Integracion SI Segunda Parte Cont.

Integracion de Sistemas
Industriales
Module 12
HART
Integracion de Sistemas Industriales

Juan R. Pimentel Page 1
Segunda Parte: Redes Industriales
HART

HART
Characteristics, FSK
An Industry standard for
digitally enhanced 4-20 mA
smart instrument
communication.
 It provides a backward
compatible solution for
smart instrument
communication as both 4-
20 mA analog and digital
communication signals are
transmitted simultaneously
on the same wiring
 Uses a modulation
technique called FSK:
frequency shift keying
HART
 The HART protocol makes
use of the Bell 202
Frequency Shift Keying
(FSK) standard to
superimpose digital
communication signals at a
low level on top of the 4-20
mA.
 Since the digital FSK signal
is phase continuous, it does
not interfere with the 4-20
mA signal.
 A logical .1. is represented
by a frequency of 1200 Hz
 A logical .0. is represented
by afrequency of 2200 Hz
HART
 HART is principally a
master/slave protocol
 a slave device speaks only
when spoken to by a master.
 Two masters (primary and
secondary) can communicate
 with slave devices in a HART
network.
 Secondary masters, such as
handheld communicators, can
be connected almost
anywhere on the network and
communicate with field
devices without disturbing
communication with the
primary master.
 A primary master is typically a
DCS or a PLC.
HART
 HART can be used in
various modes.
 Digital master/slave
communication
simultaneous with the 4-20
mA analog signal is the
most common.
 This mode, depicted in the
Figure, allows digital
information from the slave
device to be updated twice
per second in the master.
 The 4-20 mA analog signal
is continuous and can still
carry the primary variable
for control.
HART
Commands
Three command classes are
defined: The parameters include:
 Universal commands offer a
basic set of functions and are  Device identification: Device
supported by all HART tag, supplier, device type
instruments  Calibration data: Upper and
 Common practice commands
offer functions which are lower range values, upper and
optional, but whichare lower sensor limits, process
supported by many HART value damping
instruments  Process variables: Primary
 Manufacturer-specific
commands are for proprietary variable plus secondary
functions not covered by the measurements and multi-
HART specification, e.g. variable parameters
linearization, advanced
diagnosis functions, etc.

HART
Commands

HART
Cabling and Configuration

HART
Cabling and Configuration

HART
Cabling and Configurations
 Device Descriptions (DDs):
Describe the parameter set
carried by the device to the
HART master.
 Device configuration tools use
either DD or FDT
 Electronic Device Description
(EDDs)
 Successors of DDs and used
in:
 Asset Management Solution
(AMS)
 Process Device Manager
(PDM)
 375 Field Communicator
 Other DD supported
applications

HART
Cabling and Configurations
Field Device Tool (FDT)
 Provides protocol-independent
operation of digital field
devices.
 It maps all device functions,
including advanced
diagnostics.
 The information is contained in
a Device Type Manager
(DTM), a software module that
runs in a FDT frame
application, e.g.:
 FieldCare
 ABB Composer, Control
Builder,
 Fieldbus builder etc.
 Other FDT frame apps

Industriales
Module 13
WirelessHART

WirelessHART
HART Communication Foundation
 Founded in 1993 – International, not-for-profit organization
 Supported by 200+ global companies – all the majors, plus many with
unique products
 Exist for benefit of industry – provide worldwide support for application of
the HART technology
 Manage and Control the HART technology and standards
 Full time staff with technical/support specialists in 3 offices – USA,
Europe, China, others in future
 Test programs, tools and registration services to confirm compliance of
product implementations
 Training workshops, trade show exhibits, website, newsletter and other
programs to educate industry on HART Communication
 Develop new technology and enhancements to support industry needs

WirelessHART
HART Communication Foundation
 Leading communication technology for smart process
measurement and modulating control devices
 Global standard used in process applications around the
world
 An international standard – IEC 61158
 Large international support and installed base
 Traditional use has been with hand-held tools to set-up,
configure and troubleshoot smart devices
 New DCS systems use HART for continuous monitoring
and integration of advanced diagnostic and multi-
variable capabilities of smart devices
 Wireless is a new enhancement to the HART
technology with the HART 7 specifications
WirelessHART
 HART smart devices have valuable data for
DCS
improving plant operation
PAM
 HART devices are real-time data servers with CMMS
H
two simultaneous communication channels ERP A
R
 4-20mA Analog Channel - reliable, robust, T
instantaneous transfer of PV control signal Control DA

T
 HART Digital Channel - real-time device A
status, diagnostics, multi-variable process I/O

H
information A
R
T
 New DCS systems use both HART D

A
communication channels to access device T

A
information and validate integrity of the 4-20mA HART

loop current Field Devices

WirelessHART
 Initiative launched by HCF in November 2004

 Objective – Establish a wireless communication standard
for process applications
 WirelessHART
 An open and interoperable standard
 As easy as using wired HART
 Enable wireless access to existing HART devices
 Use the same configuration, maintenance, diagnostic
tools and procedures
 Require little additional training
 WirelessHART – designed by the best minds in the
industry to address the critical demands of industrial
process plant applications
WirelessHART
Connection to existing devices
Wireless Access to
HART Device
Information
Easy Access to
Intelligent Device Information
Enabled by
Wireless Adapter
Device Status, Diagnostics,

Configuration and more

WirelessHART
Connection to existing devices
Wireless Access to
Additional Process
Measurements
Wireless Gateway
Connection to Plant Systems
Minimal Installation
Cost - No Wires
Battery, Solar or Field

Powered Devices

WirelessHART
Enhancement to HART
 New Specifications 2500
2007
 SPEC-065 Physical Layer
 SPEC-075 Data-Link Layer

2000
2001
 SPEC-085 Network Management
Number of Pages
1500
 SPEC-155 Wireless Commands
 SPEC-290 Wireless Devices 1000
 Enhanced Universal Commands 1990
 Time Stamps, 16 Bit Manufacturer 500
IDs
0
 27 New Common Practice Commands HART 5 HART 6 HART 7
 Enhanced Burst Mode, Automatic

Event Notifications
 WirelessHART User Manual
WirelessHART
Multicompany Development
 Technology Development Process Specification Team
 Started with Proposal – Nov 2004
 Call for member participation Wireless Working Group
 Formed Technical Working Group

Membership
 Started with:
 Use Cases
 Requirements
 User Needs & Backward Compatibility
 WG decided key concepts – many meetings + diligent effort,
consensus
 Specifications written by small dedicated team of high knowledge
experts
 More than 25 companies involved in the development
Major contributions from ABB, Dust, Emerson, Honeywell, Siemens
plus Endress+Hauser, MACTek, Omnex, Pepperl+Fuchs, Yokogawa
and others
 Draft Specifications Reviewed at multiple Meetings
WirelessHART
Self-organizing & self-healing

WirelessHART
Self-organizing & self-healing
 Reliable - Messages routed around interference,
obstacles
 Simple - Same wireless capabilities for all field
devices
 Flexible - User chooses topology, speed, application
 Preserves the HART User Experience – Same tools
and practices as wired HART
 HART Command structure - Compatible with HART-
enabled control systems and EDDL
 Robust Security - Uses industry-standard AES-128
ciphers & keys
 IEEE802.15.4 Radio at 2.4GHz - Frequency hopping
for reliability and coexistence
WirelessHART
Devices
 Total Solution
 Wireless Field Devices
 WirelessHART Adapters
 Gateway / Access Points
 Network Manager
 Wireless Handhelds
 WirelessHART >>
HART + Wireless
 DD-enabled Application
Access to all Capabilities
 Smart Data Publishing
and other enhancements
WirelessHART
Robust Security
Denial of Service
Attacks
Trusted Node
Access
128Bit Key Codes Communication

DCS Critical Analysis
Measurements
Wired
Encrypted
Communication
Encrypted Messages
Individual
Session
Key Spoofin
g

WirelessHART
Adapter
 Wireless Access to
Request - Response
Any HART Device Smart Data Publishing
Notification by Exception
Transparent Message Routing
 Specified Requirements
 Support Multi-dropped HART Devices
 Automatically Route Messages

Wireless to Wired and back
Poll devices Block
as needed Transfers  Publish Measurement and Control Data
for attached HART devices Request -
Response
 Well specified set of commands
HART PID
TT206 Device  Gateway supports Adapter commands
Family VF206
 Acts as HART Master and Slave AT204
 Like a special Remote I/O

WirelessHART + Enhanced DDL
Makes Wireless Easy
Example DD of Dialog
to Monitor Device as it
Tracks Mode As Device joins Network
joins the Network
Uses WirelessHART
Command 769
Track Progress Tracks Progress of

and Milestones as Join Requests
Device Joins
Lights Up
Bottom to Top Tracks Progress as
Device listens for a
Network to Join
Troubleshooting a device that fails to join the

Network can be one of the most frustrating
wireless experiences
WirelessHART+DDL = Easy
Deploying and Commissioning
WirelessHART Devices
Gateway
System
Set network ID In the Shop

Set network password Enter Join password
Set security level Enter Network ID
define join process Update rate
define network and session security Configure as needed

Gateway
Initiate Join
Request
System

Gateway
System

Point to Point Topology
Gateway
System
The Network Manager provides new schedule and routing information to

all devices as new devices join the network

Point to Point Topology Mesh Topology
Gateway
System
The Network Manager provides new schedule

and routing information to all devices as new
devices join the network

Applications Enhanced by
WirelessHART
 NEW connection to HART device information
• Multivariable process data,
• Device status,
• Diagnostics and
• Configuration data
 Target Applications
• Asset management
• Environmental monitoring
• Energy management
• Regulatory compliance
New Tools for Users to Lower Costs and Stay Competitive!

WirelessHART Benchmarked
Against Real World Examples
Example –
Citric Acid
Bio-reactor

Citric Acid Bio-Reactor
Monitoring & Control Requirements
Category Tag Update Rate Measurement Comments
Measurement FT201 1 sec Feed Flow
FT202 1 sec Air Flow
FT203 1 sec Reagent Flow
AT204 8 sec pH
AT205 8 sec Dissolved Oxyg en
TT206 2 sec Return Water Temperature HART 5 Temperature Transmitter
TT207 8 sec Reactor Temperature
PT208 2 sec Reactor Gas Pressure
IT209 8 sec Agitator Amps
LT210 32 sec Reactor Level Gage + Level Switch
TT211 1 min Agitator Bearing Temperature
VT212 1 min Agitator Vibration Monitor Daily Vi bration Spectra (30kBytes)
TT213 8 sec Harvest Pump Bearing Temperature
VT214 32 Sec Harvest Pump Vibration Monitor
Regulating Valve FV201 1 sec Feed Flow
FV202 1 sec Air flow
FV203 1 sec Reagent flow
FV206 2 sec Coolant Flow HART 5 Positioner
FV208 2 sec Vent Flow
Blocking Valve FZ211 1 sec Charge Flow Solenoid Va lve with Feedback
FZ212 1 sec Harvest Flow
FZ213 1 sec Harvest Flow
Motors 1 sec Agitator
1 sec Harvest Pump
Other WA206 WirelessHART Adapter Access to TT206, FV2 06

Citric Acid Bio-reactor
Physical Plant Layout / Arrangement
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32
60 m
33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 8m
49 50 51 52 53 54 55 56
57 58 59 60 61 62 63 64
2m
60 m

Monitoring: Fast and Slow
Slow
Fast

Control (If Desired)

Commissioning, Calibration,
Configuration

Diagnostics - Basic &
Advanced
Vibration Spectra
Radar Signal
Valve Signatures

Support for Existing HART
Devices

Example Validates Many Use
Cases

Integración de Sistemas
Industriales
Module 14
Profibus PA

Profibus PA
Profibus Modular System

Profibus PA
Physical Layer
 Transfer rate: 31.25 kbps
 Transmission technology: Half-duplex, synchronous, self-
clocking, with Manchester bi-phase L encoding
 CRC (cyclic redundancy check)
 Data security: Preamble, failsafe start-end delimiters
 Cable: Shielded, twisted pair line (type A or type B)
 Topology: Line and tree topology with termination; combined
topology possible
 Number of stations: Up to 32 stations per segment
 Ignition protection: Several methodologies and
 technologies

Profibus PA
Data Link Layer
 It uses the PROFIBUS DP (Decentralized Periphery) communication
profile which defines the rules governing communication.
 DP is based on the so-called master/slave concept
 A master (active communication peer) polls the associated slaves
(passive communication peers) cyclically.
 When polled, a slave will react by sending a response frame to the
 polling master.
 A request frame contains the output data, e.g., set-point speed of a
drive
 The associated response frame contains the input data, e.g., the
latest measured value from a sensor.
 In one bus cycle, the master polls, e.g., exchanges I/O data with, all
associated slaves.
 This polling cycle is repeated as fast as possible (Cyclic comm.)
Profibus PA
Data Link Layer

Profibus PA
Data Link Layer

Profibus PA
Data Link Layer
 In addition to cyclic communications, parameter data, e.g., device
settings, can also be transmitted.
 This action is initiated by the master (typically under user program
control) between I/O cycles to read and/or write slave parameter data.
This type of communication

is referred to as acyclic
communication.

Profibus PA
Higher Layer Protocols (HLP)
 HLP for Profibus PA is based on block models shown below.

Industriales
Module 15
Profinet

Profinet
 An Ethernet standard for industrial automation.

 PROFINET facilitates vertical and horizontal communication from the field
level to the corporate management level
 It significantly simplifies the link between production processes and
systems for production planning and control, e.g., enterprise resource
planning (ERP).
 PROFINET uses globally established standard IT services and offers
scalable real time communication for all applications in the automation
sector.
 Both real-time and TCP/IP-based communications can ru concurrently
on the same cable.
 The technical integration of process data into the IT infrastructure of
the company is thus much easier than is the case with fieldbus
solutions.

Profinet
Profinet System

Profinet
Protocol Stack
 Each PROFInet device is
modeled as a standardized
collection of COM objects.
 Some of these objects exist
only during runtime.
 Thus all communication for
engineering, runtime and
diagnostics is based on the
DCOM middleware on top
of TCP/IP and Ethernet.
 For real time data an
additional Soft Real Time
(SRT) stack has been
defined as shown in the
Fig.
54
Profinet
Profibus Integration
 PROFInet defines mechanism to integrate PROFIBUS subsystems
via Proxies
 Transparent communication with PROFIBUS devices via PROFInet.
55
Integración de Sistemas
Industriales
Module 16
Introduction to the Fieldbus Foundation

Introduction to FF
FF Organization
 International non-profit organization promoting an open and interoperable
fieldbus solution
 Worldwide support by manufacturers and users
 Foundation owns underlying intellectual property
 No single company controls the technology
 Technology enables interoperable products and systems;
 eliminates proprietary protocols
 Technology enables innovation by manufacturers
 Technology provides freedom for users to choose products regardless of
manufacturer
 Technology designed to meet the information needs of all segments of
the automation industry

Introduction to FF
FF Market Data
 Today >340 Global Members & Corporate
 Affiliates,
 >600 Registered Devices, 13 Hosts
 6,000+ fieldbus control systems installed or on
 order around the world
 1,000,000+ FOUNDATION™ fieldbus devices in service world
wide
The adoption of FOUNDATION Fieldbus has

skyrocketed over the past several years. ARC
estimates that the total market for fieldbus products
and services is rapidly approaching a billion dollars
Introduction to FF
FF Device Registration Trend

Introduction to FF
FF Devices

Introduction to FF
FF Market Profile

Introduction to FF
Room for Improvement
Benchmark Results Indicate Room for Improvement
 20-40% of control loops in manual control
 80% of control loops demonstrate excessive process variability
 Many potential Advanced Process Control (APC) benefits are

being missed
 Unplanned downtime is the largest single source of lost revenue
 86% of maintenance is reactive (too late) or preventive
 (unnecessary)
 Best practice is 40% with predictive/proactive
 Most Petrochemical companies are not making returns greater
than their cost of capital

Introduction to FF

Introduction to FF
Classical Automation

Introduction to FF
Foundation Fieldbus

Introduction to FF
Foundation Fieldbus Features

Introduction to FF
Sensors, Transmitters, Controllers
 FF integrates many types of
devices.
 Primarily:
 Sensors
 Transmitters
 Controllers
 The figure shows a
configuration called
―Control in the Field‖ (CIF)

Introduction to FF
Control in the Field: CIF
 Many Foundation Fieldbus installations worldwide
 Control in the Field (CIF) technology exists within FF, where
control functions execute in Field devices
 CIF can provide many potential benefits over control in the DCS
 Potential improvements:
 DCS Controls within FF scheme
 Understand what kind of processes would benefit
 Identify potential industrial applications

Introduction to FF
Control in the Field: CIF

Introduction to FF
CIF Benefits
 Improved Control Loop
Performance
 Increased reliability and
availability
 Improved loop integrity
 Reduced loading on DCS
/ PLC and network
 Lower capital and
installation costs
 Reduced Operating costs

Introduction to FF
Control Performance Benefits
Improvements due to:
 Faster sample times
 Shorter latency (delays) in the read-

execute-write cycle
 Guaranteed determinism
For control in the DCS, sample time

and latency are typically longer
 Also, DCS and FF segment updates
can be asynchronous leading to
longer and variable latencies
 Delays in a control loop limit the
performance …. but how much ?

Introduction to FF
CIF: Latencies and Sample Rates
For CIF, latency and sample rate are
determined by:
 How many loops are being controlled
 Where the control is executed

(sensor, H1 card, actuator)
 The number of scheduled data
transfers (depends on where
executed), and the need to maintain <
50% loading for these
 The speed of the FF devices
 The complexity of the control logic
These define the “macrocycle” – the

update rate for the FF segment

Introduction to FF
CIF: Latencies and Sample Rates
A fast, but realistic, single loop
control loop is considered where
 the PID is executed in the actuator
 Rosemount 8800D Flowmeter : AI

execution – 20msec
 Data transfer AI to PID – 30msec
 Fisher Valve Positioner DVC6000F: PID

 Fisher Valve Positioner DVC6000F: AO
This fits in a typically supported fast
macrocycle of 150msec
 Sample rate = 150msec, latency =
105msec (“Case 1: CIF”)

Introduction to FF
Vendors: Partial List
 ABB - Industrial IT
 Emerson Process Management - DeltaV
 Foxboro - FoxCAE
 Honeywell - PlantScape
 Honeywell - Experion-PKS
 Rockwell - Process Logix
 Smar - System 302
 Yamatake - Industrial-DEO
 Yokogawa - CENTUM
 Yokogawa - STARDOM

Introduction to FF
Ve
 ABB - Industrial IT
 Emerson Process Management - DeltaV
 Foxboro - FoxCAE
 Honeywell - PlantScape
 Honeywell - Experion-PKS
 Rockwell - Process Logix
 Smar - System 302
 Yamatake - Industrial-DEO
 Yokogawa - CENTUM
 Yokogawa - STARDOM

Application Example
Condensate Recovery System
 The recovery system receives the
steam condensate and returns
this condensate into the water
treatment system.
 The process consists of two
tanks: a flash tank (85 gallons)
and a condensate tank (20
gallons).
 The returning condensate flows
into the flash tank, where
lowering of pressure may cause
the condensate to flash to steam.
 The liquid condensate flows
down into the condensate tank
from which it is pumped forward
into the boiler feedwater system.
76
Application Example
Instrumentation & Control
Instrumentation:
 level on each tank and across
both tanks
 pressure on the flash tank
 flow on the boiler feedwater
system
 total pump flow
 recycle flow
Control valves were equipped with
digital positioners which were
used to control the boiler
feedwater treatment and recycle
flow.
The instruments were connected to
one of two fieldbuses connected
to a DCS located in the utilities
control room.
Application Example
 The wire runs, from fieldbus
devices to the terminal panel,
averaged 28 meters of new
wire for each device.
 Two 185 meters of existing
wire runs were used from
each of the terminal panels to
the control room.
 Reduction of interface cards
(by 50%), equipment cabinet
space (caused by a reduction
of I/O interfaces).
 Elimination of termination
panels
 This resulted in a 46%
reduction in equipment costs.
Application Example
 The total condensate level is
controlled by selecting a
preferred setpoint on the level
PID, LIC-101, which is located in
the level transmitter.
 The level PID is used as the
primary loo cascaded to the flow
PID, FIC-103, located in the
valve on the feedwater system.
 The control strategy for this
cascade loop is totally
implemented in the transmitters
and flow valve as shown in the
Figure.

Industriales
Module 17
Foundation Fieldbus

Comparison
Profibus PA and FF

Virtual Communication
Relationship (VCR) Types

Publisher/Subscriber Model
 The Publisher/Subscriber VCR Type is used for buffered, one-to-
many communications.
 Buffered means that only the latest version of the data is maintained
within the network.
 New data completely overwrites previous data.
 When a device receives the Compel Data (CD), the device will
―Publish‖ or broadcast its message to all devices on the fieldbus.
 Devices that wish to receive the Published message are called
―Subscribers.‖
 The CD may be scheduled in the LAS, or it may be sent by
Subscribers on an unscheduled basis
 The Publisher/Subscriber VCR Type is used by the field devices for
cyclic, scheduled, publishing of User Application function block input
and outputs such as Process Variable (PV)

Foundation Fieldbus
Physical Layer
 The Physical Layer is defined by
approved standards from the
International Electrotechnical
Commission (IEC) and ISA (the
international society for
measurement and control).
 The Physical Layer receives
messages from the
communication stack and converts
the messages into physical signals
on the fieldbus transmission
medium and vice-versa.

Foundation Fieldbus
Physical Layer
 It is defined by approved
standards from the International
Electrotechnical Commission
(IEC) and ISA (the international
society for measurement and
control).
 It receives messages from the
communication stack and converts
the messages into physical
signals on the transmission
medium and vice-versa.
 Conversion tasks include adding
and removing preambles, start
delimiters, and end delimiters

Foundation Fieldbus
Physical Layer: Signaling
 Signals are encoded using the
well-known Manchester Biphase-L
technique.
 The signal is called ―synchronous
serial‖ because the clock
information is embedded in the
serial data stream.
 Data is combined with the clock
signal to create a signal as shown
in the figure.
 The receiver of the fieldbus signal
interprets a positive transition in
the middle of a bit time as a logical
―0‖ and a negative transition as a
logical ―1‖

Foundation Fieldbus
 Special characters are defined for
the preamble, start delimiter, and
end delimiter.
 The preamble is used by the
receiver to synchronize its internal
clock with the incoming fieldbus
signal.
 Special N+ and N- codes are in
the start delimiter and end
delimiter. Note that the N+ and N-
signals do not transition in the
middle of a bit time.
 The receiver uses the start
delimiter to find the beginning of a
fieldbus message.
Foundation Fieldbus
 The transmitting device delivers
±10 mA at 31.25 kbit/s into a 50
ohm equivalent load to create a
1.0 volt peak-to-peak voltage
modulated on top of the direct
current (DC) supply voltage.
 The DC supply voltage can range
from 9 to 32 volts.
 However, for Intrinsically Safe
(I.S.) applications, the allowed
power supply voltage depends on
the barrier rating (See Figure).

Foundation Fieldbus
Physical Layer: Wiring
 The transmitting device
delivers ±10 mA at 31.25 kbit/s
into a 50 ohm equivalent load
to create a 1.0 volt peak-to-
peak voltage modulated on top
of the direct current (DC)
supply voltage.
 The DC supply voltage can
range from 9 to 32 volts.
 However, for Intrinsically Safe
(I.S.) applications, the allowed
power supply voltage depends
on the barrier rating (See
Figure). Integracion de Sistemas Industriales
Foundation Fieldbus
Physical Layer: Features

Foundation Fieldbus
Frame Structure: H1
 FMS: Fieldbus Message
Specification
 FAS: Fieldbus Access
Sublayer
 DLL: Data Link Layer
 PHY: Physical Layer

Foundation Fieldbus
Frame Structure: FMS
 FMS services allow user
applications to send messages to
each other across the bus using a
standard set of message formats.
 FMS describes the communication
services, message formats, and
protocol behavior needed to build
messages for the User
Application.
 Data that is communicated over
the fieldbus is described by an
―object description.‖
 Object descriptions are collected
together in a structure called an
―Object Dictionary‖ (OD),
Foundation Fieldbus
Frame Structure: FAS
 The FAS uses the scheduled and unscheduled features of the Data
Link Layer to provide a service
 for the Fieldbus Message Specification (FMS).
 The types of FAS services are described by Virtual Communication
Relationships (VCR).
 Client/Server VCR Type: The Client/Server VCR Type is used for
queued, unscheduled, user initiated, one to one, communication
between devices on the fieldbus.
 Report Distribution VCR Type: The Report Distribution VCR Type is
used for queued, unscheduled, user initiated, and one-tomany
 communications.
 Publisher/Subscriber VCR Type: The Publisher/Subscriber VCR
Type is used for buffered, one-to-many communications.

Foundation Fieldbus
Frame Structure: DLL
 The DLL controls the transmission of messages onto the fieldbus.
 The DLL manages access to the fieldbus through a deterministic
centralized bus scheduler called the Link Active Scheduler (LAS).
 The DLL is a subset of the approved IEC standard
 Two types of devices are defined in the DLL specification:
 Basic Device
 Link Master
 Link Master devices are capable of becoming the LAS.
 Basic Devices do not have the capability to become the LAS

Foundation Fieldbus
Link Active Scheduler: LAS
 The Link Active Scheduler (LAS) has a list of transmit times for
all data buffers in all devices that need to be cyclically
transmitted.
 When it is time for a device to send a buffer, the LAS issues a
Compel Data (CD) message to the device.
 Upon receipt of the CD, the device broadcasts or ―publishes‖ the
data in the buffer to all devices on the fieldbus. Any device
configured to receive the data is called a ―subscriber‖.
 Scheduled data transfers are typically used for the regular, cyclic
transfer of control loop data between devices on the fieldbus.

Foundation Fieldbus

Unscheduled Communication
 All of the devices on the
fieldbus are given a
chance to send
―unscheduled‖
messages between
transmissions of
scheduled messages.
 The LAS grants
permission to a device
to use the fieldbus by
issuing a pass token
(PT) message to the
device.
Scheduler Operation
 The CD Schedule contains a list
of activities that are scheduled
to occur on a cyclic basis.
 At precisely the scheduled time,
the LAS sends a Compel Data
(CD) message to a specific data
 buffer in a fieldbus device.
 The device immediately
broadcasts or ―publishes‖ a
message to all devices.
 This is the highest priority
activity performed by the LAS.
 The remaining operations are
performed between scheduled
transfers.

Scheduler Operation
 The list of all devices that are
properly responding to the Pass
Token (PT) is called the ―Live List.‖
 New devices may be added at any
time.
 The LAS periodically sends Probe
Node (PN) messages to the
addresses not in the Live List.
 If a device is present at the address
and receives the PN, it immediately
returns a Probe Response (PR)
message.
 If the device answers with a PR,
the LAS adds the device to the Live
List.
 The LAS periodically broadcasts a
Time Distribution (TD) message on
the fieldbus so that all devices have
exactly the same data link time.
Foundation Fieldbus
I/O Blocks, Slot Time
 The LAS schedules the transmission of buffers (I/O blocks) at specific
transmit times.
 The list of transmit times for all data buffers in all devices are also
called ―slot times‖.

Function Blocks
 The Fieldbus Foundation has defined
a standard User Application Layer
based on ―Blocks.‖
 Blocks are representations of
different types of application
Functions
 Devices are configured using
Resource Blocks and Transducer
Blocks.
 The control strategy is built using
Function Blocks.
 The Resource Block describes
characteristics of the fieldbus device
such as the device name,
manufacturer, and serial number.
 There is only one Resource Block in
a device.

Function Blocks (FB)
Standard Blocks
 FB provide the control system
behavior.
 The input and output parameters of
FBs can be linked over the fieldbus.
 The execution of each Function Block
is precisely scheduled.
 There can be many function blocks in
a single User Application.
 The Fieldbus Foundation has defined
sets of standard Function Blocks.
 Ten standard Function Blocks for
basic control are defined by the FF-
891 Function Block Application
Process – Part 2 specification (See
Fig.)
 Additional Standard FBs are
specified in Parts 3 and 4 of the same
specification FF-891.
Function Blocks (FB)
Standard Blocks
 FBs can be built into fieldbus devices as needed to achieve the desired
device functionality.
 For example, a simple temperature transmitter may contain an AI FB. A
control valve might contain a PID FB as well as the expected AO block.
 Thus, a complete control loop can be built using only a simple
transmitter and a control valve

Flexible Function Blocks (FFB)
 A flexible Function Block (FFB) is a user defined block.
 The FFB allows a manufacturer or user to define block parameters and
algorithms to suit an application that interoperates with standard
function blocks and host systems

Device Descriptions (DDs)
 A device is supplied with three
device support files:
 Two Device Description Files and
one Capability File.
 To achieve interoperability, Device
Description (DD) technology is
used in addition to standard
function block parameter and
behavior definitions.
 DDs are platform and operating
system independent.
 The DD provides an extended
description of each object in the
Virtual Field Device (VFD) as
shown in the Figure
 DDs are similar to ―device drivers‖

 The DD is written in a
standardized programming
language known as Device
Description Language (DDL).
 A PC-based tool called the
―Tokenizer‖ converts DD source
input files into DD output files by
replacing key words and standard
strings in the source file with fixed
―tokens‖.
 FF provides DDs for all standard
Resource, Function and
Transducer Blocks.
 Device suppliers build a DD by
importing the Standard DDs.
 Suppliers may also add supplier
specific features such as
calibration an diagnostic
procedures to their devices.
 On the host side, library functions
called Device Description Services
(DDS) are used to read the device
descriptions.
 Note that DDS reads descriptions,
not operational values.
 The operational values are read
from the fieldbus device over the
fieldbus using FMS
communication services.
 New devices are added to the
fieldbus by simply connecting the
device to the fieldbus wire and
providing the control system or
host with the DD for the new
device (See Fig.)

 The Fieldbus Foundation has
defined a hierarchy of Device
Descriptions (DD) to make it
easier to build devices and
perform system configuration.
 The FF has written the Device
Descriptions for the first three
layers of the hierarchy.
 These are the standard Fieldbus
Foundation DDs.
 The fourth level of the hierarchy is
called Manufacturer Specific
Parameters.
 At this level, each manufacturer is
free to add additional parameters
to the FB Parameters and
Transducer Block Parameters.

Industriales
Module 18
FF Transmitters

FF Transmitters
 FF Transmitters is another designation of Transducers
 In this section we consider in more detail ―Transducer Blocks‖ because
they are important for configuration
 Transducer Blocks decouple Function Blocks from the local input/output
functions required to read sensors and command output hardware.
 They contain information such as calibration date and sensor type.
Supporting Objects
 Link Objects define the links between FB inputs and outputs internal to
the device and across the fieldbus network.
 Trend Objects allow local trending of FB parameters for access by
hosts or other devices.
 Alert Objects allow reporting of alarms and events on the fieldbus.
 Multi-Variable Container (MVC) Object serves to―encapsulate‖ multiple
FB parameters
 View Objects are predefined groupings of block parameter sets that can
be displayed by the human/machine interface

FF Transmitters
Transducer Blocks

FF Transmitters
View Objects

FF Transmitters
Transducer Blocks
 Device description for FF transmitters are found in the
manufacturers manuals of the devices
 These manuals are available online in the
manufacturers websites
 As a class exercise, we will take a look at
representatives FF transmitters in the following
categories:
 Pressure
 Temperature
 Level
 Flow
Industriales
Module 19
FF Devices

FF Devices
 The characteristics and specifications of FF devices

are in the vendor manuals that will be examined
online.
 The Configuration, Installation, and Commissioning

Troubleshooting, Operation and Maintenance of FF
devices will be done using:
 Device manufacturer Manuals (available online)

 FF Design Tool: DesignMATE
 Vendor host tools: DeltaV Online

Industriales
Module 20
Foundation Fieldbus Blocks

 There are many FF blocks

 The most important blocks
are associated with a
control loop shown in the
Figure
 The FF blocks have:
 Input and output parameters
 Signal processing structures
 Equations

 Input blocks.
 Analog input block (Al)
 Discrete input block (Dl)
 Control blocks
 PID, PI, I controller block (PID)
 Calculation blocks
 Signal characterizer clock (SC)
 Input selector (IS)
 Integrator or Totalizer (IT)
 Arithmetic (AR)
 Output blocks:
 Analog output block (AC)
 Discrete output block (DO)
 Block parameters

Supporting Objects

Common Block Parameters
 STAT_REV: indicates the revision level of the block’s static
parameters and may be used in configuration management.
 TAG_DESC: provides a description of the block which may
be used in a human interface or in block documentation to
clarify the block application.
 STRATEGY and ALERT KEY: may be used by a
configuration device or human interface to sort blocks and
alerts.
 MODE_BLK: determines the block operating mode and
available modes for a block instance
 BLOCK_ERR: indicates the error status of hardware and
software components associated with the block

Common Block Parameters
The MODE_BLK parameter controls the operational mode of the
block. It comprises four attributes with the following functions.
 Target mode: Indicates what mode of operation is desired for the
block. It is normally set by a control application or by an operator.
 Actual mode: Under certain operating conditions a block may not
be able to function in the requested mode. In such cases. In such
cases, the actual mode attribute reflects the mode of operation it is
able to achieve.
 Permitted mode: The allowed target mode values for an instance
of a block are defined by the permitted mode attribute of the mode
parameter.
 Normal mode: To help an operator select the normal mode of
operation from those available, a normal mode attribute is
provided. This may be used by a human interface application to
help guide the operator in setting the operation mode of a block.
Block Modes
 Out of service (OOS): In this mode. the execution of the block is
disabled. The output is maintained at last value or, in the case of
output blocks, the output value may be maintained at an assigned
fault state value.
 Initialization manual (IMAN): In this mode, the block output is set
in response to the back-calculation input parameter status
(BKCAL_lN). When the status indicates there is no path to the final
output element, the control blocks must initialize to provide for
bumpless transfer when the condition clears. A back-calculation
out (BKCAL_OUT) parameter is supported by all output and
control class function clocks.
 Local override (LO): the block output is set to track the value of the
track input parameter (TRK_VAL).
 Manual (MAN): In this mode, the block output is not calculated
although it may be limited. It is directly set by the operator.
Block Modes
 Automatic (AUTO: This is the normal operating mode of the block. For
control blocks a local setpoint value SP is used by the normal block
algorithm in determining the primary output value. The local setpoint
value may be written by an operator.
 Cascade (CAS): In this mode, a setpoint value supplied by another
function block through the cascade input carameter (CAS_lN) is used by
the normal block algorithm to determine the primary output value.
 Remote cascade (RCAS): In this mode, the block setpoint is set by a
control application running on an interface device through the remote
cascade in parameter (RCAS_IN).
 Remote output (ROUT): In this mode, the block output is set by a control
application running on an interface device through the remote-output in
parameter (ROUT_IN). A remote-output out parameter (ROUT_OUT) is
maintained by the block to support initialization of the control application
when the block mode is not remote-output.

Information Flow
 In the case of a sensor reading or other control output moving through
the control loop from the sensor to the actuator the information is
conveyed on a forward path.
 In the case of an actuator or PID function cascade setpoint, a backward
path carries the information about constrained movement back to the
function block that is requesting the movement

Analog Input (AI) Block
 The AI block conditions the signal
output by the transducer block and
outputs a signal to other output
block.
 PARAMETERS
 Channel: The number of the
hardware channel of the
transducer that is connected to
the AI block.
 Out: The primary analog value
calculated as a result of
executing the function
 Direct Equation:
PV = Input Value

Analog Output (AO) Block
 The AO block processes a
setpoint value received from
an upstream FB or higher
level control system.
 PARAMETERS
 Transducer Channel: The
number of the hardware
channel of the transducer
that is connected to the AO
block.
 Out: The primary analog
value calculated as a result
of executing the function
Discrete Input (DI) Block
 The DI bock takes the
manufacturers discrete
input data, selected by
channel number and makes
it availabIe to other FBs at
its output.
 PARAMETERS
the DI block.

Discrete Output (DO) Block
 The DO bock processes a
discrete pointset value
received from an upstream
FB with which various
instrument functions can be
initiated in the downstream
FB.
 PARAMETERS
the DI block.

PID Control Block
The PID FB provides proportional, integral and derivative control of the
process.

PID Control Block

SGCR Block
 The Signal Characterizer
(SGCR) function block
approximates any function that
defines an input/output
relationship.
 The function is defined by
configuring as many as twenty
X,Y coordinates.
 The block interpolates an
output value for a given input.
 The function is defined by
configuring as many as twenty
X,Y coordinates.
 The block interpolates an
output value for a given input
value using the curve defined
by the configured coordinates
Application Example

Application Example

Industriales
Module 21
Other Fieldbus Issues

Design Issues: Safety
 Safety is related to the degree of reliance on a system to avoid
loss of resources, injury, or loss of loss of life.
 Safety is different than reliability
 Safety and reliability involve failures and faults
 Safety is a multidisciplinary field that involves:
 Corporate governance
 Safety policies
 Process control systems
 Fieldbus systems
 Safety instrumented systems (SIS)
 Process alarms and operator intervention
 Mechanical protection: relief valves, pressure safety valves (PSV),
etc.
 International Standards: IEC 61508/61511, ANSI/ISA-84, ISA18.2

Safety: Leveld of Protection

Safety: Implementation Options

Redundancy, Reliability, Fault
Tolerance
 Reliability: The assurance that a system continued to operate
without faults.
 Redundancy is the main mechanisms to improve reliability.
 Redundancy enables Fault Tolerance: the capability of a system
to continue to operate in the presence of faults.
 HSE Fault Tolerance
 Use COTS hardware and software.
 Provide redundant communication paths; redundant paths must be
transparent to Applications.
 Provide for redundant devices; devices connect to all network types.
 Test connectivity through all ports; devices make independent
decisions about which port to use.
 Devices share knowledge of network status.

Tolerance

Tolerance

Tolerance

Tolerance

Tolerance

Tolerance: MTTF, MTBF
 MTTF: Mean time to failure
 MTBF: Mean time between failures
 MTTF and MTBT are measures of reliability
 MTTF and MTBT are calculated using probability techniques using
failure rates for components
 There are many techniques to calculate MTTF and MTBF
 One of the most effective techniques is using “fault trees”
 A fault tree is a physical depiction of all the possible faults in a
system categorized by sub-systems and components
 A recent study made by the Fieldbus Foundation concluded that the
reliability of an FF design is significantly better than an equivalent
analog system with a MTTF of 48.2 years versus MTTF of 15.9
years.

MTTF, MTBF: Analog Fault Tree

MTTF, MTBF: FF Fault Tree

FF Intrinsically Safe Concept:
FISCO
 FISCO:(Fieldbus Intrinsically Safe COncept)
intrinsically safe bus limited power
 The FISCO concept has been developed to provide a
means of supplying additional power to the
network/segment while still keeping the energy level
below that which could cause an explosion
 Due to the limited DC power to be shared by a number
of field devices, long cable runs and terminators
storing capacitive energy, the traditional intrinsic safety
installation and interconnection rules restrict the
application of Intrinsically Safe (I.S.) systems.
FISCO
 The key advantages of FISCO, compared with systems installed
according to the conventional FF-816 ―Entity‖ concept, are:
 Higher bus current, allowing more field devices per segment
 Elimination of cable parameter calculations
 Simplification of the safety documentation—just a list of devices
 Addition of new devices without reviewing the safety case
 In each IS segment, only one active device—normally the associated
apparatus (power supply)—is allowed to provide the necessary power
for the bus.
 All other equipment connected to the bus cable has to be passive,
meaning that except for a leakage current of 50 μA for each connected
device, the apparatus is not allowed to provide energy to the system.
 Power supplies, terminators, cable and field instruments for use in
FISCO systems must comply with the requirements of next Table

FISCO Parameters

FISCO Parameters

Cost Considerations
 Cost savings in design and engineering
 CAPEX: capital expenditure
 reduced wiring
 reduced control room space
 reduced engineering and documentation
 easier configuration
 faster commissioning
 ................
 Cost savings in operation and maintenance
 OPEX: operational expenditure
 increased process data
 reliable digital transmission technology
 flexible and easy expansions
 reduced down time (availability)
 improved diagnostics and maintenance

Cost Considerations:
Comparison Example

Comparison Example

Comparison Example

Comparison Example
 Cost benefit over the investment lifecycle a typical plant, which
modern technology has reduced to something like ten years.
 In this case, the fault-tolerant system yields the following
savings:
 CAPEX saving ($218,700 minus $198,170, or $20,530) which
generates $33,441 at, say, 5% for ten years.
 Therefore, selecting a fault tolerant system generates:
 CAPEX Return: $33,441 (savings in capital expense)
 OPEX Return: $400,000 (savings in spurious trips)
 Total: $433,441 (“free” additional income over ten years)

Industriales
Industrial Networks Summary

Workshop Summary
This workshop covered the following:
 Fundamentals of data communications and fieldbuses
 We focused on the Foundation Fieldbus (FF)
 We provided an overview of the FF technology
 Configuration, Installation, Commissioning, Troubleshooting,

Operation and Maintenance of FF devices and systems are best
done using:
 Device manufacturer Manuals (available online)
 FF Design Tool: DesignMATE
 Vendor host tools: DeltaV Online
 FF Manuals
 Other vendor manuals

Industriales
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 SPEC-290 Wireless Devices 1000

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