Yokogawa Update on Fieldbus Offering

Yokogawa Electric Corporation

Copyright © Yokogawa Electric CorporationYokogawa User Group 2003

Yokogawa Fieldbus Update

2003-08-25

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

Today’s Items

Introduction of FieldbusInteroperabilityIntrinsic SafetyFieldbus Products by YokogawaFieldbus Systems by Yokogawa Plant Asset Management for the 21st CenturyJOB Information


Fieldbus

P

T

L

F

Process

DCS

Control & Monitoring

A Fieldbus is a digital, two way, multi-drop communication system for instruments and other plant automation equipment

Definition:

What is Fieldbus ?


IEC 10 protocols

IECPROFIBUS (PA & DP)P-NetWorldFIPFOUNDATION fieldbus High Speed EthernetControlNetInterbus SSwiftNetFOUNDATION fieldbus H1ProfiNet


H1 ... Low Speed• 31.25 kbps• 2 - 32 Devices• Two-wired• I.S. capability• 1900 m

(max)

H1 ... Low Speed• 31.25 kbps• 2 - 32 Devices• Two-wired• I.S. capability• 1900 m

(max)

PLCPLC

PLC Analyzer LinkingDevice

Controller

Control System

High Speed Ethernet• 100 Mbps• Redundancy

High Speed Ethernet• 100 Mbps• Redundancy

oooooo

H1 Fieldbus and HSE Fieldbus

SwitchesSwitches


Expected Benefits From Foundation Fieldbus Technology

Typical Benefits of Foundation Fieldbus:– Necessity of Fewer Devices (Muliti Sensing)– Reduction of Wiring (50 – 70 % Saving)– 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)– 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)

CAPEX

OPEX


Reduction of Wiring & Control Room Space

Wiring & RackCable CostJunction BoxCable ConduitProcessing of CableMarshallingBarrierProcess I/O Card

ConventionalSystem

Fieldbus System

Cabinet Cable

Case of 350 I/O points


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 RateInstrument $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.


Evolution of Maintenance Work From Corrective Maintenance to Preventative Maintenance

Relative Maintenance Cost


Cost Saving in Maintenance by Plant Asset Management Software (ARC Report)


Working Worldwide

EuropeAfrica

AsiaOceania

Japan

South America

North America

0500

100015002000250030003500400045005000

1997 1998 1999 2000 2001 2002 2003

Fieldbus System Installation Trend

Fieldbus Installations Are Growing ! – Over 200,000 Fieldbus Devices Shipped – Over 4,000 Fieldbus Systems Shipped

FF Report, as of 30 June 2002


Today’s Items

Introduction of Fieldbus

InteroperabilityIntrinsic SafetyFieldbus Products by YokogawaFieldbus Systems by Yokogawa Plant Asset Management for the 21st CenturyJOB Information


What Is Interoperability?

Interoperability DefinitionInteroperability 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.


How To Achieve Interoperability?

Interoperability Test(IT) For DevicesTo 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.


n Yokogawa transmitters, the First unit to be FF- Registered in the world in 1998. uDifferential Pressure Transmitter EJAuVortex Flow Meter YEWFLO*E

n FF-Registered Yokogawa devicesuValve Positioner

n Yokogawa System (CENTUM) Acknowledged as HIST ready 1st

upH and Conductivity AnalyzeruMagnetic Flow Meter ADMAG AEuTemperature Transmitter YTAuDAQ Station, etc.

Yokogawa Equipment #1 in the Interoperability


Device(EJA) on WEB site


HIST Exhibit of CENTUM

CT0003FFTest Camp. Number

FF-IF-PCAT-H1 v1.20Revision

Softing GmbHManufacturer

Stack

21pskvc+22+23+24Comm. Profile Class

N/ASerial No

R3.10Revision

SSSSM01-C1 FOUNDATION

fieldbus toolType

CENTUM CS/CS1000/CS3000Modeln

Yokogawa Electric Corporation

Manufacturer

Host System Under Test

For more information, contact host vendor

YesDD Menu

YesCapability Files

YesDD Method Execution

YesDevice Description Services

YesFunction Block Linkage Configuration

YesCustom Blocks

YesEnhanced Blocks

YesStandard Blocks

YesBlock Tag Configuration

YesConfiguration of Link Master Devices

YesDevice Address Assignment

YesDevice Tag Assignment

YesAlert

YesAlert Configuration

Host Feature Supported


Today’s Items

Introduction of FieldbusInteroperability

Intrinsic SafetyFieldbus Products by YokogawaFieldbus Systems by Yokogawa Plant Asset Management for the 21st CenturyJOB Information


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


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


Fieldbus System Configuration(Example)

CS3000 R3HIS

V-NET

ALF111

Field Control Station

Dual-Redundant

ValvePositioner

PressureTransmitter

Terminal

TemperatureTransmitter

Terminator

FISCO ModelIS Barrier (Max.100mA)

SegmentNo.3

TerminalTerminator

Terminator

Terminal

AEF9D

4PortsSegmentNo.2

SegmentNo.1

SegmentNo.4

Max.1000m

Max.30m


Today’s Items

Introduction of FieldbusInteroperabilityIntrinsic Safety

Fieldbus Products by YokogawaFieldbus Systems by Yokogawa Plant Asset Management for the 21st CenturyJOB Information


Field Devices from Yokogawa

LINKMASTERAIx1, PIDx1YEWFLOStyle EVortex flowmeter

LINKMASTERAIx8, MAIx1, MAOx1DAQSTATIONPaperless recorder

BASICAIx3EXA SC202/ISC202Conductivity transmitter

BASICAIx3EXA PH202pH transmitter

LINKMASTERAOx1, DIx2, PIDx1, OSx1YVP110Positioner

LINKMASTERAIx1, PIDx1ADMAG AEMagnetic flowmeter

LINKMASTERAIx2, PIDx1,DIx2Digital YEWFLOVortex flowmeter

LINKMASTERAIx4, DIx4, PIDx2YTA SeriesTemperature transmitter

LINKMASTERAIx2, PIDx1EJA SeriesPressure,d/ptransmitter

Device classFunction blockModel


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

Alliance for Fieldbus Integrated Solutions


Valve Maintenance Package - ValveNavi with YVP

Main Panel

Setpoint

Actual Position

Mode ofeach block


ValveNavi with YVP (2)

Trend Display

Calibration


YVP Valve Diagnostics with ValveNavi

Signature DiagnosticsBasic Diagnostics

l Valve maintenance data management

ü Cycle ü Travel distanceü Total open time ü Total close timeü Total NEAR-CLOSE time

l Valve characteristic data measuring for auto-tuning and self-check

ü Valve Gainü Valve Hysteresisü Valve Slip width Etc.

l Standard Actuator Signaturel Extended Actuator Signaturel High Resolution Actuator Signaturel Step Response Testl Positioner Signature


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


“Multi-Point” Temperature Transmitter with “Local Display”

AI(x8),MAI FOUNDATION fieldbus H1

LAN / WAN

TC, RTD, Volt etc(Universal Input)

Field Instruments

Publishes Measured Data(Up to 12 ch)

Ethernet Interface

(Standard)

DAQSTATION

DAQSTATION submits its measured data to Fieldbus segment using AI function block.

YTA:Temp.Transmitter

Specifications are subject to change

EJA:Pressure YEWFLO

DAQSTATION: The 1st FF recorder in the world

DCS

YVP


DAQSTATION: The 1st FF recorder in the world

H1 fieldbus segment

Fieldbus ready Field Instruments

Ethernet communications

Analog Inputs

Remote Host orPC via Internet

Small data acquisition (Run-time Master function)Accepts Inputs From Fieldbus Field Instruments andSend Data As A Network Device via Ethernet

MAO


New Magnetic Flowmeter

Concept

User-Oriented Functionality!Offers you the service that leaves nothing to be desired.

Predictive diagnostics-lowers TCOuReducing process downtime & serviceuSimplifying and optimizing maintenance

Super high performance – global leader in stabilityOffers you more stable & more accurate measurement.Also for the most difficult application!


Adhesion Diagnosis Function (Patent Pending)

Always Monitoring the fluid impedance and Always Monitoring the fluid impedance and detecting the change caused by the insulating detecting the change caused by the insulating adhesion on Electrodes.adhesion on Electrodes.

ElectrodeElectrode

CommonCommon

Predictive diagnostics



Monitoring Adhesion Level on Electrodes!

Level:

0.996m/s

19.938 mA F R

ADH

F R

013



Easy replaceable!

No Sweat Work Anymore!

Special Tool Electrode Unit

The Surface can be cleaned.


Alternative

Alarm mode

Countermeasure message for Alarm

Process Alarm31: Empty Pipe

Fill flow tube with fluid

2 second

2 second

Display mode1.2345 m3/h

12345678FR

FTL

Example : EnglishExample : English

Tell you what you have to do!



Today’s Items

Introduction of FieldbusInteroperabilityIntrinsic SafetyFieldbus Products by Yokogawa

Fieldbus Systems by Yokogawa Plant Asset Management for the 21st CenturyJOB Information


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)


Field Network in CS3000 R3

HIS

RIOFIO

H1

HARTProfibusDP

RS485

4-20mA

4-20mA Remote IOH1

H14-20mAHART


Example of CS 3000 System Configuration

Ethernet

Vnet

H1 fieldbus segment

Terminator

Fieldbus devices

HIS

ALF111 in service

KFCSRFCS2

Legacy field devices

Standby ALF111

World-first dual-redundant fieldbus ports; up to 4 ports

HIS-ENGLFS2610 FOUNDATION Fieldbus Communication Package

Bus power supply


n Cable LengthuCable Type : Type-A (1900 meters) or Type-B (1200 meters) in IEC’s

Specificationu1000 meters for I.S Application

n Maximum Number of Devices Connected to a Segment u32 Nodes (Including FF Interface Cards and temporary devices) in IEC’s

Specificationsu4 - 6 Devices per Barrier at Hazardous Area in IEC’s Specification.uParallel Usage of Barriers with Repeater Function Available

u16 Devices as a Recommendation by Communication Performance

Minimum Working Voltage at Deviceu Min. 9 volts in IEC’s Specificationu 9.5 volts as a Recommendation

Points of FOUNDATION fieldbus Segment Design


n Communication Scheduling uCommunication Time Between Any Devicesu30 – 40msec. per one Communication in Average

uPeriodical communication Time: Up To 70 % of Cycle TimeuUp 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 Consumptionu Average : 20mA (EJA 16.7 mA, Fisher/DVC5000f 26.5mA)u Max. 16 Devices / 350mA Power Supply Unit

n Other ConsiderationsuCable Routeu JB Allocation and JB GroupinguTerminal Type Selection

Points of FOUNDATION fieldbus Segment Design


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)


Integrated Engineering

3ALF111

FUNCTION_BLOCK


Multi Schedule

Automatic Scheduling

0 500 1000msec

Control Period 500msec

Control Period 1000msec


Today’s Items

Introduction of FieldbusInteroperabilityIntrinsic SafetyFieldbus Products by YokogawaFieldbus Systems by Yokogawa

Plant Asset Management for the 21st CenturyJOB Information


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


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


Device Navigator

(Plant View)

Display sample

Plant ViewAndDevice Details

Network ViewAndParameter

Display


Device Viewer

Alarm Number

Transducer Status

Hardware Information

Additional Information

Device Diagnostic

Parameter values of Device

Device State

If Self-diagnostic error happened, Status Color Changed

PRM Device Viewer provides•Remote maintenance

•Yokogawa provides open interface for DeviceViewerApplications for 3’rd Party (Device vendor)


PLUG-INApplication

Maintenance Work Evolution by PRM PIA

PLUG-INApplication

Call

Data

Event

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

PIAKit

Field InformationDatabase

(PIA History)

PRM integrated PLUG-IN Application provides •Tool base maintenance•Remote Maintenance •Automatic Maintenance

History

Field devices

PRM

PIANavigation

•Device Maintenance Software-Calibration -Inspection-Set up &Tuning etc

•Valve Management Software-ValveNavi-ValVue etc.

<<Example of PIA>>


ValveNavi as PLUG-IN Application


Diagnostics of Fieldbus System

PlantDiagnostics

Process orEquipment

Level 4

Actuators, Elementsvalves, Connections

Loop Diagnostics

Level 3

Fisher

DeviceDiagnostics

Level 2

Electronics

CommunicationsDiagnostics

Level 1

CommunicationsDresser Diagnostics

at field level

Diagnosticsat CCR level


Regional

Device Diagnostics Process/UnitDiagnostics

Device InstallationDiagnostics

Local

Self

n DP/P Transmitter- Impulse line Blocking Diagnostics - Steam tracing Diagnostics

n FF/Pneumatic Converter- Instrument air line clogging

Diagnostics

n Valve Positioner- Signature diagnostics - Valve stick-slip diagnosticsn DP/P Transmitter- Clogging diagnostics- Orifice wearing diagnostics- Diaphram corrosion diagnosticsn Temperature Transmitter- Temp. element diagnostics n Vortex Flowmeter- Clogging diagnostics- Vibration diagnosticsn Magnetic Flowmeter- Adhesion diagnostics- Signal insulation diagnostics

PT

L

F

Diagnostics

L

Yokogawa FF Devices – Advanced Diagnostics Line-Up


Today’s Items

Introduction of FieldbusInteroperabilityIntrinsic SafetyFieldbus Products by YokogawaFieldbus Systems by Yokogawa Plant Asset Management for the 21st Century

JOB Information


Trend of Order Intake

0

20

40

60

80

100

120

140

97 98 99 00 01 02


System Configuration ExampleAromatic Plant (1900 devices, in Engineering Phase)

XXXXXXXXXXXXXXXX


What can Yokogawa provide ?

Addition to Above Mentioned Products:n Consulting Service Regarding Fieldbus System Designn System Integration Services for Multi Vender Devicesn Engineering Know How for Integration of Brain, Hart, 4-

20mA, FOUNDATION Fieldbus and Profibus-DPn Test Procedures and Field Commissioningn Technical Support for Q & An Training for Operation, Maintenance and Engineering.

Yokogawa Update on Fieldbus Offering

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