Controllers - FieldComm Group Forums for FOUNDATION Fieldbus

V1.04
Foundation Fieldbus Project
Bonny Island, Nigeria - export gas compressor
with Foundation Fieldbus and SMAR
Implemented by:
Arjan Asbreuk
Leo van den Hoorn
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
1
Bonny Island - Compressor skid
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
2
Introduction
• Agenda of presentation
 Introduction: Siemens and Imtech
 Introduction: project ‘Bonny Island’
 System architecture: in 3 parts
 Foundation Fieldbus (part1)
 Control logic (part2)
 BN3500 / CCC-controllers (part3)
 OPC communication
 Advantages and disadvantages of FF
 Lessons learned / tips for the future
 Issues for the Fieldbus Foundation
 Conclusion / wrap up
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
3
Introduction: Siemens
Siemens Demag Delaval Turbomachinery
• When you are partner with Siemens, you can rely on our
“System competence” to provide you with a complete
compression solution from a single source.
As a global leader in the application of high-power electric
motors and other high performance drive systems, our
compression solutions cover every conceivable
application in the oil & gas industry.
• Compression solutions at a glance:
 Gas injection,
 Gas lift,
 Gas boosting,
 Fuel gas compression,
 Recompression.
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
4
Introduction: Imtech
Imtech ICT Industry Solutions
• Imtech ICT Industry Solutions combines know-how of
business processes, information technology and
manufacturing operations to flexible customer centric
solutions that lead to effective production management.
• Our expertises at a glance:
 Process and production automation,
 Application integration,
 Performance Management,
• Our services at a glance:
 Consultancy,
 Project Management,
 Design and Build,
 Support en maintenance.
Your Business
Consultancy
ICT
Cycle
Maintenance
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
Design
Build
Technology Organisation Processes
5
Introduction: project ‘Bonny Island’
• Compressor package
Type: Back-to-back compressor (two stages, one body)
 Function: Gas export compressor
• Customer & location
 Customer: Hyundai Heavy Industries (contractor)
 End user: SPDC Nigeria (Shell)
 Location: Bonny Island, Nigeria
• Choice of hardware/software
 Foundation Fieldbus
 SMAR Fieldbus Controller & Co-processor
 Bently Nevada monitoring & CCC controllers
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
6
System architecture: without FF
Human
Machine
Interface
Everything
is controlled
by the PLC
Ethernet
PLC
• Start/stop logic
• Oil pump logic
• Seal gas system
• Analog I/O
• Digital I/O
• Controllers
• etc.
Modbus
4-20 mA
Hardwired
CCC controllers
Bently Nevada 3500
Analog I/O
Digital I/O
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
7
System architecture: without FF
• Hardwired signals (digital and 4-20mA)
• Controllers in PLC or implemented with CCC
• Modbus communication between PLC and
Bently Nevada / CCC controllers.
• PLC handles everything
• Communication between PLC/HMI through
Ethernet (use of OPC or dedicated driver)
• HMI is used for supervisory and control
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
8
System architecture: with FF
Human
Machine
Interface
Ethernet
DF51
Fieldbus
Controller
4 x H1
Segments
Comm. gateway
DF65 CPU
(local I/O)
Hardwired
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
Modbus
CCC
controllers
Bently
Nevada
3500
9
System architecture: FF + redundant
Human
Machine
Interface
Ethernet
Ethernet
DF51
Fieldbus
Controller
Modbus
remote I/O
4 x H1
Segments
Fieldbus part
Comm.
gateway
DF65
CPU
Hardwired
Control logic part
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
CCC
controllers
Bently
Nevada
3500
BN3500/CCC part
10
System architecture: with FF
• All devices are connected through Fieldbus
• Time critical (digital) signals remain hardwired
• Controllers in FF (CIF) or implemented with CCC
• Modbus communication between co-processor
and Bently Nevada / CCC controllers.
• Every part has it’s own controller (FF / Logic / BN + CCC)
• Use of Control in the field (CIF)
• Communication between PLC/HMI through
Ethernet (use of OPC)
• HMI is used for supervisory and control
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
11
Foundation Fieldbus (part1)
• Electrical design
• Division of FF segments
 What devices communicate with each other?
 How much power is needed?
 What is the cable length for each segment?
• Example of control in the field
• FF devices used in the project
• Control of oil pumps not implemented in FF.
• Anti-surge / Performance control not implemented in FF.
• Device Description-files (DD-files)
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
12
Foundation Fieldbus (part1)
• Electrical design (4 x H1 segment)
Hazardous area
FF ‘hub’ + Lightning
protection + Terminator
Trunk cable
(approx. 500m)
Panel power
supply 24V DC
spur
FF host
spur
FISCO power
supply + terminator
Lightning protection
Lightning protection
Compressor skid
Unit Control Panel
Tree or “Chicken foot” topology
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
13
Foundation Fieldbus (part1)
• Example of CIF:
Communication between devices
(same segment)
AIblock
IN_1
OUT
Oil reservoir level
ISELblock
Display on gauge board
752 remote indicator
3051S pressure transmitter
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
14
Foundation Fieldbus (part1)
• FF devices used in the project:
Vendor
Type
Description
Rosemount
3051
Pressure transmitter
Rosemount
3051S
Pressure transmitter
Rosemount
3244MV
Temperature transmitter
Rosemount
752
Remote indicator
Fisher
DCV5000f Valve controller
ValveAutomation FieldQ
Valve Actuator
Dresser
Valve positioner/controller
FVP110
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
15
Control logic (part2)
• Example of control logic
• Interface to Fieldbus segments
 modbus communication
 communication through Fieldbus I/O module
• Interface to hardwired signals
• Interact with HMI/DCS
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
16
Example: control logic
Translate control
logic into a program
Hardwired (DI)
Foundation
Fieldbus (DI)
OPC (DI)
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
17
BN3500 / CCC (part3)
• Introduction
• Modbus multidrop
• Interface to co-processor
• Values displayed on HMI/DCS
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
18
OPC communication
• With OPC all values in
the Fieldbus devices can
be used
AIblock
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
OUT
OUT_D
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Advantages FF
• Control in the field (CIF)
• Less cables in control panel
• Less I/O modules
• No loopchecks anymore
• Speed up commissioning
• More detailed information about devices
• Devices of various vendors are compatible
• Device settings are easy to change
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
20
Disadvantages FF
• FF is relatively slow (this application)
• FF is not certified for safety (yet?)
• Not everybody “thinks” FF yet
 Commissioning is more difficult
 Service is more difficult
 More difficult to discuss FF with the customer
• The accent is put on ‘software’ not on ‘electric’
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
21
Issues for the Fieldbus Foundation
• Design rules seem not “waterproof”?
• “Trouble” with DD-files should not be a
problem for the integrator (=customer).
• Vendors should work together more openly.
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
22
Lessons learned / tips for the future
• “Think” FF from the start!
• Do not start an FF-project without any training
• Order devices based on functional specification
(not only mechanical/electrical specifications)
• Create a functional design regarding the use of
FF function blocks
• Create a functional design regarding the
communications between different systems
• Use the experience of your FF vendors!
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
23
Conclusion / wrap up
FF is definitely a good technology with a future!
However we must work on improvements:
 Not suitable for all applications
 Use of DD-files not as simple as it seems:
• DD-files are not supplied by one vendor
• DD-files seem not always compatible with host
 Each vendor should test (FAT?) their DD-files
with other host-suppliers to create a real ‘plugand-play’ environment.
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
24
Conclusion / wrap up (continued)
 The basic functions in FF function blocks are
not always identical for different devices/vendors.
 Specification of the FF architecture must be
clear from the start; for the customer and for the
integrator (knowledge of FF).
 It is preferred to test the control panel
together with all Fieldbus segments and devices
present. This to simulate a real live situation for
the customer/end-user (during FAT).
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
25
Questions…
Discussion…
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
26
Imtech ICT Industry Solutions
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
27
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
28
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
29
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
30
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
31
Siemens Demag Delaval Turbomachinery B.V.
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
32
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
33
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
34
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
35
“Freedom to Choose. Power to Integrate”
FIELDBUS FOUNDATION
© 2003 Fieldbus Foundation
36