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Yokogawa Fieldbus Update

2003-08-25

Yokogawa Electric Corporation

Copyright © Yokogawa Electric Corporation


Yokogawa User Group 2003
Today’s Items

Introduction of Fieldbus
Interoperability
Intrinsic Safety
Fieldbus Products by Yokogawa
Fieldbus Systems by Yokogawa
Plant Asset Management for the 21st Century
JOB Information

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What is Fieldbus ?

Definition: Control & Monitoring

A Fieldbus is a digital, two


way, multi-drop
communication system for
instruments and other plant
automation equipment

Fieldbus

P
T
Process

L DCS

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IEC 10 protocols

IEC
PROFIBUS (PA & DP)
P-Net
WorldFIP
FOUNDATION fieldbus High Speed Ethernet
ControlNet
Interbus S
SwiftNet
FOUNDATION fieldbus H1
ProfiNet
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H1 Fieldbus and HSE Fieldbus

High
HighSpeed
SpeedEthernet
Ethernet
••100 Mbps
100 Mbps
• •Redundancy
Redundancy
Control System

Switches Switches Controller

Analyzer Linking
PLC Device
PLC
PLC

H1
H1......Low
LowSpeed
Speed
••31.25 kbps
31.25 kbps
• •22- -32
32Devices
Devices
• •Two-wired
Two-wired
• •I.S.
I.S.capability
capability
• •1900
1900m m
ooo
ooo

(max)
(max)

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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) CAPEX
– 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) OPEX
– 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)
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Reduction of Wiring & Control Room Space

Cabinet Cable

Wiring & Rack Conventional


System
Cable Cost
Junction Box
Cable Conduit
Processing
of Cable
Fieldbus System
Marshalling
Barrier
Process I/O Card
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 Rate


Instrument $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

Fieldbus Installations Are Growing !


– Over 200,000 Fieldbus Devices Shipped
– Over 4,000 Fieldbus Systems Shipped
FF Report, as of 30 June 2002
5000
4500
4000
3500
3000
North
America
2500 Europe Japan
2000 Africa
1500
1000 Asia
500
South Oceania
0
America
1997 1998 1999 2000 2001 2002 2003

Fieldbus System Installation Trend

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Today’s Items

Introduction of Fieldbus
Interoperability
Intrinsic Safety
Fieldbus Products by Yokogawa
Fieldbus Systems by Yokogawa
Plant Asset Management for the 21st Century
JOB Information

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What Is Interoperability?

Interoperability Definition
Interoperability 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 Devices


To 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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Yokogawa Equipment #1 in the Interoperability

n Yokogawa transmitters, the First unit to be


FF- Registered in the world in 1998.
u Differential Pressure Transmitter EJA
u Vortex Flow Meter YEWFLO*E

n FF-Registered Yokogawa devices


u Valve Positioner
u pH and Conductivity Analyzer
u Magnetic Flow Meter ADMAG AE
u Temperature Transmitter YTA
u DAQ Station, etc.
n Yokogawa System (CENTUM)
Acknowledged as HIST ready 1st

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Device(EJA) on WEB site

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HIST Exhibit of CENTUM

Host System Under Test Host Feature Supported


Manufacturer Yokogawa Electric Alert Configuration Yes
Corporation
Alert Yes
Modeln CENTUM CS/CS1000/CS3000
Device Tag Assignment Yes
Type SSSSM01-C1 FOUNDATION
fieldbus tool Device Address Assignment Yes

Revision R3.10 Configuration of Link Master Yes


Devices
Serial No N/A
Block Tag Configuration Yes
Comm. Profile Class 21pskvc+22+23+24
Standard Blocks Yes
Stack Enhanced Blocks Yes
Manufacturer Softing GmbH Custom Blocks Yes
Revision FF-IF-PCAT-H1 v1.20 Function Block Linkage Yes
Configuration
Test Camp. Number CT0003FF
Device Description Services Yes
DD Method Execution Yes
Capability Files Yes
DD Menu Yes
For more information, contact host vendor
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Today’s Items

Introduction of Fieldbus
Interoperability
Intrinsic Safety
Fieldbus Products by Yokogawa
Fieldbus Systems by Yokogawa
Plant Asset Management for the 21st Century
JOB Information

<Document Number>
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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 R3
HIS

Max.1000m
Terminal Terminator
V-NET FISCO Model
IS Barrier (Max.100mA) Max.30m
Field Control Station

ALF111
Segment
No.1
Pressure Temperature Valve
Terminal Transmitter Transmitter Positioner
Terminator

Dual-
Redundant Segment
4Ports No.2
AEF9D Segment
Terminal No.3
Terminator
Segment
No.4

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Today’s Items

Introduction of Fieldbus
Interoperability
Intrinsic Safety
Fieldbus Products by Yokogawa
Fieldbus Systems by Yokogawa
Plant Asset Management for the 21st Century
JOB Information

<Document Number>
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<date/time>
Field Devices from Yokogawa

Model Function block Device class

Pressure,d/p
EJA Series AIx2, PIDx1 LINKMASTER
transmitter
Temperature
YTA Series AIx4, DIx4, PIDx2 LINKMASTER
transmitter
Vortex flowmeter Digital YEWFLO AIx2, PIDx1,DIx2 LINKMASTER
YEWFLO
Vortex flowmeter AIx1, PIDx1 LINKMASTER
Style E

Magnetic flowmeter ADMAG AE AIx1, PIDx1 LINKMASTER

AOx1, DIx2, PIDx1,


Positioner YVP110 LINKMASTER
OSx1

pH transmitter EXA PH202 AIx3 BASIC

Conductivity
EXA SC202/ISC202 AIx3 BASIC
transmitter
AIx8, MAIx1,
Paperless recorder DAQSTATION LINKMASTER
MAOx1

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Alliance for Fieldbus Integrated Solutions

Market Leaders
Yokogawa and Dresser
Equipment Group
Announced Customer-
Focused Alliance for
Fieldbus-Integrated
Solutions in October 4th,
1999.

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Valve Maintenance Package - ValveNavi with YVP

Main Panel

Mode of
each block

Setpoint

Actual Position

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ValveNavi with YVP (2)

Calibration

Trend Display

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YVP Valve Diagnostics with ValveNavi

Basic Diagnostics Signature Diagnostics

l Valve maintenance data


management
ü Cycle
ü Travel distance
ü Total open time
ü Total close time
ü Total NEAR-CLOSE time
l Valve characteristic data l Standard Actuator Signature
measuring for auto-tuning and
l Extended Actuator Signature
self-check
ü Valve Gain l High Resolution Actuator Signature
ü Valve Hysteresis l Step Response Test
ü Valve Slip width Etc. l 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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DAQSTATION: The 1st FF recorder in the world

DCS
“Multi-Point” Temperature Transmitter with “Local
Display”
LAN / WAN

AI(x8),MAI FOUNDATION fieldbus H1


Ethernet Publishes Measured Data
Interface (Up to 12 ch)
(Standard) YVP
EJA:Pressure YEWFLO

DAQSTATION
YTA:Temp.Transmitter

Field Instruments
TC, RTD, Volt etc
DAQSTATION submits its measured data to Fieldbus
(Universal Input)
segment using AI function block.

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DAQSTATION: The 1st FF recorder in the world

Small data acquisition (Run-time Master function)


Accepts Inputs From Fieldbus Field Instruments and
Send Data As A Network Device via Ethernet
Ethernet communications

Remote Host or MAO H1 fieldbus segment


PC via Internet

Analog Inputs
Fieldbus ready Field Instruments

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New Magnetic Flowmeter

Concept
User-Oriented Functionality!
Offers you the service that leaves nothing to be desired.
Predictive diagnostics-lowers TCO
uReducing process downtime & service
uSimplifying and optimizing maintenance
Super high performance – global leader in stability
Offers you more stable & more accurate measurement.
Also for the most difficult application!

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Predictive diagnostics

Adhesion Diagnosis Function (Patent Pending)

Always Monitoring the fluid impedance and


detecting the change caused by the insulating
adhesion on Electrodes.

Electrode

Common

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Predictive diagnostics

Monitoring Adhesion Level


on Electrodes!

0.996 m/s
FR

19.938 mA FR

Level: 013 ADH

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Predictive diagnostics

No Sweat Work Anymore!

Easy replaceable!

The Surface can be cleaned.

Special Tool Electrode Unit


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Predictive diagnostics

Tell you what you have to do!

Example : English

1.2345 m3/h FR Display mode

12345678 FTL 2 second

Alternative

Process Alarm
31: Empty Pipe Alarm mode
Fill flow tube with 2 second
fluid

Countermeasure message for Alarm


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Today’s Items

Introduction of Fieldbus
Interoperability
Intrinsic Safety
Fieldbus Products by Yokogawa
Fieldbus Systems by Yokogawa
Plant Asset Management for the 21st Century
JOB Information

<Document Number>
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<date/time>
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

FIO
RIO

H1 H1 Remote IO
4-20mA
4-20mA
ProfibusDP HART
4-20mA H1
RS485
HART

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Example of CS 3000 System Configuration

Ethernet
HIS HIS-ENG
LFS2610 F OUNDATION Fieldbus
Communication Package

Vnet
World-first dual-redundant
KFCS fieldbus ports; up to 4 ports
RFCS2 Fieldbus devices
ALF111 in service
Standby ALF111 Terminator

Bus power supply


Legacy field
devices H1 fieldbus segment

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Points of FOUNDATION fieldbus Segment Design

n Cable Length
u Cable Type : Type-A (1900 meters) or Type-B (1200 meters) in IEC’s
Specification
u 1000 meters for I.S Application
n Maximum Number of Devices Connected to a Segment
u 32 Nodes (Including FF Interface Cards and temporary devices) in IEC’s
Specifications
u 4 - 6 Devices per Barrier at Hazardous Area in IEC’s Specification.
uParallel Usage of Barriers with Repeater Function Available
u 16 Devices as a Recommendation by Communication Performance
Minimum Working Voltage at Device
u Min. 9 volts in IEC’s Specification
u 9.5 volts as a Recommendation

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Points of FOUNDATION fieldbus Segment Design

n Communication Scheduling
u Communication Time Between Any Devices
u30 – 40msec. per one Communication in Average
u Periodical communication Time: Up To 70 % of Cycle Time
uUp 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 Consumption
u Average : 20mA (EJA 16.7 mA, Fisher/DVC5000f 26.5mA)
u Max. 16 Devices / 350mA Power Supply Unit
n Other Considerations
u Cable Route
u JB Allocation and JB Grouping
u Terminal Type Selection

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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

0 500 1000msec

Control Period 1000msec

Control Period 500msec

Automatic Scheduling
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Today’s Items

Introduction of Fieldbus
Interoperability
Intrinsic Safety
Fieldbus Products by Yokogawa
Fieldbus Systems by Yokogawa
Plant Asset Management for the
21st Century
JOB Information

<Document Number>
Copyright © Yokogawa Electric Corporation Proprietary info goes here…
<date/time>
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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Display sample

Network View
Plant View
And
Parameter
Device Details
Display

Device
Navigator
(Plant View)

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Device Viewer
PRM Device Viewer provides •Yokogawa provides open
•Remote maintenance interface for DeviceViewer
Applications for 3’rd Party
(Device vendor)
If Self-diagnostic
error happened,
Status Color
Changed
Device State

Device Diagnostic Hardware Information

Alarm Number

Transducer Status

Parameter values of
Additional Information Device

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Maintenance Work Evolution by PRM PIA

PRM integrated PLUG-IN Application provides


•Tool base maintenance
•Remote Maintenance
•Automatic Maintenance

<<Example of PIA>>
PRM
•Valve Management Software
Call
PIA -ValveNavi
Data -ValVue etc.
Navigation
PLUG-IN
PLUG-IN
Application •Device Maintenance Software
Event
Field Information Application -Calibration
History
Database
(PIA History)
PIA -Inspection
Kit -Set up &Tuning etc

Open interface
PIA interface development
Field devices Kit for 3’rd Party Application

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ValveNavi as PLUG-IN Application

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Diagnostics of Fieldbus System

Plant
Diagnostics Diagnostics
at CCR level
Loop Level 4
Diagnostics

Device Level 3 Process or


Diagnostics Equipment
Fisher

Communications Level 2 Actuators, Elements


Diagnostics valves, Connections

Level 1
Electronics

Dresser
Diagnostics
Communications at field level

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Yokogawa FF Devices – Advanced Diagnostics Line-Up

Device Diagnostics Device Installation Process/Unit


Diagnostics Diagnostics
P
Diagnostics T

n Valve Positioner
- Signature diagnostics
L F

- Valve stick-slip diagnostics


n DP/P Transmitter
- Clogging diagnostics n DP/P Transmitter
- Orifice wearing diagnostics - Impulse line Blocking Diagnostics
- Steam tracing Diagnostics
- Diaphram corrosion diagnostics
n Temperature Transmitter n FF/Pneumatic Converter Regional
- Temp. element diagnostics - Instrument air line clogging
Diagnostics Local
n Vortex Flowmeter
- Clogging diagnostics
- Vibration diagnostics
Self
n Magnetic Flowmeter
- Adhesion diagnostics
- Signal insulation diagnostics

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Today’s Items

Introduction of Fieldbus
Interoperability
Intrinsic Safety
Fieldbus Products by Yokogawa
Fieldbus Systems by Yokogawa
Plant Asset Management for the 21st Century
JOB Information

<Document Number>
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<date/time>
Trend of Order Intake

140
120
100
80
60
40
20
0
97 98 99 00 01 02

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System Configuration Example
Aromatic Plant (1900 devices, in Engineering Phase)

XXXXXXXX
XXXXXXXX

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What can Yokogawa provide ?

Addition to Above Mentioned Products:


n Consulting Service Regarding Fieldbus System Design
n System Integration Services for Multi Vender Devices
n Engineering Know How for Integration of Brain, Hart, 4-
20mA, FOUNDATION Fieldbus and Profibus-DP
n Test Procedures and Field Commissioning
n Technical Support for Q & A
n Training for Operation, Maintenance and Engineering.

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