Fieldbus Foundation's open, integrated architecture for information integration

1. Fieldbus Foundation's open, integrated architecture for information integration Jonas Berge SMAR See Speaker Notes

2. “web” Ethernet Ethernet “web” OPC FF Ethernet FF Fieldbus Second Generation Fieldbus System Business (ERP) Level 4 Business Network Execution (MES) Historian Level 3 Information Network Control (PAS) OPC Data Servers Level 2 Control Network Linking Devices Instruments Level 1 Device Network Process Level 0 ISA-95

3. Fieldbus (H1) • Device Level • Transmitters and analyzers • Valve positioners • Logic I/O • Unique Features • Bus power • Intrinsically safe • Long distance • 2-wire • Multidrop • Control in the field

4. Ethernet (HSE) • Backbone of second generation FF systems • Takes the place of RS485 and coax solutions • For higher level devices • Linking device • Controller • Gateway • Remote I/O • Unique features • High speed • “DCS style” redundancy • FOUNDATION application layer • FOUNDATION function block diagram programming language • FF throughout the system

5. Interoperability • Standard backbone • Eliminates many gateways • Interoperability for controllers etc. Does for us what H1 did, but at a higher level.

6. Gateways Operator consoles Linking devices Flow computers Controllers Device servers Barcode readers Single station loop controllers Paperless recorders Local operator panels Annunciators Ticket printers Weighing scales PLCs Remote-I/O (primarily high density discrete) Tank gauging systems Burner management systems Compressor controls Turbine controls Corrosion monitoring Emergency Shut Down (ESD) system integration Fire & gas system integration Chromatographs Generator set controls Leak detection Paper web scanner Vibration monitoring Pipe wall thickness monitoring Where will Foundation on Ethernet be Used? Some are already available

7. Software Process visualization Configuration tools OPC servers Bus analyzers Network management Tightly integrated online instrument asset management Networking Accessories Switches Routers Wireless access points Industrial cables and connectors Where Else Will HSE Solutions Be Seen?

8. Relation to OPC • Software-to-Software • OPC Foundation • OPC server for HSE exists • Permits non-HSE applications to access data • Read/Write (DA) • Capture (A&E) • Link (DX) • Software gateway to other systems

9. Relation to Web Technologies • HTML/XML on HTTP/SOAP used in MES & ERP • Firewall friendly • Suitable for simple parameterization

10. HSE Benefits and Savings

11. Ethernet Benefits • High speed • 10 Mbit/s, 100 Mbit/s, faster • Handles more information than other media • Well understood • Plenty of books • Lots of experienced technicians • Many media options • Copper • Optical fiber • Short-range wireless • Long-range wireless • ADSL connectivity • Dial-up connectivity • Multi-protocol • HSE • Others There are more Ethernet technicians in Austin than there are Fieldbus technicians world wide.

12. Open IP and Ethernet SCADA Architecture Central Control Room Host Computers Ethernet Radio FF H1 Instruments FF HSE Device & Ethernet Radio

13. HSE Fieldbus: Interoperable Ethernet • Ethernet and TCP/IP is not sufficient for interoperability • Most Ethernet solutions are proprietary • HSE is the standard application layer and user application • Interoperability at the controller level • Integration of package units

14. Technician’s nightmare:System Integration Technician’s dream:Integrated System Ethernet Integrated System vs. System Integration • Single tool • Single interface • Single wire rules • Homogenous • Distributed No EDDL No FDT/DTM Proprietary on Ethernet and IP HSE Fieldbus P S C P U F H 1 A S i H RT D N M O D P D P Linking Device Profibus-DP H1 Fieldbus AS-i Modbus H1 Fieldbus DeviceNet Flow Comp. Flow Comp. RIO VSD VSD VSD VSD HART

15. ¥ ₪ ₧ £ ₣ ₫ € ¢ ₤ Reduced capital expenditure (CAPEX) • Lower cost of purchase • Cheaper parts • Less spare capacity • Engineering savings • Faster device and strategy selection • Less documentation • Easy to integrate with enterprise • Easy to integrate subsystems • Construction savings • Less installation works • Faster commissioning • More possibilities • Lower cost of expansion and change • Scalability • Easy to modify • Protected investment

16. ¥ ₪ ₧ £ ₣ ₫ € ¢ ₤ Lower Cost of Purchase • Cheaper parts • Standard communications equipment • Multiple HSE sources • Less spare capacity • Plug-in expansion makes installed spares unnecessary

17. ¥ ₪ ₧ £ ₣ ₫ € ¢ ₤ Engineering Savings • Faster device and strategy selection • Homogenous programming environment • No data mapping • Less documentation • Homogenous naming convention • No cross-reference lists • Easy to integrate with enterprise • Standard Ethernet and IP • No proprietary gateways • Easy to integrate subsystems • Standard Ethernet connection • Ideally HSE to eliminate data mapping

18. ¥ ₪ ₧ £ ₣ ₫ € ¢ ₤ Construction Savings • Less installation works • Easier than coax • Lots of competing subcontractors • Faster commissioning • Well known tool and tricks: PING, sniffer • HSE network status table • More possibilities • Available and affordable optical fiber solutions • Ever more innovative products • Radio instead of leased lines • VPN over the public Internet

19. ¥ ₪ ₧ £ ₣ ₫ € ¢ ₤ Lower Cost of Expansion and Change • Scalability • Plug-in expansion • No need to break or stop network • Easy to modify • Plug-in expansion • No need to break or stop network • Single technology to worry about • Less complex dependencies than for mixed protocols • Does not hinder improvements • Protected investment • Ethernet constantly developing • Retains compatibility with installed base

20. ¥ ₪ ₧ £ ₣ ₫ € ¢ ₤ Reduced operational expenditure (OPEX) • Operation savings • Less process downtime • Information access • Less training • Maintenance savings • Market based replacement part and maintenance prices • Single technology to support

21. ¥ ₪ ₧ £ ₣ ₫ € ¢ ₤ Operations Savings • Information access • All plant areas integrated • Automated data collection • Intra-area control • Set higher level control goals • Less training • Many already trained • Standard IT training available • Expect HSE courses to become available • Less process downtime • Industrial grade equipment • Topologies designed for greater availability • Complete device and network redundancy

22. Workstation Workstation Workstation Switch Linking Device Linking Device Linking Device Star Topology • One device per wire reduces extent of shutdowns

23. Switch Switch Switch Ring Topology • Even less process disruption

24. Workstations with Dual NIC Primary switch Secondary switch Redundant dual port Linking device Redundant single port Linking device Single dual port Linking device Complete Redundancy • Availability unmatched by other open Ethernet solutions

25. ¥ ₪ ₧ £ ₣ ₫ € ¢ ₤ Maintenance savings • Market based replacement part and maintenance prices • Multiple source for networking hardware • Multiple sources for HSE devices • Single technology to support • Minimize media confusion of multiple bus technologies

26. System integration or integrated system

27. Standardize • Don’t make new investments in diverse technologies • Standardize on one technology • Use “foreign” buses only to connect with installed base • To enable users to have a single bus in their plant... • ...Manufacturers will have to support many options for bus for their products • Some HSE device types may not appear until manufacturers understand users are serious about it. • May need to a corporate position/strategy paper

28. Tower of Babel • In most systems you can mix buses • Mixed buses are hard to maintain • Media • Topologies • configuration tools and methodology • Tools • Gateways/interface cards • Cost may outweigh benefits

29. Diminishing Returns • Adding another bus may not be worthwhile • Additional buses primarily support cyclic I/O • Don’t support e.g. EDDL or FDT/DTM for Profibus parameterization • Rely on third-party tools or proprietary pages

30. Mix • Weak link • Loss of integration • Don’t support status propagation • Different data types and object structure FOUNDATION HSE Linking Device Controller Gateway Device V S D V S D V S D

31. Conclusion • Core HSE products exist • H1, HSE, and OPC are complementing each other, not competing • Minimize other buses • Get involved • Interoperability demos • HSE installation guidelines: grounding etc. • HSE VLAN practices • OPC profile • System level value files

32. Where Can I Learn More? • Title: " Fieldbuses for process control: Engineering, Operation and Maintenance" • Author: Jonas Berge • Publisher: The Instrumentation, Systems and Automation Society (ISA) • ISBN 1-55617-760-7 • Context: • Introduction • Benefits & Doubts • Installation & Commissioning • Configuration • Integration & Migration • Troubleshooting • Operation • Design & Engineering • Maintenance • Availability & Safety • How Fieldbus Works