Segment Design

Segment Design Points and Design Recommendation

Yokogawa Blue Star

Copyright © by Yokogawa Blue Star 2004

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 Segment Design Points

 Control Function, such as PID Allocation

 Macrocycle (Control Period)

 Redundancy

 Numbers of Devices per Segment

 Control Application

Copyright © by Yokogawa Blue Star 2004

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Segment Design
 Segment Design Recommendation

Design Recommendation to be Simplified and

Standardized Segment Design Works

 Control Function, such as PID Allocation

 Macrocycle (Control Period)

 Redundancy

 Numbers of Devices per Segment

Copyright © by Yokogawa Blue Star 2004

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Segment Design
 Control Function Allocation (1) -
Recommendation

Allocate Control Function to FCS.

Use only Input/Output function blocks (AI, AO, DI, DO,
MAI and MAO)
Advantages:
 Flexible and selectable control algorism

 Built-in Self-Tuning Function

 Can achieve complex and advanced process control loops

 Can achieve complicated calculation

 Need to schedule only input and output communication time

 Easy to modification of control application

 Reduce numbers of FF Faceplate blocks

 Parameter name consistency

Copyright © by Yokogawa Blue Star 2004

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Segment Design
 Control Function Allocation (2) –
In case of Allocate Control Function to Fieldbus Devices

Consider following advantages and disadvantages if you

intend to use control functions of FF devices.

Advantages:
 Synchronous control as closed loop
within a Fieldbus H1 segment.
 Possible faster control responds than
DCS (within one second)
 Control function continues when host
interface (ALF111) failure
Disadvantages:
 Function Blocks may be out-of-service
longer time when modification of
control application
 Control algorism may be different
across manufacturers
 Limited control loop configuration

 Limited calculation function

 Need to schedule AI, PID and AO block

execution time addition to AI / AO data
communication time
 Parameter name inconsistency, such as
“P” in FCS and “GAIN” in FF devices
 Backup Link Master devices are
necessary

Copyright © by Yokogawa Blue Star 2004

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Segment Design
 Macrocycle

Recommendation:

1 second or Slower
Background:
 It is enough for most control loops

 Numbers of Fieldbus devices per segment will be fewer when using faster
macrocycle.

In case of using faster macrocycle

 Consider communication/block execution schedule based on following
condition
 Number of communication data
 Function block execution time
 Spare time for un-scheduled communication

Copyright © by Yokogawa Blue Star 2004

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Segment Design
 Redundancy (1) – Fieldbus Power Supply

Recommendation:

Use Redundant Power Supply Unit

Background:
 Prevent failure all devices on the segment in case of failure of power supply
unit
 Prevent failure all devices on the segment in case of maintenance of power
supply unit

In case of using Single Power Supply:

 Confirm it is acceptable that failure all devices on the segment in case of
maintenance.
 Confirm failure rate and it complies customer requirement.

Copyright © by Yokogawa Blue Star 2004

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Segment Design
 Redundancy (2) –
Fieldbus Interface Module (ALF111)
Recommendation:
Use Redundant Interface Module

Background:
 Prevent failure all devices on the segment in case of failure of interface
module
 Prevent failure all devices on the segment in case of maintenance of interface
module

In case of using Single Interface Module:

 Confirm it is acceptable that failure all devices on the segment in case of
maintenance.
 Confirm failure rate and it complies customer requirement.

Copyright © by Yokogawa Blue Star 2004

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Segment Design
 Redundancy (3) –
Backup Link Master Devices
In Case of Using Control Function in FF Devices:

Requires Backup Link Master Devices

In Case of NOT Using Control Function in FF Devices:

Backup Link Master Device is NOT Required

Background:
 Control can not continue if host interface module failure in case of NOT using
control function in FF Devices even backup LM is available.

In case of using Backup Link Master Devices:

 Pay attention for the link master capability of expecting backup device. Some
devices have insufficient storage for communication schedule.

Copyright © by Yokogawa Blue Star 2004

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Segment Design
 Numbers of Devices per Segment (1) -
Recommendation

Up to 12 devices for Monitoring Loops

Up to 8 devices for Control Loops
Assumed Loop Configuration
Monitoring Loop: Control Loop:
1 input per measurement device 1 input for measurement device, 1 output
for manipulate device

PVI PID

FCS

Fieldbus
Devices
AI AI AO

Measurement Measurement Manipulate

Device Device Device

Copyright © by Yokogawa Blue Star 2004

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Segment Design
 Numbers of Devices per Segment (2) -
Background
Background:
 This recommendation is based on 1 second macrocycle.

 We recommend to reserve 30% of macrocycle for un-scheduled

communication (QUU and QUB. They are used for alarm notify, on-demand
parameter reading/writing, etc.) at least.
 1 scheduled communication (BNU) spends approx. 40 msec. Input connection
uses 1 scheduled communication. Output connection uses 2 scheduled
communications (writing and reading-back a value).
 CS3000 FF faceplate block reads View3 object in specified update period
(default: 4seconds). Reading View3 object spends approx. 50 msec.
 From above conditions, the general formula is as follows.

[Macrocycle] * 0.7 >=

[Nos. of scheduled communication (BNU)] * 40 msec +
[Nos. of FF faceplate blocks] * 50 msec / [Update period of FF faceplate block] * [Macrocycle]

Copyright © by Yokogawa Blue Star 2004

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Segment Design
 Numbers of Devices per Segment (3) -
Background
Monitoring Loop:
Condition:
[Nos. of scheduled communication] = [Nos. of FF Devices]
[Nos. of FF faceplate blocks] = [Nos. of FF Devices]
Calculation:
700 msec >= [Nos. of FF devices] * 40 msec + [Nos. of FF devices] * 50 msec / 4
[Nos. of FF devices] <= 700 msec / (40 msec + 50 msec/4) = 13.3
With considering safety margin, [Nos. of FF devices] <= 12

Control Loop:
Condition:
[Nos. of scheduled communication] = [Nos. of FF devices] * 3/2
[Nos. of FF faceplate blocks] = [Nos. of FF devices]
Calculation:
700 msec >= [Nos. of FF devices] * (3/2) * 40 msec + [Nos. of FF devices] * 50 msec / 4
[Nos. of FF devices] <= 700 msec / (40 msec*(3/2) + 50 msec/4) = 9.7
With considering safety margin, [Nos. of FF devices] <= 8
Copyright © by Yokogawa Blue Star 2004
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Segment Design
 Numbers of Devices per Segment (4) –
Other Restriction to be Considered

 Power Consumption
 The Fieldbus devices connected to each segment
must be determined such that the total current
dissipation of those field devices may not exceed the
supply current capacity of the power supply used.
Namely, the following condition must be met:

n
n  Ip /  I
i 1
where,
n = number of Fieldbus devices per segment
Ip = supply current capacity of power supply (mA)
I = current dissipation of each Fieldbus device (mA)

Copyright © by Yokogawa Blue Star 2004

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Segment Design
 Current Power Consumption of devices

 Current power consumption by devices

 Average : 20mA (EJA 16.0 mA, Fisher/DVC5000f 26.5mA)

Model Power Supply Max No. Of

Capacity Devices
MTL5995 Fieldbus Power Supply 350mA 16

MTL5053 I.S. Barrier 80mA 3 or 4

P+F KLD2- I.S. Repeater barrier 80mA 3 or 4

PR-Ex1.IEC

P+F KLD2- FISCO model I.S. 100mA 5 or 6

PR-Ex1.IEC1 repeater barrier

Copyright © by Yokogawa Blue Star 2004

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Segment Design
 Numbers of Devices per Segment (5) –
Other Restriction
 The FOUNDATION™ Fieldbus limits the maximum
number of devices per H1 segment to 32.
 This limit encompasses all devices that potentially
exist on the segment in question, including a host
interface device such as an ACF11 or ALF111
module, and devices which are to be connected
temporarily, such as maintenance equipment.
 If a pair of ALF111s is used to configure dual-
redundancy, it is counted as two devices. Hence, in
principle, up to 31 field devices can be connected
per segment linked to a single ACF11 or ALF111, and
up to 30 per segment linked to dual-redundant
ALF111s.

Copyright © by Yokogawa Blue Star 2004

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Segment Design
 Numbers of Devices per Segment (6) –
In case of out of recommended condition
In case of Faster Macrocycle:
 Time duration for the communication are the same. Therefore, the number of
device must be reduced.

In case of Using Control Function in FF Devices:

 It is required to consider communication schedule and block execution
schedule based on desired application configuration. If you intend to make
very complex application, the number of devices may be fewer.
 A Fieldbus block cannot execute simultaneously with another block in the same
Fieldbus device.
 Fieldbus blocks in different Fieldbus devices can execute simultaneously.
 Data transmissions can be performed during execution of a function block.
 A periodic inter-device transmission cannot be performed simultaneously with
another.
 Fieldbus block executions and inter-block transmissions should be scheduled so
that they may take place in line with the flow of data.

Copyright © by Yokogawa Blue Star 2004

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Segment Design
 Numbers of Devices per Segment (7) –
In case of out of recommended condition
PID

FCS
%Znnuscc %Znnuscc
Fieldbus TERMO-1.IN TERMI.OUT TERMO-2.IN
devices

OUT

AI1
Sensor 1

CAS_IN BKCAL_OUT
OUT IN OUT CAS_IN
AI2 BKCAL_IN BKCAL_OUT
Sensor 2 PID AO Control period of function block application (FBAP)
Positioner

Execution of AI1
AI1.OUT (to TERMO-1.IN)
Execution of AI2
AI2.OUT (to PID.IN)
TERMI.OUT (to PID.CAS_IN)
Execution of PID
PID.BKCAL_OUT (to TERMO-2.IN)
Execution of AO

Fieldbus blocks in A periodic inter- No need of A fieldbus block

different fieldbus device transmission transmission cannot execute
devices can cannot be performed inside the same simultaneously
execute simultaneously with device with another
simultaneously. another. block in the
same fieldbus
device.
Function block execution
Transmission (publishing)

Copyright © by Yokogawa Blue Star 2004

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Segment Design