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Da PROFIBUS a PROFINET nel mondo del Processo Dipartimento di Ingegneria dell Informazione, Università di Brescia Via Branze 38-25123 Brescia (Italy) Tel: +39-030-3715445 fax: +39-030-380014 e-mail: paolo.ferrari@unibs.it 1 CSMT Gestione Scarl Centro di Competenza PROFIBUS e PROFINET - Brescia http://www.csmt.it profilab@csmt.it PI Italia PROFIBUS e PROFINET - 2016 PROFINET and process automation Process automation has special requirements: The plants have a lifespan of 15-40 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 PI Italia PROFIBUS e PROFINET - 2016 paolo.ferrari@unibs.it 1
PROFINET and process automation PROFINET fulfils all the requirements (but PROFIBUS still helps) 3 PI Italia PROFIBUS e PROFINET - 2016 PROFINET per l automazione di processo 4 Integrazione di altri bus di campo PI Italia PROFIBUS e PROFINET - 2016 paolo.ferrari@unibs.it 2
PROFINET per l automazione di processo PROFINET integration with other fieldbuses 5 PI Italia PROFIBUS e PROFINET - 2016 PROFINET is the backbone PROFINET per l automazione di processo New direct integration with PROFIBUS PA is available! DCS ERP MES Ethernet backbone 6 PROFIBUS DP 4 3 5 6 2 1 PROFIBUS PA 7 8 PROFINET PROXY 16 1 2 3 4 5 HART 6 7 8 16 4 PROFINET 1 2 3 FF H1 5 6 7 8 16 PI Italia PROFIBUS e PROFINET - 2016 paolo.ferrari@unibs.it 3
PROFINET per l automazione di processo 7 Architetture avanzate con PROFINET IO PI Italia PROFIBUS e PROFINET - 2016 Come fare diagnostica di una rete PROFINET? 8 Problemi tipici di una rete PROFIBUS Cavi rotti, riflessioni terminazioni errate, derivazioni, indirizzi duplicati, configurazione errata Problemi tipici di una rete PROFINET Cavi rotti, connessioni ridondanti non volute, nomi mancanti, indirizzi IP duplicati, network mask errate, problemi di configurazione Differenze Tutti possono parlare con tutti, non è master-slave! In generale, in una rete switched-ethernet i collegamenti sono tutti punto-punto Per controllare il livello fisico bisognerebbe accedere a tutti i cavi PI Italia PROFIBUS e PROFINET - 2016 paolo.ferrari@unibs.it 4
PROFINET IO: Diagnostica in generale Informazioni diagnostiche strutturate in modo gerarchico Station name, slot, subslot,channel, channel type, error information Diagnostica trasmessa come allarmi da IO-Device all IO-Controller SNMP completa la diagnostica a livello di rete 9 Livello1: Errore nel Device (es. Valve Station 2) SF BF ON subslot Channel Kanal 00 Channel Kanal 11 Kanal Channel 0 0 Kanal 0 Kanal Channel 1 1Kanal 1 Layer 2: Errore nel Modulo (es. Analog Input Module 3) Channel Kanal 22... Kanal Channel 2 2Kanal 2...... Diagnostica Channel Kanal x x di Kanal Channel retex x Kanal Channel x x Slot 1 Slot 2 Slot 3 Layer 3: Errore nel Channel (e.g. Cable Break in Channel 2) PI Italia PROFIBUS e PROFINET - 2016 PROFINET IO: topologia. dove è il dispositivo? I dispositivi PROFINET IO supportano il protocollo LLDP che permette di ricostruire la topologia della rete (anche dopo averla cablata!) 10 PI Italia PROFIBUS e PROFINET - 2016 paolo.ferrari@unibs.it 5
PROFINET IO: diagnostica/manutenzione di rete on-line 11 Tutti i dispositivi PROFINET IO forniscono delle informazioni base sullo stato della comunicazione Ethernet Sono possibili interrogazioni automatiche di queste informazioni Si possono usare strumenti standard IT, perchè il protocollo è SNMP Il traffico di monitoraggio è TCP/IP e usa una banda trascurabile Disponibili anche soluzioni mirate per PROFINET Maggiori dettagli e altre informazioni specifiche Integrate con l applicazione di automazione Più veloci nel trovare i problemi PI Italia PROFIBUS e PROFINET - 2016 PROFINET per l automazione di processo 12 Caso applicativo PI Italia PROFIBUS e PROFINET - 2016 paolo.ferrari@unibs.it 6
Some details on the plant The site has large extension (in three dimensions!) Complex architecture that follows the physical processing of product 13 * Sample rendering PI Italia PROFIBUS e PROFINET - 2016 Synergy among partners Objectives Eliminate usual problems related to installation and configuration of PROFIBUS/PROFINET networks Speed up commissioning Help maintenance people 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 14 PI Italia PROFIBUS e PROFINET - 2016 paolo.ferrari@unibs.it 7
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 Involved people Design office of the final customer Main contractor design office (automation software) 15 PI Italia PROFIBUS e PROFINET - 2016 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 16 PROFIBUS DP Switch PI Italia PROFIBUS e PROFINET - 2016 paolo.ferrari@unibs.it 8
Example of specific topology for process plant Modular and hierarchical structure 17 PI Italia PROFIBUS e PROFINET - 2016 Some details on the plant networks Summary table 18 Number of PROFINET networks 2 Number PROFINET controllers (S7 400) 8 Number of PROFINET devices 230 Number of PROFIBUS DP networks 40 Number of PROFIBUS PA networks 31 PI Italia PROFIBUS e PROFINET - 2016 paolo.ferrari@unibs.it 9
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 19 Maintenance Use Ethernet infrastructure to constantly check network status and take immediate countermeasures Automatic access to diagnostic information using the network PI Italia PROFIBUS e PROFINET - 2016 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 20 Involved people Final customer personnel (plant personnel) Contractor (electric works) Contractor (automation software) PI Italia PROFIBUS e PROFINET - 2016 paolo.ferrari@unibs.it 10
Final validation: good stuff 21 OK OK PI Italia PROFIBUS e PROFINET - 2016 Network validation: bad ones 22 Not OK Not OK PI Italia PROFIBUS e PROFINET - 2016 paolo.ferrari@unibs.it 11
Network validation: bad ones 23 Ferrules Not OK High contact resistance Not OK Connector destroyed PI Italia PROFIBUS e PROFINET - 2016 Network validation: bad ones 24 Oh no, no, no! PI Italia PROFIBUS e PROFINET - 2016 paolo.ferrari@unibs.it 12
Speed up of commissioning: PROFIBUS results 25 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 PI Italia PROFIBUS e PROFINET - 2016 PROFINET network performance: results 26 I/O refresh cycle time: 32 ms Maximum band occupancy of PROFINET traffic : 9% Cables with cabling errors: 5 (five!) (<1%) PI Italia PROFIBUS e PROFINET - 2016 paolo.ferrari@unibs.it 13
Final customer feedback 27 Installed length of cables with the proposed architecture 9 km Installed length of cables in similar plants with PROFIBUS only: 27 km PI Italia PROFIBUS e PROFINET - 2016 28 Photo - Copyright 2016 Thank you for your attention! PI Italia PROFIBUS e PROFINET - 2016 paolo.ferrari@unibs.it 14