Fieldbus Basics 1
Fieldbus Basics 1
Modern distributed systems partially solve this problem by locating remote multiplexing
devices out in the field. The ultimate solution, however, is to be able to connect a
reasonable number of sensors all located in the same area to the same cable. This is
exactly what Fieldbus allows. Finally, Fieldbus will replace the 4-20 mA standards,
although this will not happen overnight. There are millions of instruments in the world
using this standard right now, which does in fact have some advantages. It is simple and
well understood. Devices from different suppliers using the 4-20 mA standards can easily
operate together (ie.interoperate). More about this later. Ultimately, however, a digital
standard is necessary to realize the benefits of Fieldbus. Some hybrid protocols, such as
HART®, are now being used to bridge this gap between analog and digital technology.
Using the HART protocol, the analog signal is still used to transmit the process value
while a digital value is superimposed on top of the analog value for exchanging
additional information with the device.
Communications over a Fieldbus is achieved by installing a Fieldbus interface device in
all of the devices communicating over the Fieldbus. One end of this interface device
connects to the Fieldbus and the other end to the sensor electronics or the host computer
system. Initially, these Fieldbus interface devices are small printed circuits that fit into
the device or the host computer system. Ultimately, these devices will be little more than
a single integrated circuit that can be included in the device.
Fieldbus is designed to allow for both low-speed and high-speed communications. Low-
speed, or H1 Fieldbus, is currently in use in the industry. High-speed Fieldbus is
currently under development and will use high-speed Ethernet at a speed of 100Mbits/s.
Linking devices will be developed for bridging between low-speed and high-speed
Fieldbus segments. These linking devices will also be used to bridge to other bus systems
such as Device Net which handle high-speed contact I/O.
Fieldbus Benefits
Fieldbus is expected to reduce the life-cycle cost of production line and then total cost of
ownership (TCO) of the plant.
Planning Phase
Fieldbus allows you to integrate your plant assets on a single plant automation system on
digital communication networks. You can connect devices from multiple suppliers
without custom software and these network-based systems allow for smaller control
rooms, smaller cabinet rooms and more information productivity.
Installation Phase
Fieldbus offers reduced installation and material cost by replacing the traditional one-to-
one wiring scheme with networking or multi-drop configuration, while intelligent field
instruments make commissioning and plant startup much faster and less expensive.
Operation Phase
Maintenance Phase
Fieldbus allows for the reporting of self diagnostics, calibration, and environmental
conditions of field instruments without disturbing the plant control. Since it uses
intelligent instruments, your stock for spare or replacement instruments can be
dramatically reduced. Software packages for asset management are useful to minimize
maintenance costs.
Renovation Phase
Analog Transmission
Hybrid Communication
Fieldbus Communication
The introduction of Fieldbus reduces wiring cost by means of multi-drop connections and
multivariable transmission.
Multi-drop Connections
In a conventional analog transmission system, only one field device can be connected to a
single cable that leads to a system. Multi-drop connections connect multiple field devices
to a single cable, and so allow additional field devices to be connected to a cable which
has already been laid.
In the past, it was costly to connect multiple field devices. Using a Fieldbus
communication system, it is possible to connect a large number of field devices to the
Fieldbus because of low wiring cost by multi-drop connections. This expands the scale of
process control systems and promotes a higher level of plant automation
Multivariable means multiple measured variables, and multivariable detection means that
one field device can detect multiple measured variables, which is also called multi-
sensing.
A conventional analog transmission system requires one cable for each measured
variable.Fieldbus supports multivariable transmission. Therefore, a field device can
transmit all measured variables detected by the field device via a single cable.
The difference in wiring a control valve between analog and Fieldbus communication
systems is shown below.
In the conventional analog transmission system, the control output signal to the positioner
is usually transmitted. In a Fieldbus communication system, multiple pieces of
information such as control signals, limit signals, and valve opening signals can all be
detected and transmitted.
• Monitoring the condition of the steam heat tracing of differential pressure transmitters
by ambient temperature information.
• Detecting clogging in impulse lines by static pressure information. Many other pieces of
information will also be used to expand measurement and control capabilities.
Improved Transmission Accuracy
Fieldbus improves transmission accuracy by eliminating errors that occur during data
transmission in the conventional analog transmission system.
The following three factors cause errors in the conventional analog transmission system.
• D/A conversion in the field device
• Analog signal transmission
• A/D conversion in the system
For example, if data is transmitted from a field device with a microprocessor in the
conventional analog transmission system, an error may result during A/D and D/A data
conversion.Fieldbus eliminates transmission errors and conversion errors during data
transmission.
The difference in transmission accuracy between the conventional analog transmission
system and the Fieldbus communication system is shown below.
Fieldbus transmits data using digital signals. Signal transmission errors rarely occur in
digital signal transmission, unlike analog signal transmission. In addition, Fieldbus does
not need A/D and D/A conversions because data is always transmitted digitally. Fieldbus
Removes these three error factors, improving transmission accuracy.
System reliability also improves as a result of higher transmission accuracy, which allows
stricter quality control and greater production efficiency.
Making the Most of Field Device Accuracy
The conventional analog transmission system cannot transmit data other than PVs and
MVs. Although hybrid communication, an analog communication protocol with a digital
data transmission function, allows various types of data transmission, the hybrid
communication protocol has the following problems:
• The transmission speed is slow.
• Only one-to-one communication between a system and a field device is possible.
Fieldbus solves the problems associated with hybrid communication.
• The transmission speed is fast.
• Multiple pairs of devices can simultaneously communicate among a system and field
devices, and between field devices.
Transmission of various types of data allows the following advanced functionalities.
• Since past maintenance information can be easily acquired, maintenance efficiency
improves.
• Device management such as field device master file creation can be automated.
Bidirectional Communication
Fieldbus transmits multiplexed digital information. This enables the system to perform
bidirectional communication, which is not possible with the conventional analog
transmission system.
The use of Fieldbus implements integrated control over the entire plant and autonomous
distributed control.
Fieldbus allows the exchange of field information used for control in addition to PVs and
MVs.
Field devices with a calculation function and other functions can thus be adjusted from a
system. Although some functions such as correction computation have been installed in
current field devices, various functions that use more information are expected to be
included in future field devices.
By doing this, a field device such as a positioner will be able to field-adjust valve control
characteristics.
By increasing the functionality of field devices and distributing control functions, the
functions will vary between field devices and system.
For example, the user can install the PID function for each control object in a field device
or system. If the relation between loops is tight and they cover a wide range in a large-
scale plant, the PID function will be generally installed in the system. Conversely, if the
loops are relatively independent in a small-scale plant, the PID function may be installed
in a field device.
In an oil refinery or a petrochemical, for example, the PID function is closely related to
complex control, advanced control, optimized control, and integrated control over the
entire plant. Therefore, excluding some independent control loops, the PID function will
be installed in the system.
Interoperability
Fieldbus Foundation started the Host Interoperability Support Test (HIST) for host
computer in September 2000. On September 14, 2000, Yokogawa’s CENTUM series
were certified as the system able to execute the Host Interoperability Support Test
(HIST), becoming the world’s first vendor to carry out the HIST. The HIST is to prove
the interoperability between the host computer and devices. The various devices from
different manufacturers has been tested by the CENTUM series with the HIST procedure,
and the interoperability has been proved.
When Fieldbus is introduced, the type and amount of transmissible information will
drastically increase. Also, bidirectional communication of digital information
cantakeplace between a field device and a system, and between field devices. To make
the most of communication improvements and to satisfy more advanced needs, big
changes are taking place with field devices. This section explains the differences infield
devices when Fieldbus is introduced in a communication system.
Since the Fieldbus communication system transmits information digitally, it can transmit
the measured data from a transmitter to the system with minimum error. Many
transmitters with drastically higher accuracy come to market.
The Fieldbus communication system provides for higher data transmission accuracy
compared to the analog transmission system.
Using the example of the orifice flow meter which uses a differential pressure transmitter,
the difference in transmission accuracy between the analog transmission and
Fieldbuscommunication systems is described below.
In contrast, the Fieldbus communication system transmits the flow signal in engineering
units as a digital signal. Therefore, there is no error during transmission. In this example,
the differential pressure generated by the orifice is calculated and converted to a flow rate
by the microprocessor of the differential pressure transmitter. The flow signal in
engineering unit is transmitted to the system as a digital signal without conversion.
For example, conventional mechanical flow meters and level meters will be replaced by
electric flow meters and level meters that employ digital technology.
Since the Fieldbus communication system transmits the measured data in engineering
units, without dependence on measuring range, a transmitter with a wide measuring
rangewill show the original measuring performance. The width of the measuring range is
one of the most important factors in determining the quality of transmitters.
Multi-sensing Function Equipment
The function used to measure multiple variables with a single transmitter is known as the
multi-sensing function.
The Fieldbus communication system allows the Coriolis flowmeter to transmit multiple
measurement variables via a single cable.
Transmitters that have been used to perform only one measurement are enhanced to
perform the multi-sensing function using the Fieldbus communication system.
For example, the differential pressure transmitter is able to measure process pressure,
ambient temperature, etc., in addition to flow rate, which was the transmitter’s original
function. If a temperature sensor for measuring the process temperature is combined with
this differential pressure transmitter, all flow rate, pressure, and temperature variables
necessary for process control will be measurable by the transmitter alone.
Possible data that will be gained by multi-sensing function for the main transmitters are
shown below.
Multifunction Equipment
For example, assume that there is a differential pressure transmitter which can multi-
sense the flow rate, pressure, and temperature. If a calculation function is added to this
differential pressure transmitter, it allows the transmitter to calculate the mass flow rate
after temperature-pressure compensation using the measured flow rate, pressure, and
temperature, and before executing transmission.
To attain the above functions, a conventional analog transmission system would require
three transmitters, one each for flow rate, pressure, and temperature, and an additional
calculator for temperature-pressure compensation. A single multifunction transmitter
with Multi-sensing can process all of this.
This will not only drastically reduce the instrumentation cost, but will also improve the
reliability.
Actuator
The progress brought about by Fieldbus communication will drastically change the role
of the control valve.
A control valve with a conventional analog transmission controls a valve using a
positioner according to the MV value transmitted from the system.
On the other hand, a control valve with Fieldbus communication does not only control
the valve to a constant opening, but also returns the valve opening value back, with
respect to the MV value, and outputs limit signals to the system. This will promise more
stabilized control of the system without valve opening meter and limit switches
separately.
Also, this valve and its positioner are able to perform valve characteristic modifications,
temperature compensations, etc., which were usually made by the system. This will make
it possible to compensate for valve operation as close to the process state as possible,
while monitoring the valve characteristics.
If this positioner and valve are combined with a flowmeter, the feedback control of a
control valve, which is currently handled by the system, will be handled by only the
control valve.
Features of control valves with the Fieldbus communication are summarized next.
The following figure shows the compensation curves of valve flow characteristics. By
using the control valve with the Fieldbus communication, the following valve flow
characteristics will be change easily. In addition, it is possible to adopt the customized
characteristics.
Using Self-diagnostics Function
The Fieldbus communication system can predict a problem in a field device using the self
diagnostics function.
The conventional analog transmission system can handle only one signal on a single
cable. The system handles the PV or MV value and the self-diagnostics information as
completely different data, even if it is information from the same field device.
The Fieldbus communication system can handle multiple signals on a single cable. The
system can handle the PV or MV value and the self-diagnostics information in the same
environment. Instrumentation and self-diagnostics will be performed under the same
environment by integrating work in the field into a single network.
This idea is far different from the conventional one which has separated instrumentation
from self-diagnostics.
Problem Prediction Function
Since Fieldbus handles the measured values in engineering units, it allows the system to
accurately measure slight changes in pressure and temperature, other than the PV value.
This enables the system to detect the symptoms of problems that were difficult to predict.
For example, suppose the system cannot judge whether the self-diagnostics result of a
field device is abnormal or normal. The conventional analog transmission system can
transmit a self-diagnostics result as either abnormal or normal. Therefore, if a result
cannot be judged as being abnormal or normal, the system always handles it as abnormal
for safety. If a minor abnormality is generated in field devices, a number of alarms will
be displayed on the panel in the control room. However, if minor abnormalities in field
devices are handled as normal to reduce alarms in the control room, the symptom of a
major problem may not be detected.
Using the dedicated package software will make the maintenance work easier.
The number of field devices that can be connected to an H1 segment is restricted by the
power supply current capacity of the segment, macrocycle corresponding to the control
period, and Fieldbus cable length.
The sum of the current consumption of field devices connected to one Fieldbus segment
cannot exceed the current supply capacity of the power supply.
In an intrinsic safety system, the sum of the current consumption of field devices
connected to one Fieldbus segment can not exceed the current supply capacity of the
power supply or limitation value of the safety barrier unit.
The number of field devices that can be connected to an H1 segment should be decided
by the macrocycle corresponding to the control period.
A macrocycle is the period of the control or measurement and the unit is 1/32 ms (1 sec =
32000 units). The scheduled control and communication on macrocycle is executed by
the LM device with LAS capability.
Consideration of Voltage Drop Restrictions
The voltage drop limits are set so that the minimum output voltage of the power supply,
less the voltage drop in the cable resistance, is not less that the minimum operating
voltage of the device, even considering the voltage fluctuation. Yokogawa recommends
minimum 9.5 volts as operating voltage design.
The typical resistances per unit length of the various cable types that can be used for
Fieldbus are shown below. The following resistance values are for reference only. For
actual values, contact the cable manufacturer.
The following general formula is used to check whether the minimum supply voltage is
secured.
Minimum Power Supply Voltage > (resistance per unit length X cable length) X device
current X minimum operating voltage
If using a twisted-pair cable for the main line, carefully consider the kind and total length
of cabling.
Some Type B cables attenuate signals largely. To secure sufficient signal amplitude, no
more than 20 field devices must be connected with a maximum total cable length of 600
m, or no more than 10 field devices must be connected with a maximum total cable
length of 1,200 m.
When using Type D cables, up to two pairs of cables must be used for Fieldbus and each
pair must be separated from each other to prevent interference.
When using multi-core cables, do not send signals other than Fieldbus signals or analog
signals (including hybrid communication) through the same cable.
Number of Branch Cables and Total Length
In tree type wiring, carefully consider the total length of cabling in accordance with the
number of spur (branch) cables (number of field devices to be connected).
The typical maximum total lengths of spur cables shown in the IEC and ISA standard
(*1) are given below.