Integracion SI Segunda Parte

Integración de Sistemas
Industriales
Segunda Parte
Module 1
Introduction to Industrial Networks
Integracion de Sistemas Industriales

Segunda Parte: Redes Industriales
Introduction to data communications
Overview
 The first process control systems
were analog
 Digital systems (Networking) was
introduced in industrial
automation in the 70s: DDC –
direct digital control
 Later DCS (distributed control
systems) and PLCs
(programmable logic controllers)
 Digital communications in small
devices (transmitters): 80s
 True networking of field
instruments: 90s
 This is different from the history
of traditional networking:
Ethernet, Internet

Overview
 Many networks: telephone,

radio, and television are still
analog
 The trend is towards all-digital
communications
 Networking in automation is
all digital: a stream of ones
and zeros.
 Digital communications makes
possible data transfers
between: transmitters, valve
positioners, controllers,
workstations, and servers.

Overview
 Main Advantage: Lots of information on a single cable (Instead of
one hardware cable for each variable)
 Thousands, even millions of pieced of data can be communicated.
 Before, it was impossible to transmit anything but I/O
 Configuration and
Tuning had to be
done locally.
 Sensors and
actuators were
hardwired to the
controllers

Overview
 Digital communications made it possible for DCS and PLC
controllers to be placed away from the control room in auxiliary
rack rooms
 All the supervisory

information for
hundred of control
loops and
monitoring points
can be transmitted
to the control room
over a single
network

Overview
 In addition to I/O and
variables, data in the
network carry:
 Setpoints and modes of
operation
 Alarms
 Tuning in both directions
 Networking enabled:
distributed processing,
diagnostics, configuration,
identification,
troubleshooting, operation,
maintenance, other.

Multi-drop and digital control loop
 Muti-drop: the interconnection of several devices to

same single pair of wires.
 Reduces the wiring requirements: hardware and
installation savings
 Each device is called a node and it is given a unique
address to distinguish from the others.

Multi-drop and digital control loop
 Digital Control Loop: A

multi-drop configuration
involving sensors,
actuators, and controllers
 The sequence: Sensors 
Controller  Actuators 
Process  Sensors
constitute a control loop.
 Thus, the sensor, actuator,
controller and process are
the fundamental elements
of a process control
system.

Modern Instrumentation and Control
Systems
 Instrumentation is the
basis for process control
in Industry
 It comes in many forms:
 Domestic water heaters
 HVAC (heating,
ventilation, air
conditioning)
 Laboratory
instrumentation
 Industrial
instrumentation
 Industrial process control
(oil, gas, chemical)
Modern Instrumentation and Control
Systems
Why Instrumentation?
 You cannot control what
you cannot measure
 Monitoring, Observation
 Security
 Accounting
 Costing
 Saving
 Trending, performance
 Gauging, Measurement Power Plant
 Pressure
 quantity
Modern Instrumentation and
Control Systems
Definitions
 “Instrumentation is the
branch of engineering that
deals with measurement
and control”
 “A collection of Instruments
and their application for the
purpose of Observation,
Measurement and Control”
ISA: Instrument Society of
America

Modern Instrumentation and
Control Systems
Control Functions
 Sensing
 Measurement
 Comparison
 Filtering
 Control
 Actuating
 Transmission/Reception
 Storing
The figure shows a DCS:

Distributed Control System
“Smart” Instrumentation
 Has a microprocessor which
checks the complete system and
itself before validating the signal.
 Flashing LEDs serve as heartbeat
to indicate a healthy system.
 In the event of a system fault,
LED glows, display indicates “Err-
-“ and the relay contacts revert
to their fail-safe condition.
 System fault: incorrect wiring,
open or short sensor connection,
failure of probe insulation,
improper grounding or electronic Level Transmitter
insert failure, the heartbeat Capacitance based, continuous
stops, level control & indicator
www.sapconinstruments.com/capacitance/mpilc-level-instrument.html

Distributed Control Systems (DCS),
PLC (Programmable logic controllers)
 They both share similar
architecture:
 I/O: input output system Main Application Areas
 Set of controllers, in a  DCS: Process
hierarchy Automation
 Communication network
 PLC: Factory
 DCSs and PLCs are mostly Automation
centralized controllers
 Fieldbuses enable more
descentralized
architectures:
 FCS: field control system
 CIF: control in the field

PLC (Programmable logic controllers)
Process Automation
 Regulatory control in Factory Automation
process industries:  Regulatory control in assembly
 Oil & gas line manufacturing:
 Pulp & paper  Automotive
 Power systems  Bottling
 Chemicals  Machinery
 Measurement is analog  Measurement and Actuating
 Actuating is modulating are binary
 Networks:  Networks:
 Foundation Fieldbus  DeviceNet, ControlNet
 Profibus PA  Profibus DP, FMS
 HART  Interbus-S
 AS-I (actuator sensor Int.)

PLC

Distributed Control Systems (DCS), PLC
Example of a DCS: Delta V (Emerson)

Introduction to data
communications: Summary
 Traditional analog
communications is being  Networks has enabled:
replaced by digital  Modern instrumentation
communications.  Control systems
 Networks are being used  Smart instrumentation
for closed loop control in  Distributed control systems
process automation (DCS)
 Other advantages of  Programmable logic
networking include: controllers
 Configuration  In major application areas:
 Troubleshooting  Process automation
 Operation  Factory automation
 Maintenance
Integracion de Sistemas
Industriales
Module 2
Basic Process Principles

Purpose of Process Control
Definitions
 A Control system effects
the output(s) according to
a pre-scribed fashion.
 “A collection of
components, sensors,
actuators, and controllers
to perform control
functions”
 Main types:
 Analog
 Digital
 Figure on right shows a

batch reactor scheme

Batch reactor controller
 Reactant A is injected into the vessel. Steam is fed into the
jacket to bring the reaction mass up to a desired temperature.
Then cooling water must be added to the jacket to remove the
exothermic heat of reaction and to make the reactor
temperature follow the prescribed temperature-time curve.
 This temperature profile is fed into the temperature controller
as a set-point signal. The set-point varies with time. First order
consecutive reactions take place in te reactor as time proceeds.
 The desired product (process variable, PV) is concentration of
component B.
 Measurements: steam valve opening, water valve opening,
reactor temperature, steam flowrate, water flowrate, and
components A and B concentrations.

Batch reactor controller signals

Location of Control Functions
Control Functions
 Sensing
 Measuring
 Comparing
 Filtering
 Controlling
 Actuating
 Transmitting/Receiving
 Storing
The Figure shows a DCS:

Distributed Control System

Control Signals, Variables
 Reference, set point
 Measured signal
 Output signal (reaction signal)
 Error signal
 Controller (Correction) signal
 Actuator (Power) signal
 Network Interfaces:
 Controller: PID (proportional,
integral derivative), PI, PD, etc.
 Sensors: AI (analog input)
 Actuators: AO (analog output)

Location independent model for distributed control

Variables Measured and Controlled
Illustrative Examples:
 Pressure
 Positive pressure
 Negative pressure
 Absolute pressure
 Differential pressure
 Gas
 Liquids
Differential pressure
sensor 0 – 250 kPa
www.directintustry.com

 Temperature
 Resistance temperature
detectors (RTDs)
 Thermistors
 Thermocouples (TCs)
 Cable sensors as both TCs
and RTDs.
www.ls-windpower.com
 Level
 Point level
 Continuous
 Capacitance
 Radar gauging
Level Transmitter
Capacitance based, continuous
level control & indicator
www.sapconinstruments.com

Final Control Elements
Actuators
 Pressure controllers
 Flow control actuators

(Valves)
 Power control
 Motors
 Application considerations
Steam solenoid valve.

www.directindustry.com

Definition of terms
Stirred tank
control
systems: Fin, Tin Stirrer Level
 Temperature
recorder
control
Temperature
TE
recorder
 Level control Controller
Desired
LT value Hs
Controller Fout, Tout

CV
CV
Desired
value Ts Condensate
Steam
Transmission lines
Fst, Tst
Definition of terms
1) a process - the stirred tank;

2) controlled variables - temperature of the effluent liquid
(or temperature of the liquid in the tank) and level of
the liquid in the tank;
3) a transducer, a measuring instrument, a transmitter;
4) a transmission line (electrical, pneumatic or hydraulic)
that carries a measurement signal from a measuring
instrument (or transducer) to a controller;
5) a control signal from a controller to a final control
element (for example, a control valve);
6) a controlling device or a controller;
7) a final control element - a control valve.

Definition of terms
Symbols and abbreviations:

CV: a control valve.
Fin, Fout, Fst: flowrates of inlet and outlet streams of the liquid,
and steam, respectively;
Hs: a desired value (set point) of the liquid level in
the stirred tank;
LT: a level transmitter;
TE: a thermocouple;
Tin, Tout, Tst: temperatures of inlet and outlet streams of the
liquid, and steam, respectively;
Ts: a desired value (set point) of the temperature in
the stirred tank

Process lag, capacitance and
resistance
 All physical systems can be categorised in terms of types of

energy used.
 Most common: electrical, hydraulic, pneumatic and thermal.
 A system can be of any physical type.
 Regardless of their type, each has a single capacity and a
single resistance.
 How these systems behave in respect to time?
 Behaviour of an
electrical system Uc, V
to an imposed R
step upset, step E C
change, or step
t, sec
input.
Process lag, capacitance and
resistance
 As the voltage of the capacitor approaches to the voltage of the
battery (corresponds to 100%) the charging rate gradually
decreases.
 The time interval necessary for the capacitor to charge to the
63.2% of the battery voltage (no matter what is the battery
voltage) is constant for any one value of the resistance and the
capacitance. ,
100
Percentage of chargable voltage,

 This time is called the time 90
80 Series1
constant (τ). The units are in 70
seconds. 60
50
 To get the value of the time
%
40
constant we must multiply the 30
values of resistance and 20
capacitance: 10
0
  RC 0 20 40 60
Time, sec
80 100 120

Process reaction curve
gH,
Pa
C
Hydraulic
R gH
t, sec
P, Pa
Pneumatic R
Gas
, t, sec

Temp.
T, K
C
Thermal Heat
Heat
t, sec
source
The above processes examined are called transient process. The
response curve is called a reaction curve. The form of this curve is
exponential, and sometimes the curve is called exponential-transient
curve .
Dynamic characteristic of a system defines behaviour of a process in
respect to time
Static characteristic of a system defines behaviour of a process which
,
does not involve time. They can be linear or non-linear.
Static characteristic of a thermocouple of Type K.
60
Thermal electromotive force, mV
50
40
30 Type K
20
10
,
0
-10
-300 0 300 600 900 1200 1500 1800
Temperature, C

1st and 2nd order reactions
The reactions seen thus far are of 1st order (purely exponential)
Some systems exhibit a 2nd order reaction like the one below.
Dynamic Response of Bellows Pressure Sensor

0.010
0.008
Deviation, m
0.006
0.004
damp. = 1
damp. = 0.5
0.002
, damp. = 1.5
damp. = 0.2
0.000
0.0 2.0 4.0 6.0 8.0 10.0
X

P & ID Symbols
Piping and Instrument Diagrams
 are the “schematics” used in the
field of instrumentation and PID
control (Automation)
Proportional control with
 The P&ID is used to by field derivative and integral
techs, engineers, and operators actions
to better understand the process
P&ID
and how the instrumentation is
inter connected. Piping and instrument
 Versions
diagrams
 Piping & Instrumentation
Drawing (original) Using pictorial diagrams may be
informative however it is not
 Process & Instrumentation
practical or CAD friendly
Diagram (also used)
especially in a multi-loop
 Process Flow Diagram – PFD process.
(simplified version of the
P&ID)
P & ID Symbols

P & ID Symbols
Tag Numbers
 Tag “numbers” are letters and
numbers placed within or near
the instrument to identify the
type and function of the
device.
Generic Tag Descriptor: XYZ
 The first letter is used to
designate the measured
variable
 The succeeding letter(s) are
used to designate the function
of the component, or to
modify the meaning of the
first letter.
P & ID Symbols
Tag Descriptors
 Pressure
 Level
 Flow
 Temperature
 Indicator
 Recorder
 Controller
 Transmitter

P & ID Symbols: ISA S5.1 ID Letters

P & ID Symbols: Type and location

P & ID Symbols
Piping and Connection
Symbols
 These symbols are
used to identify how
the instruments in
the process connect
to each other.
 And what type of
signal is being used.
(electrical,
pneumatic, data,
etc)
P & ID Symbols:

P & ID Symbols: Example

P & ID Symbols
 Process Flow Diagram: PDF

 A PFD shows less detail than a P&ID and is used
only to understand how the process works

Basic process principles:
Summary
 Main components of a
 Process control is the effect
of system outputs process control system:
according to a prescribed  Controller: PID, PI, PD, etc.
fashion.  Sensors: AI (analog inputs)
 It involves measurement,  Actuators: AO (analog
instrumentation, controllers outputs)
and actuators.  The final control element is
 All processes involve a lag, the one that effects change
capacitance, and resistance on the process, e.g., a
effects. control valve.
 Process variables:
 DCS (Distributed control
 Temperature, flowrate,
concentration, pressure, System):
level, etc.  A hierarchical, centralized
control architecture
Industriales
Module 3
Data Communications and Fieldbus
Standards

RS-232, RS-485 standards
 They specify the exact way
that transmitters and receivers
exchange digital data.
 Specifications:
 Speed of transmission
 Cable characteristics
 Length of cable
 Type of communications
 Speed of transmission
 Most important:
 RS-232, RS-424
 RS-485
 Coaxial cable
 Optical fiber Integracion de Sistemas Industriales

RS-232 Standard
 Recommended Standard to facilitate compatibility and
interchangeability between computers and peripherals through a
serial link.
 Established by EIA (Electronic Industries Association).
 Equivalent to V.24 standard.
 Voltage levels: Uses

negative logic:
 Logic 0 = +3 V to +25 V
(typically +12 V)
 Logic 1 = -3 V to -25 V
(typically -12 V)

RS-232 Standard
 Connectors
 RS232 defines a 25-pin D
connector but only 9 pins
are implemented in most
applications:
 Frame Ground (pin 1, FG)
 Transmit Data (pin 2, TD)
 Receive Data (pin 3, RD)
 Request to send (pin 4,
RTS)
 Clear to send (pin (pin 5,
CTS)
 Data set ready (pin 6, DSR)
 Signal Ground (pin 7, SG)
 Data Carrier detect (pin 8,
DCD)
 Data terminal ready (pin
20, DTR)

RS-232 Standard
 DTE: Data Terminal
Equipment, typically a
computer.
 DCE: Data Communications
Equipment, typically a modem.
 Data transmission
 Asynchronous.
 Similar to UART.
 One start bit.
 5-8 data bits
 1, 1.5, or 2 stop bits.
 Limitations
 Distance < 50 ft (can be
higher if cable is shielded)
 Maximum data rate of 20
Kb/s.
 Only one transmitter and one
receiver. Integracion de Sistemas Industriales
RS-422 Standard
 Uses balanced transmission.
Overcomes limitations of RS-
232.
 Voltage levels
 Logic 0 = +2 V to +6 V Logic
1 = -2 V to -6 V
 Features
 Longer distances are possible.
High data rates can be
achieved.
 (100 Kb/s at 1200 m, 10 Mb/s
at 12 m)
 Allows up to ten receivers for
each transmitter.
 Balanced transmission is more
immune to noise.

RS-485 Standard
 Intended for multipoint
systems.
 Uses balanced
transmission.
 One or more transmitters
may be connected to one
or more receivers.
 Multidrop, Multipoint
 Maximum number of
nodes:
 Data rates up to 12 Mb/s.
32
 Maximum distance: 1200 m
 Voltage levels: - 5V to + 5V
Voltage

IEC 61158 Fieldbus Standard
 A data communication standard
for:
 Measurement
 Control
 For industrial control systems
 Uses ISO networking terminology
 61158-1: Overview and guidance
for the IEC 61158 series
 61158-2: Physical Layer
specification and service definition
 61158-3: Data Link Service
definition
 61158-4: Data Link protocol
specification
 61158-5: Application Layer
Service definition
 61158-6: Application Layer
protocol specification
A Generic Fieldbus Network

CPF: Comm. Protocol Profiles
 CPF Number 1 –
FOUNDATION Fieldbus
 H1, H2, HSE
 CPF Number 2 – CIP
 ControlNet, EtherNet/IP,
DeviceNet
 CPF Number 3 – Profibus
 DP, PA, Profinet (4 types)
 CPF Number 4 – P-NET
 P-NET RS-485, P-NET RS-
232, P-NET on IP
 CPF Number 5 – WorldFIP
 3 types
 CPF Number 6 – InterBus
 Several types

Physical Layer Comparison

IEC 61508 Safety Standard
Sources of hazards:
 Safety expresses the notion of  Human
absence of catastrophic  Unforeseen events
consequences on the user(s)  Component failures
and the environment.  Fault/error propagation
 Catastrophic consequences:
 Personal injury
 Loss of equipment Benign Failure
 Loss of life Benign
Interruption B
 Two types of safety
 Intrinsic safety (IS)
A Accomplishment
 Functional safety Restoration
 IEC 61508/61511 addresses

functional safety Catastrophic
Failure
 IS is addressed by appropriate Catastrophic
Interruption
C
fieldbus standards (e.g.,
61158)
 Safety Integrity Levels (SIL): severity levels for the catastrophic

consequences:
 SIL-1:Minor
 SIL-2:Intermermdiate
 SIL-3:Major
 SIL-4:Catastrophic
 PFD: Probability of failure on demand
 RRF: Risk reduction factor

FF Fault Tree

Data Communications and Fieldbus
Standards: Summary
 Main data  IEC 61158/61784: Broad
communication fieldbus standards that
standards: inlcudes most fieldbus
networks
 RS-232
 Foundation Fieldbus
 RS-422 (point to point)
 Profibus
 RS-485 (multidrop)
 HART, others
 RS-485 used in fieldbus  IEC 61784 defines
networks communication protocol
families (CPF)
 IEC 61508/61511 are
functional safety standards
applicable for fieldbuses.
Industriales
Module 4
Main Parameters of Fieldbus Networks

Main Parameters
Bus Cycle Time
 Several but similar Cyclic period
definitions due to Time it takes for scanning of
underlying technology inputs, execution of
 Also called algorithms and
transmission of output
communication cycle
values to devices.
time
Acyclic period
 When activities are
 Time during which
repeated periodically, the
period is called cycle information other than
time. Publish/Subscribe data is
transmitted.
 In FF, cycle time has:
 In FF networks the cycle
 Cyclic period
 Acyclic period
time is called “Macrocycle”

Main Parameters
Bus Cycle Time

Main Parameters
Number of Nodes (or devices)
 A limitation imposed by the physical layer
 It is due to the power levels of the power supply, and transmitters
and receivers
 For trunks that limit power to meet intrinsically safe (IS)
requirements, segment length and number of devices supported will
be severely limited.
 For FF, the maximum number of devices (including future devices)
on any segment should be no greater than 12 (depends on bus
power options)

Main Parameters
Number of Nodes (FF)

Main Parameters
Terminator Resistance
 FF segments require  Terminators at a field
EXACTLY two terminators, device shall not be used
one at each end of the
(due to the impact on the
 trunk (home run) cable.
whole segment should the
 The terminator is comprised
of an RC network that device need replacement).
provides 100 Ω
 impedance. The terminator
allows the current-based
FOUNDATION fieldbus
communications
 signal to be viewed as a
voltage while being offset
on the DC segment voltage
supply.

Main Parameters
Terminator Resistance
 Notes:
 Constructing your own
terminator using a 100 Ω
resistor and a 1 μF capacitor
will not guarantee correct
segment communications, and
is therefore not
recommended.
 Most fieldbus power supplies
and/or field device couplers
have a built-in segment
terminator.
 Some wiring components have
switchable terminators. Care
should be taken to verify the
correct quantity of terminators
on a segment. Integracion de Sistemas Industriales
Main Parameters
Jitter
 Jitter is the variation of
Control Response Period in
timing variables:
FF
 Cycle time
 Latency (Response Period)
 Token hold time
 Execution time
 Systems based on
“synchronization” (e.g., FF)
minimize jitter.
 Jitter is particulary
important for PID control
systems
 Real time systems require
small jitter.
Main Parameters
Latencies (Response Period)
 Latency is a delay that Control Response Period in
includes: FF
 Block processing times
 Bus communication delays
 The figure shows the
latency from when a sensor
measurement is taken until
the final control element
outputs the control value to
the system.
 Also called:
 response time
 response period
Main Parameters
Sample Rates
 The rate (or period) at  For CIF, latency and sample
which process variables are rate are determined by:
sampled  How many loops are being
 Improvements in control controlled
loop performance for CIF  Where the control is executed
arise from: (sensor, H1 card, actuator)
 Faster sample times  The number of scheduled data
transfers
 Shorter latency (delays) in
the read-execute-write  The speed of the FF devices
cycle  The complexity of the control
 Guaranteed determinism logic
 Oversampling: When faster  These define the “macrocycle”
sample times does not yield – the update rate for the FF
any additional benefits segment

Main Parameters
Sample Rates
 A fast, but realistic, single loop control loop is considered
where the PID is executed in the actuator
 Rosemount 8800D Flowmeter : AI execution – 20msec
 Data transfer AI to PID – 30msec
 Fisher Valve Positioner DVC6000F: PID execution – 30msec
 Fisher Valve Positioner DVC6000F: AO execution – 25msec
 This fits in a typically supported fast macrocycle of 150msec
 Sample rate = 150msec ; latency = 105msec (“Case 1: CIF”)

Main Parameters
Datagrams (Frames)
 Datagrams is the
structure of data as it
travels from the
application to the bus
 Parameters: Information
other than user data
 Headers:
 PCI
 Start delimiters
 Preambles
 Trailers:
 FCS
 End delimiters

Main Parameters: Summary
 Fieldbus networks are complex systems with many parameters
 Most important parameters reviewed:
 Cycle time: Period of performing all periodic activities
 No. of nodes: Depends on power supply characteristics
 Terminator resistance: 100 Ohms at each end of a segment
 Jitter: Variation of execution or transmission times
 Latency: Delay in execution or transmission times
 Sample rate: Rate at which sensors values are read
 Datagram parameters (header and trailer)
 PCI (Protocol control information)
 Start delimiters
 Preambles
 End delimiters
 FCS (Frame check sequence)
Industriales
Module 5
Industrial Applications

 Fieldbus systems are used in the lower layers of the automation
hierarchy
 But they are
complemented by
other solutions to
cover the entire
hierarchy
 The figure shows FF
solutions featuring:
 Device integration
 Sub-system
integration
 Server integration

 H1 Integrates devices at the field level

 HSE Integrates sub-systems and data servers

H1 + HSE Provides Full Information Integration
 H1 and HSE Have the Same Proven Function Block User Layer
 H1 and HSE Have Plug and Play Interoperability
 H1 Provides Distributed Process Control and Device Integration
 HSE Provides High Performance Control and Subsystem

Integration
 End User Selects Communications Performance Desired: H1 or
HSE
 HSE Allows Data Servers to Integrate all Plant Information

H1 + HSE Flattens the Plant Hierarchy, Cuts Cost and Increases
Performance
 Integration of Sensors, I/O Converter and Controller into a
Single Device
 Single Architecture Reduces Networks and Gateways in the
Plant
 Open Architecture has Suppliers Competing on Features, Not
Network
 High Volume of H1 Devices and COTS Ethernet is Driving Down
Cost
 Diagnostics Reduce Shutdowns and Reduce MTTR (mean time
to repair)

Example Applications
 Single Loop Control  Advanced Alarming
 Feedforward Control  Motor Control
 Cascade Control  Math
 Override Control  Supervisory Data
 Ratio Control Acquisition
 Manual Loader  Sensor bus interfacing
 Lead/Lag Compensation
 Coordinated Drives
 Signal Characterization
 Batch Control
 Timing and Integration

Industrial Applications: Summary
 Fieldbus networks provide solutions at the lowest layers of the
automation hierarchy.
 They are complemented by other solutions to provide a total
solution
 Foundation Fieldbus solutions: F1 and HSE
 Profibus solutions: PA and ProfiNet
 Example applications include:
 Process control systems (CIF: control in the field)
 Advanced Alarming
 Motor Control
 Supervisory Data Acquisition
 Sensor bus interfacing
 Coordinated Drives
 Batch Control

Industriales
Module 6
Communication and Network Requirements

Communication and Network
Requirements
 There are many application domains each with specific requirements
 There are also many fieldbus solutions

Requirements
Solutions are matched to applications in terms of requirements
 Synchronization: A central (master) device controls when devices send
data on the bus.

Requirements
 Speed: The data rate of the
data communication channel
 H1 speed: 31.5 Kpbs
 HSE speed: up to 100 Mbps
 Real-time: The system
response time matches the
process

Requirements
Latency: The time it takes for:
 Function blocks to execute
 Messages to be delivered on a network

Requirements
 Fault Tolerance: The means
that a system has to tolerate
faults, e.g., redundancy
 Reliability: The means that a
system has to avoid failures,
e.g., good connectors
 Safety: The means that a
system has to avoid loss of
equipment, injuries, or loss of
life, e.g., limit power in
explosive environments
 Figure shows an HSE Fault
Tolerant Example: Dual
Interface – Dual LAN
Requirements
 Applications: The means that
a network solution has to
address application
requirements.
 For example: Manufacturing
applications have many
different types of sensors,
switches, and binary
actuators.
 For Manufacturing, solutions
involve:
 PLCs
 Sensor networks: AS-I,
Profibus DP, DeviceNet, etc.

Requirements: Summary
 There are many application domains each with specific
requirements
 There are also many fieldbus solutions:
 Process automation: FF, Profibus PA
 Manufacturing automation: Profibus DP, DeviceNet, AS-I
 Automotive (on-board networking): CAN
 Machines: CAPOpen
 Solutions are matched to applications in terms of requirements
 We have addresses the following requirements:
 Speed and synchronization
 Real-time and latency
 Fault tolerance, reliability, and safety
 Applications
94
Industriales
Module 7
ISO OSI Model

ISO OSI Model
 All modern fieldbus systems
are designed using OSI model
principles.
 This is particularly true of FFs
that uses IEC 61158
 ISO: The “International
Standards Organization” that
standardized the model
 OSI: The name of the model
(Open System
Interconnection)
 It arranges all communication
functions into a layered
architecture with 7 layers.
ISO OSI Model
 Each layer in the model has
specific functions
 Together these functions
enable computers to
communicate with any other
computer regardless of
location
 For fieldbus networks, not all
layers are significant
 Fieldbus also includes a layer
outside the OSI model: the
application
 The figure shows the
Foundation Fieldbus model
ISO OSI Model
 For specification and
commissioning reasons, yet
another model is used (See
Fig.)
 “Open” means that the
specifications are public and
well defined
 Physical layer: Converts binary
data (0s and 1s) inside devices
into signals to be transported
by media.
 Media types:
 Wires
 Optical fiber
Industriales
Module 8
LAN Standards

LAN Standards
 LAN: Local Area Network
 Characterized by layers 1
and 2 of the OSI model
 Thus LANs primarily
deals with:
 Topologies
 Media
 Encoding, Data rates
 Data link layer protocols
 LAS: schedulers
 Token passing
 Wired Ethernet
 Wireless Ethernet
LAN Standards
Topologies
Main Topologies
 Point-to-point
 Bus
 Variations (later)

LAN Standards
Communication Media
Main Media Types
 Wire pairs
 Optical fiber

LAN Standards
Communication Media

LAN Standards
Communication Media: Fibers
Fiber optic cable has huge advantages over copper
 It’s immune to Electromagnetic Interference
 Support of long distances
Fiber is made from
 Glass –High quality, used for long distances or high speed
 Plastic –Cheaper, used for short distances and low speed
 Glass core + plastic cladding –compromize, fieldbusses only
There are 3 basic light sources
 LEDs–low cost, used for MMF
 ELEDs-medium cost, used for SMF, cheaper than LDs, no Laser
protection measures needed
 Laser, Laser Diodes LD –used with SMF over long distances

LAN Standards
Communication Media: Fibers

LAN Standards
Protocols
MAC (Medium Access Control) Protocol

LAN Standards
Protocols
MAC (Medium Access Control) Protocol

LAN Standards
Protocols: Links
Two types of “links”:
 point-to-point
 PPP for dial-up access
 point-to-point link between Ethernet switch and host
 broadcast (shared wire or medium)
 old-fashioned Ethernet
 upstream HFC
 802.11 wireless LAN
humans at a
shared wire (e.g., shared RF shared RF cocktail party
cabled Ethernet) (e.g., 802.11 WiFi) (satellite) (shared air, acoustical)
LAN Standards
Protocols: MAC
 single shared broadcast channel
 two or more simultaneous transmissions by nodes:
interference
 collision if node receives two or more signals at the
same time
multiple access protocol
 distributed algorithm that determines how nodes share
channel, i.e., determine when node can transmit
 communication about channel sharing must use channel
itself!
 no out-of-band channel for coordination
LAN Standards
Protocols: MAC
Three broad classes:
 Channel Partitioning
 divide channel into smaller “pieces” (time slots,
frequency, code)
 allocate piece to node for exclusive use
 Random Access
 channel not divided, allow collisions
 “recover” from collisions
 “Taking turns”: Token
 nodes take turns, but nodes with more to send can
take longer turns
LAN Standards
Protocols: Channel Partitioning
TDMA: time division multiple access
 access to channel in "rounds"
 each station gets fixed length slot (length = pkt
trans time) in each round
 unused slots go idle
 example: 6-station LAN, 1,3,4 have pkt, slots
2,5,6 idle
6-slot
frame
1 3 4 1 3 4

LAN Standards
Protocols: Random Access
 When node has packet to send
 transmit at full channel data rate R.
 no a priori coordination among nodes
 two or more transmitting nodes ➜ “collision”,
 random access MAC protocol specifies:
 how to detect collisions
 how to recover from collisions (e.g., via delayed
retransmissions)
 Examples of random access MAC protocols:
 slotted ALOHA
 ALOHA
 CSMA, CSMA/CD, CSMA/CA
LAN Standards
Protocols: CSMA
CSMA: Carrier sense multiple access
 listen before transmit:
 If channel sensed idle: transmit entire frame
 If channel sensed busy, defer transmission
 human analogy: don’t interrupt others!

LAN Standards
Protocols: CSMA
collisions can still occur: spatial layout of nodes
propagation delay means
two nodes may not hear
each other’s transmission
collision:
entire packet transmission
time wasted
note:
role of distance & propagation
delay in determining collision
probability

LAN Standards
CSMA/CD (Ethernet)
CSMA/CD: carrier sensing, deferral as in CSMA
 collisions detected within short time
 colliding transmissions aborted, reducing channel

wastage
 CD: collision detection:
 easy in wired LANs: measure signal strengths,

compare transmitted, received signals
 difficult in wireless LANs: received signal strength
overwhelmed by local transmission strength
 human analogy: the polite conversationalist

LAN Standards
CSMA/CD Collision Detection

LAN Standards
Wireless Ethernet: IEEE 802.11
Wireless Ethernet cannot use the CDMA/CD protocol
as in wired networks because:
 Hidden terminal problem (left figure)
 Large signal attenuation problem (right figure)
 Instead of CD, a CA (collision avoidance) version is
used.
A B C
C
A’s signal C’s signal

strength
B strength
A
space
LAN Standards
CSMA/CA: CSMA with Collision Avoidance
 Avoid collisions: 2+ nodes transmitting at same time
 802.11: CSMA - sense before transmitting

 don’t collide with ongoing transmission by other node
 802.11: no collision detection!
 difficult to receive (sense collisions) when transmitting due
to weak received signals (fading)
 can’t sense all collisions in any case: hidden terminal,
fading
 goal: avoid collisions: CSMA/C(ollision)A(voidance)

LAN Standards
802.11 sender
1 if sense channel idle for DIFS then sender receiver
transmit entire frame (no CD)
2 if sense channel busy then DIFS
start random backoff time

timer counts down while channel idle data
transmit when timer expires
if no ACK, increase random backoff interval,
repeat 2 SIFS
802.11 receiver ACK

- if frame received OK: return ACK after SIFS
(ACK needed due to hidden terminal
problem)

LAN Standards
Wireless Ethernet: Coll. Avoidance
idea: allow sender to “reserve” channel rather than random
access of data frames: avoid collisions of long data frames
 sender first transmits small request-to-send (RTS) packets to
BS using CSMA
 RTSs may still collide with each other (but they’re short)
 BS broadcasts clear-to-send CTS in response to RTS

 CTS heard by all nodes
 sender transmits data frame
 other stations defer transmissions
avoid data frame collisions completely

using small reservation packets!
LAN Standards
Wireless Ethernet: Coll. Avoidance
A B
AP
reservation collision
DATA (A)
defer
time

Industriales
Module 9
Ethernet

Ethernet
Foundation Fieldbus Architecture

Ethernet
Ethernet Frame
ETHERNET today is not the same when it was invented 30 years ago
Improvements:
 -Higher bandwidth -10Mbit/100Mbit/1Gbit/10G
 -Full-duplex communication →without collisions
 -Switching
 -Prioritization and flow control
 -VLANs -Virtual Local Area Networks
 SOF: Start of Frame
 FCS: Frame check sequence

Ethernet
Media Access Control (MAC)
2b: Logical Link Control (LLC)
 Link make and break, packet traffic control, packet sequencing,
packet ack.
 LLC: link control
2a: (MAC)
 Controls access to
shared media
 Uses a random
access protocol that
involves collisions
 CSMA/CD
 CD: Collision
detection
Ethernet
Collision Detection (CD)
1. Interface receives datagram 4. If interface detects another
from network layer, creates transmission while
frame transmitting, aborts and
2. If the interface senses sends jam signal
channel idle, starts frame 5. After aborting, interface
transmission. If the interface enters exponential backoff
detects a collision, waits until where it waits for a random
channel idle, then transmits
amount of time, then, returns
3. If the interface transmits to Step 2
entire frame without
detecting another collision, A collision is detected by
interface is done with frame ! detecting an energy level
much higher than normal.

Ethernet
Industrial Ethernet
 There are many versions of “Industrial Ethernet” solutions
marketed by vendors
 Most significant include:
 HSE
 ProfiNet
 Ethernet/IP
 Modbus
 EtherCat
 EtherLink

Ethernet
Industrial Ethernet: HSE
 HSE for use as a control backbone
 HSE enhances access to H1 technology via Linking Devices (LD)
 HSE uses standard Fast ETHERNET (IEEE802.3u)
 Preserve all H1 functions and carry H1 services
 High speed transfer/huge bandwidth
 Commercial off the shelf (COTS) Ethernet components
 Redundancy on the network level

Ethernet
Industrial Ethernet: HSE
HSE is Designed for High Performance Control
 Distributed Control on a COTS 100 Megabit per Second Backbone
 Same Function Blocks and Device Description Technology as H1
 Function Block Synchronization on the Backbone
 System Time Synchronization - Master Clock (e.g. GPS) to HSE to H1
 New Flexible Function Blocks for Hybrid/Batch/PLC/Remote I/O

Applications
 Uses Standard Internet DHCP - Address Lease Reuse Reduces Startup
Time
 Short Messages Can be Packed to Reduce Interrupts on Receiving
CPUs
 Provides Redundant Network Interface and Redundant Devices

Ethernet
Industrial Ethernet Vs Office
HSE is

Ethernet
Industrial Ethernet: Requirements
(1)
 Secure mounting
 Rapid mounting of robust devices by
means of simple clipping onto a
standard DIN-Rail.
 24/48VDC power supply
(redundant)
 Different application fields
 Robust design suitable for industrial
applications.
 Ambient conditions
 Extended temperature range -40 ~
+70°C
 Conformal coating
 IP 20/IP30/IP67
 Rel. atmospheric humidity up to
95% (non-condensing)
Ethernet
(2)
Mechanical stability
 Vibration, shock and free-fall
tests in accordance with PLC
standards EN 61131-2 (IEC
1131-2:1992), IEC 60068.
Electrical requirement
 EMI: EN 50022, EN 50082-2,
FCC Part 15 (Class B)IEC
1000-4-2, IEC 1000-4-6, IEC
1000-4-4, EN 61000.

Ethernet
(3)
Certifications / Approvals
 CE, cUL60950, cUL508
 cUL1604 Class 1 Div 2 (A, B, C, D)
or FM 3611 Class I Div 2
 ATEX 100a Zone 2
 Maritime applications, e.g., GL
(GermanischerLloyd), DNV
 Substation IEC61850
High MTBF (Mean Time Between
Failure)
 Approx. from 20 to >100 years, in
comparison with office devices with
typically 3 to 5 years.

Ethernet
Industrial Ethernet: Vs Office
Home/Office product
Industrial-graded product
 -Link status LED not visible
 -Link status easily monitored
 -110/230 V AC
 -24 V DC
 -Unprofessional mounting
 -DIN-rail mounting
using cable ties

Ethernet
Industrial Ethernet: Products

Ethernet
Industrial Ethernet: Switches

Industriales
Module 10
Internet Layer Protocols

Established Internet Protocols

Fundation Fieldbus HSE Arch.

Fundation Fieldbus HSE Arch.
FF HSE architecture comprises:
The user application
 The physical layer (PHY)
comprises:
 The communication “stack”:
 Data link layer (IEEE 802.3  System management
MAC)  Network management
 Network layer
 LAN redundancy
 Transport layer (TCP/UDP)
 Fieldbus access agent (FAS)  HSE management
 Fieldbus message services  Function block
(FMS)
application process
 End user application
 H1 interface
 H1 bridge

Establishing a connection
 FF Application layer is
managed by the Field Device
Access (FDA)
 All Ethernet devices contain an
FDA agent
 FDA uses the underlying
Internet protocols in the
following fashion:
 Client/server sessions use UDP
or TCP connections
 Publisher/subscriber sessions
use UDP connections
 Report distribution sessions
use UDP connections

Ports and Sockets
 Unlike H1, an HSE session is
capable of supporting
multiple virtual
communication relations socket
(VCR) a host-local,
 This is thanks to Ports and application-created,
Sockets OS-controlled interface (a
 Sockets: explicitly created, “door”) into which
used, released by apps application process can
 client/server paradigm both send and
 two types of transport receive messages to/from
service via socket: another application process
 unreliable datagram
 reliable, byte stream-oriented

Ports and Sockets
Socket: a door between application process and end-
end-transport protocol (UCP or TCP)
TCP service: reliable transfer of bytes from one process
to another
controlled by
controlled by process application
application process
developer
developer
socket socket
TCP with TCP with controlled by
controlled by
buffers, operating
operating buffers, internet system
system variables variables
host or host or
server server
Ports and Sockets
Client must contact server  When client creates socket:
 server process must first client TCP establishes
be running connection to server TCP
 server must have created  When contacted by client,
socket (door) that server TCP creates new
welcomes client’s contact socket for server process to
communicate with client
Client contacts server by:
 allows server to talk with
 creating client-local TCP
multiple clients
socket
 source port numbers
 specifying IP address, port
used to distinguish
number of server process clients

Ports and Sockets
 When contacted by client,
server TCP creates new
socket for server process to
communicate with client
 allows server to talk with
multiple clients
 source port numbers used
to distinguish clients
application viewpoint
TCP provides reliable, in-order
transfer of bytes (“pipe”)
between client and server

Ports and Sockets
Server (running on hostid) Client
create socket,
port=x, for
incoming request:
welcomeSocket =
ServerSocket()
TCP create socket,
wait for incoming
connection request connection setup connect to hostid, port=x
connectionSocket = clientSocket =
welcomeSocket.accept() Socket()
send request using

read request from clientSocket
connectionSocket
write reply to
connectionSocket read reply from
clientSocket
close
connectionSocket close
clientSocket
Ports and Sockets
UDP: no “connection” between
client and server
 no handshaking
application viewpoint
 sender explicitly attaches IP
address and port of UDP provides unreliable transfer
destination to each packet of groups of bytes (“datagrams”)
between client and server
 server must extract IP
address, port of sender
from received packet
UDP: transmitted data may be
received out of order, or
lost
Ports and Sockets
HSE uses two Internet protocols to send data
over a network: TCP and UDP
 UDP: It is a
 TCP: It enables two hosts
to establish a connection connectionless protocol
and exchange streams of  Unlike TCP, UDP
data. provides few error
 TCP guarantees delivery recovery services
of data and guarantees  It offers a direct way to
delivery in the same access IP services
order that was sent.
 Primarily used for
broadcasting messages
over a network
Ports and Sockets
UDP: no “connection” between
client and server
 no handshaking
 sender explicitly attaches IP

address and port of
destination to each packet
 server must extract IP
address, port of sender
from received packet
UDP: transmitted data may be
received out of order, or
lost
Industrial Ethernet Standards
ProfiNet
ProfiNet uses Ethernet in
three ways:
1. Uncritical data: TCP/IP
2. Time critical (e.g.,

alarms): a real time
channel, RT
3. For motion control
isochronous real time
communication (IRT)

Industrial Ethernet Standards

Industriales
Module 11
Device Types

Device Types
Device location follows an architecture

Device Types
 Host: Devices that do not have a network management agent (NMA)

nor a function block application process (FBAP), but communicate
with devices that do.
 HSE field device: Similar to an H1 field device.
 HSE I/O Gateway: Connects foreign I/O buses of fieldbuses to the FF
network
 Linking device:
Connects an HSE
subnet to one or more
H1 links.

Device Types
 Bridges: Interconnect links at different speeds or over

different media
 Cable: 100BaseT
 Hubs/repeaters: Used to connect together two or more
Ethernet segments of any media/type.
 Network interface cards (NIC): Connects a PC to a
network.
 Switches: Enable to expand and link several Ethernet
segments together.
 Routers: Filter traffic based on IP addresses. An IP router
divides a network into various sub-nets.
 Transceivers: The connect nodes to Ethernet media.


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Integración de Sistemas

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

 Many networks: telephone,

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

 All the supervisory

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

 Muti-drop: the interconnection of several devices to

Integracion de Sistemas Industriales

 Digital Control Loop: A

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

The figure shows a DCS:

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

 Profibus PA  Profibus DP, FMS

 AS-I (actuator sensor Int.)

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

 Figure on right shows a

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

The Figure shows a DCS:

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

 Flow control actuators

Steam solenoid valve.

Integracion de Sistemas Industriales

 Level control Controller

Controller Fout, Tout

1) a process - the stirred tank;

Integracion de Sistemas Industriales

Symbols and abbreviations:

Integracion de Sistemas Industriales

 All physical systems can be categorised in terms of types of

step upset, step E C

Percentage of chargable voltage,

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

Dynamic Response of Bellows Pressure Sensor

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

 Process Flow Diagram: PDF

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

 Optical fiber Integracion de Sistemas Industriales

 Voltage levels: Uses

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales

Integracion de Sistemas Industriales