CSMT Gestione Scarl -Centro di Competenza PROFIBUS e PROFINET

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1 1 Un caso virtuoso di PROFINET applicato all industria di processo Paolo Ferrari Dipartimento di Ingegneria dell Informazione, Università di Brescia Via Branze Brescia (Italy) CSMT Gestione Scarl Centro di Competenza PROFIBUS e PROFINET - Brescia Tel: fax: PROFINET and process automation Process automation has special requirements: The plants have a lifespan of years. Data and information flow both horizontally and vertically. Installation technology and field devices can must handled easily Application in hazardous areas (e.g. intrinsically safe protection) Long cable distances (up to 1,000 m) Flexible topology design Robust connection technology Redundancy concepts for critical components 2 The communication interface and the systems for engineering, asset management, and plant control should have the following properties: Maximum reliability and availability Disturbance-free configuration during plant operation Easy handling, especially for device replacement Investment protection for existing plants, including changes of the process control technology Suitable for large quantity structures of 10,000 or more devices

2 PROFINET and process automation PROFINET fulfils all the requirements (but PROFIBUS still helps) 3 Some details on the plant The site has large extension (in three dimensions!) 4 Complex architecture that follows the physical processing of product * Sample rendering

3 Synergy among partners Objectives Eliminate usual problems related to installation and configuration of PROFIBUS/PROFINET networks Speed up commissioning Help maintenance people 5 In order to maximize benefits, a global approach has been applied since the earlier stage of the project Tight connection with the design team Creation of specific (customer oriented) installation guidelines for PROFINET and PROFIBUS Periodic audits during the assembly Final audit and validation of the entire plant Design stage: a good start from the beginning! Specific objectives Consultancy on design and installation guidelines (customization to specific plant, eliminating thing not needed, from 1000 pages to 100!) Definition of station addressing and naming strategies Evaluation of cycle times Evaluation of loads in PA networks Evaluation of diagnostic possibilities and their scalability 6 Involved people Design office of the final customer Main contractor design office (automation software)

4 Some details on the plant networks Hierarchical architecture with redundancy rings Generally, all the devices are reachable from the top level by means of proxies connected to PROFINET 7 PROFIBUS DP Switch Esempio topologia specifico per impianto di processo Struttura modulare e gerarchica

5 Some details on the plant networks Summary table 9 Numero di reti PROFINET 2 Numero di controllori PROFINET 8 Numero di dispositivi PROFINET 230 Numero di reti PROFIBUS DP 40 Numero di reti PROFIBUS PA 31 Maintenance and diagnostics of PROFINET networks PROFINET offers excellent diagnostics by means of standard Ethernet protocols LLDP : it allows topology discovery SNMP: it can access statistics information on network errors and traffic HTTP: it allows easy access to device parameters 10 Maintenance Use Ethernet infrastructure to constantly check network status and take immediate countermeasures Automatic access to diagnostic information using the network

6 Audit and final validation of the entire plant Audit during assembly Verify during the work the compliance with the installation guidelines Immediately highlight and avoid potentially dangerous situations. Suggest improvements Final validation Take a snapshot of the status of the PROFIBUS and PROFINET at the end of commissioning Eliminate the last problematic situations Suggest further improvements 11 Involved people Final customer personnel (plant personnel) Contractor (electric works) Contractor (automation software) Final validation: good stuff 12 OK OK

7 Network validation: bad ones 13 Not OK Not OK Network validation: bad ones 14 Ferrules Not OK High contact resistance Not OK Connector destroyed

8 Network validation: bad ones 15 Oh no, no, no! Speed up of commissioning: PROFIBUS results 16 Missing DP terminations: 1 (one) Missing PA terminations: 0 (zero) PA segment with physical layer problems: 1 (one) Cables with damages: 3 (three - due to accidental steam release) Cabling errors: 3 (three) Exchanged A and B wire due to wrong labelling inside a device Device connector damaged

9 PROFINET network performance: results 17 I/O refresh cycle time: 32 ms Maximum band occupancy of PROFINET traffic : 9% Cables with cabling errors: 5 (five!) (<1%) Final customer feedback 18 Installed length of cables with the proposed architecture 9 km Installed length of cables in similar plants with PROFIBUS only: 27 km

10 19 Thank you for your attention!

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