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Understanding Fieldbus
User Benefits
H1 H1
H2
Fieldbus I/O
Improves Maintenance
H1 H1 H1
Daisy-Chain
Tree
December 1995:
Chocolate Bayou Field Trial
Understanding Fieldbus
INTRODUCTION
One of the most anticipated changes in the process control industry has been the introduction of fieldbus. Ten years in development, fieldbus has been long awaited by many process control industry users. In March 1996, the Fieldbus Foundation will release the low-speed (H1) fieldbus technology. With this release, a fully functional fieldbus will be defined. The Fieldbus Foundation was formed from the merger of ISPF and WorldFIP North America in October, 1994, and has since grown to over 100 companies. Rosemount Inc. was one of the founding members of ISPF, and is now a sponsoring member of the Fieldbus Foundation. FOUNDATION fieldbus is a digital, two-way communication link among intelligent field-level and control devices that will replace the 420 mA standard. Fieldbus is both open and interoperable, and it is an enabling technology that allows migration of control functions to field devices. FOUNDATION fieldbus has also tackled the tougher issuesintrinsic safety, hazardous areas, volatile process, and tough regulatory environments. FOUNDATION fieldbus was developed using ISA and IEC standards, and has been specifically designed to provide solutions to meet requirements of the toughest automation environments. No other digital protocol has met these stringent needs. Once FOUNDATION fieldbus is introduced, process engineers will not only have a new way to communicate, but will have a whole new way to control the process. Using fieldbus, end users will reduce installation and maintenance costs, and will develop new ways to improve plant performance, plant safety, and plant availability.
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Fieldbus Architecture
Fieldbus is more than just a new signal communications protocol, but a whole new way to control the process. With the release of the low-speed fieldbus (H1), the entire fieldbus structure will be defined. Most of the recent published literature has focused on the intricate details of the fieldbus architecture, especially those layers that have not been released. However, except for the physical layer and user layer, these layers are essentially transparent to plant engineers and managers. A good analogy is to compare binary code to Microsoft Windows a computer operator does not need to understand machine code language to use computer software. It will be the same for fieldbusinstrument manufacturers and host manufacturers need to understand these layers, but end users will not need to know they exist.
Multivariable Transmitter Workstation Maintenance Information System
System Management
User Layer
Application Layer
Network Management
Physical Layer
Valve
Level Transmitter
Pump
This expanded view will aid in maintenance because the status of the instruments will be available, and will speed troubleshooting and debugging since operators will have better information. Fieldbus will also enable on-line diagnostics, easier calibration, and predictive maintenance. This expanded view will also lead to audit trail benefits. As regulatory agencies require more detailed management and documentation of critical processes, fieldbus will provide an easier way to access the required data.
Improved Performance
With the migration of control away from the DCS and out to the individual control loops, system integrity and reliability increase because of faster and more accurate local control. Fieldbus also takes advantage of new devices that combine several sensors into one device, since several pieces of information can flow over one set of wires. As fieldbus expands the ease of information collected from the field, plant operators and managers will be able to have tighter control and improved performance over their process. This will lead to improvements in plant performance, and will increase process availability and improve process consistency.
Stack
Understanding Fieldbus
Data Highway
Bridge H2 - H1
H1 H1
H2
Fieldbus I/O
Junction Box
H1 H1 H1
Point-to-Point
NOTE Terminators and power supplies not shown.
Daisy-Chain
Tree
fieldbus-0001
IMPACT ON INSTALLATIONS
Fieldbus has been designed to take advantage of current industry standard wiring practices. This allows end users to use existing plant wiring for fieldbus upgrades, thereby maximizing funds already spent. This also allows plant engineers to design plant upgrades, segment by segment and device-by-device, to fieldbus technology. In fact, fieldbus technology accommodates current system components and devices (see Table 1), and will also accommodate future product innovations.
Fieldbus Wiring
Table 2 identifies fieldbus wiring capacity as identified in the ISA S50.021992 Physical Layer Subcommittee standard. Table 3 identifies cable types, cable sizes, and maximum cable run lengths. Fieldbus greatly expands the topology options for wiring devices. Where traditional wiring is limited, fieldbus includes point-to-point, bus with spurs, daisy-chain, and tree (see Figures 1 and 2).
Figure 3 illustrates fieldbus device capacity, and Figure 4 illustrates an H1 bus with spurs wiring diagram on a fieldbus segment. Just because one fieldbus segment can hold 32 devices does not mean the plant designer would actually connect 32 devices on a single segment. Because of security considerations, it would be unusual for a segment to exceed twelve devices.
TABLE 2. Fieldbus Wiring Capacity per ISA S50.021992 Physical Layer Subcommittee and IEC 1158-2:1993.
H1 (Low-Speed Bus) 31.25 kilobits per second (k/bs)
Devices (not bus-powered) Bus-Powered Devices Bus-Powered Intrinsically Save Devices Response Time Range (Typical Response Time) (3) 232 213 (practical limit = 13) 26 (1) 32 msec 2.2 msec (1 msec)
(1)
(1) Practical limit determined by security considerations and device power requirements. (2) Power requirements for H2 devices normally limit bus-powered connections at H2 speeds. (3) Actual response time depends on wire length, topology implementation, and message size.
TABLE 3. Fieldbus Cable Types per ISA S50.021992 Physical Layer Subcommittee and IEC 1158-2:1993.
Cable Types Type A, Shielded, Twisted-Pair Type B, Multi-twisted-pair, (a) with shield Type C, Multi-twisted-pair, (a) without shield Type D, Multi-conductor (a)
Size
18 AWG 22 AWG 26 AWG 16 AWG
Size
22 AWG
Size
22 AWG
(a) Types B, C, and D cables are typical guidelines, based on installed cable.
fieldbus-0002
Understanding Fieldbus
Data Highway
H2 H2 Bridge H2 - H1 H1 32 Devices H1
NOTE Terminators and power supplies not shown. fieldbus-0003
32 Devices
H1 H1 H1 H1
32 Devices
FIGURE 3. Fieldbus Device Capacity.
Bus
100 1 F 100 1 F
Terminator
+
Terminator
INTEROPERABILITY
One of the improvements with fieldbus is device interoperability. Interoperability allows mixing devices from different manufacturers on the same fieldbus, and allows replacing a defective device with a device from a different vendor. Interoperability is provided by two major components: Function Blocks and Device Descriptions.
Function Blocks
A key interoperability component is standardized function blocks. Function Blocks provides common structure for defining inputs, outputs, control algorithms, events, alarms, and block control diagrams. Since function blocks are common for similar class devices, they allow one manufacturers device to be replaced with a different manufacturers device. The common function block definition ensures system integrity. Function blocks also allow timing and synchronization of control strategies so that system schedules can be built. The use of standardized function blocks permits information to be accessed by the control system in a consistent manner, regardless of device manufacturer.
Vendor E Honeywell
LT-101 PT
Vendor A Foxboro
LT-104
Flash Tank
TT Rosemount TT-102
LT
Rosemount LT-103 LT
Steam
Cond Pump
LIC
Vendor Valtek C
CV-204
Vendor B FT Yokogawa
To Condensate Stack
FT-206
FIC
FT
FIC
Vendor D Smar
TT-208 TT
FT FT
fieldbus-0005
Vendor D Smar
To D1 To D1 andD2 & D2
Understanding Fieldbus
TABLE 4. Available Process Automation Function Blocks (partial list).
Initial Function Blocks
Analog Input Digital Input Manual Loader Bias/Gain Selector PD Control PID Control Ratio Analog Output Discrete Output
Alarm Subsystem
Inputs
Vendor Algorithms
Outputs
Event Subsystem
fieldbus-0006
Even with standardized function blocks, vendors can design their own vendor algorithms (Figure 6). Thus, the vendor can develop advanced functionality, without sacrificing fieldbus interoperability. Function blocks also allow migration of functionality, especially the migration of control strategies to field devices. Figure 7 shows a flow transmitter, valve, PID control, and the fieldbus connections between devices. In this example, the control strategies have migrated to the field, allowing the DCS to perform other tasks. Table 4 identifies process automation function blocks that will be available when H1 technology is released, and also identifies some of the function blocks that will be available in the near future. Additional manufacturing automation function blocks will also be released shortly thereafter.
H1
H1
PID 110
FC
A1 110
FT
AO 110
fieldbus-0007
FLOW
FIGURE 7. Function Block Implementation ExampleDistributed PID Control.
SS
Stack Supplier (SS) develops and tests stack Pass ? Third Party Test Agent (TT) tests stack for FF conformance Yes
TT
FF
Pass ? Yes
FOUNDATION
DS
Device Supplier (DS) 1. Purchases Conformance Stack rights 2. Adds Function Blocks and other features 3. Installs stack, function blocks, and other features into device output board
FF DS
Device Supplier (DS) 1. Creates DD (Device Description) 2. Tests device for Interoperability 3. Registers device with FF (optional) 4. Registers DD with FF (optional) 5. Submits interoperability test to FF
Fieldbus Foundation will periodically: - Distribute DDs (Device Descriptions) - Distribute DD Services Interpreter (allows host to interpret DDs) - Publish catalog identifying FF Stacks and FF Devices
Understanding Fieldbus
PATH TO FIELDBUS
Fieldbus will provide an explosion of data not previously available. Working with this data will provide solutions for problems faced by plant engineers and managers. In fact, this level of data will soon be required for many critical processes, and some agencies already require non-control information. For example, regulatory compliance agencies (OSHA, EPA, the Clean Air Act) mandate time-intensive maintenance documentation. ISO compliance, predictive maintenance, and process validation are other areas that will require extensive documentation and information.
Control Data
Field Data
Value Added Application Software ValveLink, Cornerstone, and ProLink are three Fisher-Rosemount software application packages. These packages provide calibration and maintenance tools, advanced diagnostics, predictive maintenance applications, and regulatory compliance tools. With these packages, plant engineers can get a head start on the coming fieldbus information explosion, and can obtain improvements in regulatory compliance, process availability, and process consistency. Enabling Communications Technology Cost effective communications allow information to flow to and from the field devices. Currently, the HART protocol is the defacto standard for process industries, and our FMS solution is available now using HART. Both the FMS/HART architecture and fieldbus are designed to collect control and non-control information from field devices. And the FMS/HART solution can easily migrate to fieldbus when the technology is released without loss of the initial investment in HART equipment (see Figure 10).
10
Because Rosemount Inc. designs forward and backwards compatibility into all our transmitters, your instrumentation investment is protected. The transmitters you buy today can be upgraded to future technology. And with our long leadership position in fieldbus development, we will introduce fieldbus upgrades the most secure and risk free.
Transition to Fieldbus
Most plant engineers are not likely to upgrade an entire plant to fieldbus, but are more likely to install fieldbus on one segment, test the application out, and make some process improvements. All this while the traditional 420 mA sections operate normally. After the initial test is over, plant engineers are then likely to design new sections of an existing plant with fieldbus devices, or design new plants entirely using fieldbus. In fact, the true benefits of fieldbus will be maximized with new installations. It is not likely that existing plants will be retrofitted to fieldbus, especially early on. It is more likely that existing plants will continue to use HART devices for MRO (Maintenance and Repair Orders) business, in order to maximize the start-up, engineering, and installation funds already invested. When a major plant expansion or upgrade is required, the FMS applications will be able to support both HART and fieldbus devices in the same environment, ensuring that the investments you make today are secure long into the future.
Control Data
Field Data
Bridge
H1 Lower Speed Fieldbus
11
Rosemount and the Rosemount logotype are registered trademarks of Rosemount Inc. Multivariable and MV are trademarks of Rosemount Inc. ValveLink, Cornerstone, and ProLink are trademarks of Fisher-Rosemount Systems Inc. FOUNDATION and the FOUNDATION logo are trademarks of the Fieldbus Foundation. HART is a registered trademark of the HART Communications Foundation. Microsoft and Windows are registered trademarks of Microsoft Corp.
Cover graphic: fieldbus-0001.
ED
PR