmitter
LINKMASTERAIx2, PIDx1EJA SeriesPressure,d/ptransmitter
Device classFunction blockModel
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Market Leaders Yokogawa and Dresser Equipment Group Announced Customer-Focused Alliance for Fieldbus-Integrated Solutions in October 4th, 1999.
Alliance for Fieldbus Integrated Solutions
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Valve Maintenance Package - ValveNavi with YVP
Main Panel
Setpoint
Actual Position
Mode ofeach block
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ValveNavi with YVP (2)
Trend Display
Calibration
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YVP Valve Diagnostics with ValveNavi
Signature DiagnosticsBasic Diagnostics
l Valve maintenance data management
ü Cycle ü Travel distanceü Total open time ü Total close timeü Total NEAR-CLOSE time
l Valve characteristic data measuring for auto-tuning and self-check
ü Valve Gainü Valve Hysteresisü Valve Slip width Etc.
l Standard Actuator Signaturel Extended Actuator Signaturel High Resolution Actuator Signaturel Step Response Testl Positioner Signature
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Standard Actuator Signature
– Mesure basic valve characteristics.Measure by 10 % from 10 to 90 % of full strock, to back and forth.
– Measured data : Output Pressure and Position (%)– The result can be stored in non-volatile memory
Change in hysteresis>> Deterioration of gland packing
Change in curve >> Deterioration/Break
of valve spring
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“Multi-Point” Temperature Transmitter with “Local Display”
AI(x8),MAI FOUNDATION fieldbus H1
LAN / WAN
TC, RTD, Volt etc(Universal Input)
Field Instruments
Publishes Measured Data(Up to 12 ch)
Ethernet Interface
(Standard)
DAQSTATION
DAQSTATION submits its measured data to Fieldbus segment using AI function block.
YTA:Temp.Transmitter
Specifications are subject to change
EJA:Pressure YEWFLO
DAQSTATION: The 1st FF recorder in the world
DCS
YVP
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DAQSTATION: The 1st FF recorder in the world
H1 fieldbus segment
Fieldbus ready Field Instruments
Ethernet communications
Analog Inputs
Remote Host orPC via Internet
Small data acquisition (Run-time Master function)Accepts Inputs From Fieldbus Field Instruments andSend Data As A Network Device via Ethernet
MAO
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New Magnetic Flowmeter
Concept
User-Oriented Functionality!Offers you the service that leaves nothing to be desired.
Predictive diagnostics-lowers TCOuReducing process downtime & serviceuSimplifying and optimizing maintenance
Super high performance – global leader in stabilityOffers you more stable & more accurate measurement.Also for the most difficult application!
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Adhesion Diagnosis Function (Patent Pending)
Always Monitoring the fluid impedance and Always Monitoring the fluid impedance and detecting the change caused by the insulating detecting the change caused by the insulating adhesion on Electrodes.adhesion on Electrodes.
ElectrodeElectrode
CommonCommon
Predictive diagnostics
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Predictive diagnostics
Monitoring Adhesion Level on Electrodes!
Level:
0.996m/s
19.938 mA F R
ADH
F R
013
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Predictive diagnostics
Easy replaceable!
No Sweat Work Anymore!
Special Tool Electrode Unit
The Surface can be cleaned.
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Alternative
Alarm mode
Countermeasure message for Alarm
Process Alarm31: Empty Pipe
Fill flow tube with fluid
2 second
2 second
Display mode1.2345 m3/h
12345678FR
FTL
Example : EnglishExample : English
Tell you what you have to do!
Predictive diagnostics
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Today’s Items
Introduction of FieldbusInteroperabilityIntrinsic SafetyFieldbus Products by Yokogawa
Fieldbus Systems by Yokogawa Plant Asset Management for the 21st CenturyJOB Information
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Integration of Fieldbus Technology by Yokogawa
Seamless Evolution In The Same Operation Interface– Same Operability Of Control Function In Field Device– Integration Of Maintenance Data Collection With Control &
Monitoring Operation
Coordination Of Fieldbus And System In Engineering– Smooth Connection (Single Window) Of Function Blocks In
Field Device And That In System
Coexistence Of Various Field Network Technology (4-20mA, Smart, Fieldbus etc.)Redundant Process Interface Cards– FF: ALF111(New FIO)
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Field Network in CS3000 R3
HIS
RIOFIO
H1
HARTProfibusDP
RS485
4-20mA
4-20mA Remote IOH1
H14-20mAHART
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Example of CS 3000 System Configuration
Ethernet
Vnet
H1 fieldbus segment
Terminator
Fieldbus devices
HIS
ALF111 in service
KFCSRFCS2
Legacy field devices
Standby ALF111
World-first dual-redundant fieldbus ports; up to 4 ports
HIS-ENGLFS2610 FOUNDATION Fieldbus Communication Package
Bus power supply
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n Cable LengthuCable Type : Type-A (1900 meters) or Type-B (1200 meters) in IEC’s
Specificationu1000 meters for I.S Application
n Maximum Number of Devices Connected to a Segment u32 Nodes (Including FF Interface Cards and temporary devices) in IEC’s
Specificationsu4 - 6 Devices per Barrier at Hazardous Area in IEC’s Specification.uParallel Usage of Barriers with Repeater Function Available
u16 Devices as a Recommendation by Communication Performance
Minimum Working Voltage at Deviceu Min. 9 volts in IEC’s Specificationu 9.5 volts as a Recommendation
Points of FOUNDATION fieldbus Segment Design
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n Communication Scheduling uCommunication Time Between Any Devicesu30 – 40msec. per one Communication in Average
uPeriodical communication Time: Up To 70 % of Cycle TimeuUp to 16 Periodical (including Scheduled) Communication in 1 second
(Recommended)uNon-periodical communication Time for Parameter Handling and Event
Notification: 30 %
n Limitation of Connected Devices by Current Consumptionu Average : 20mA (EJA 16.7 mA, Fisher/DVC5000f 26.5mA)u Max. 16 Devices / 350mA Power Supply Unit
n Other ConsiderationsuCable Routeu JB Allocation and JB GroupinguTerminal Type Selection
Points of FOUNDATION fieldbus Segment Design
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Engineering Procedure
n Standard Builder Support Fieldbus Configuration
n Shortens the Period for Plant Start up and Plant
Shutdown
uEngineering May be Completed Before Installing Field
Devices at site
uConcurrent Engineering Without Actual Devices
uYokogawa Uses Fieldbus Foundation Standard
Information Formats (Capabilities File)
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Integrated Engineering
3ALF111
FUNCTION_BLOCK
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Multi Schedule
Automatic Scheduling
0 500 1000msec
Control Period 500msec
Control Period 1000msec
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Today’s Items
Introduction of FieldbusInteroperabilityIntrinsic SafetyFieldbus Products by YokogawaFieldbus Systems by Yokogawa
Plant Asset Management for the 21st CenturyJOB Information
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Plant Resource Manager Package - PRM
Provides Total Management of Instruments And Equipment with Direct Device Access Function Through the Interfaces of Hart, FOUNDATION fieldbus, Profibus and Others.Based on Oracle RDBMS.Equipment Management and Maintenance Activity Management
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Merit of PRM
Reduction of Maintenance Work Cost– Status Monitoring and Parameter Tuning from the Central
Control Room– Execution of Device Diagnosis
Improvement of Maintenance Work Using the Maintenance Information in PRM Database.Self Documentation Helps You to Make Maintenance Work Report from Maintenance Record in PRM.Use of Various Plug In Application (PIA) on PRM– Valve Support Package from Valve Manufacturer– Device Viewer Packages
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Device Navigator
(Plant View)
Display sample
Plant ViewAndDevice Details
Network ViewAndParameter
Display
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Device Viewer
Alarm Number
Transducer Status
Hardware Information
Additional Information
Device Diagnostic
Parameter values of Device
Device State
If Self-diagnostic error happened, Status Color Changed
PRM Device Viewer provides•Remote maintenance
•Yokogawa provides open interface for DeviceViewerApplications for 3’rd Party (Device vendor)
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PLUG-INApplication
Maintenance Work Evolution by PRM PIA
PLUG-INApplication
Call
Data
Event
Open interface PIA interface development Kit for 3’rd Party Application
PIAKit
Field InformationDatabase
(PIA History)
PRM integrated PLUG-IN Application provides •Tool base maintenance•Remote Maintenance •Automatic Maintenance
History
Field devices
PRM
PIANavigation
•Device Maintenance Software-Calibration -Inspection-Set up &Tuning etc
•Valve Management Software-ValveNavi-ValVue etc.
<<Example of PIA>>
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ValveNavi as PLUG-IN Application
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Diagnostics of Fieldbus System
PlantDiagnostics
Process orEquipment
Level 4
Actuators, Elementsvalves, Connections
Loop Diagnostics
Level 3
Fisher
DeviceDiagnostics
Level 2
Electronics
CommunicationsDiagnostics
Level 1
CommunicationsDresser Diagnostics
at field level
Diagnosticsat CCR level
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Regional
Device Diagnostics Process/UnitDiagnostics
Device InstallationDiagnostics
Local
Self
n DP/P Transmitter- Impulse line Blocking Diagnostics - Steam tracing Diagnostics
n FF/Pneumatic Converter- Instrument air line clogging
Diagnostics
n Valve Positioner- Signature diagnostics - Valve stick-slip diagnosticsn DP/P Transmitter- Clogging diagnostics- Orifice wearing diagnostics- Diaphram corrosion diagnosticsn Temperature Transmitter- Temp. element diagnostics n Vortex Flowmeter- Clogging diagnostics- Vibration diagnosticsn Magnetic Flowmeter- Adhesion diagnostics- Signal insulation diagnostics
PT
L
F
Diagnostics
L
Yokogawa FF Devices – Advanced Diagnostics Line-Up
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Today’s Items
Introduction of FieldbusInteroperabilityIntrinsic SafetyFieldbus Products by YokogawaFieldbus Systems by Yokogawa Plant Asset Management for the 21st Century
JOB Information
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Trend of Order Intake
0
20
40
60
80
100
120
140
97 98 99 00 01 02
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System Configuration ExampleAromatic Plant (1900 devices, in Engineering Phase)
XXXXXXXXXXXXXXXX
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What can Yokogawa provide ?
Addition to Above Mentioned Products:n Consulting Service Regarding Fieldbus System Designn System Integration Services for Multi Vender Devicesn Engineering Know How for Integration of Brain, Hart, 4-
20mA, FOUNDATION Fieldbus and Profibus-DPn Test Procedures and Field Commissioningn Technical Support for Q & An Training for Operation, Maintenance and Engineering.