9 Bus Diagnostics and Troubleshooting PDF

Fieldbus FoundationTM
Bus diagnostics and

troubleshooting
Andreas Agostin
MTL Instruments Pte Ltd Singapore
On behalf of
Fieldbus Foundation TM Marketing Committee (Malaysia)
Foundation Fieldbus Seminar Malaysia

1 November 2009
Bus diagnostics and troubleshooting
Plant life cycle

Costs of diagnosis

2 November 2009
Which tools for which purpose?
Plant life cycle
Engineering Installation Commissioning & Operation &

Troubleshooting Maintenance
Predictive
Calculation tools Wiring tools Commissioning & Maintenance
troubleshooting tools tools
3 November 2009
Plant life cycle
Engineering
Proper engineering ensures that the plant works as

designed.
Flaws in engineering will cause the actual plant not to
work, and will trigger expensive redesign and re-work.
Calculation tools
4 November 2009
Plant life cycle
Installation
1Source:
http://forums.fieldbus.org/showthread.php?t=1298 According to field experience,
approx. 95%1 of the problems
occuring in a plants lifetime are
related to installation.
Cause can be:
- Wrong ferrule diameter
- Wrong crimping tool
- Wrong crimping method
- Wrong wire cutter
- Wrong screw driver
Wiring tools
- Wrong torque
-
5 November 2009
Plant life cycle
Commissioning &
Troubleshooting
Commissioning should be done

one-by-one. There are voices
suggesting to connect all
instruments and then switch on.
However, a fault such as the
frequently seen short-to-shield, will
be impossible to locate.
Connecting devices one-by-one
will tell you that the problem
occurred at the device you
connected last.
Commissioning &
troubleshooting tools
6 November 2009
Plant life cycle
Operation &
Maintenance
In large installations with hundreds of bus segments, it

can be of help to use physical layer online monitoring
(advanced diagnostics for the physical layer). Using
such tool you can detect degradation in the installation.
There are voices suggesting to use such tool for

troubleshooting. However, due to the location of the
tool in the control room, accurate measurements are
not possible, and some faults are even not detectable
(e.g. short to shield on a spur of a fieldbus barrier).
Predictive
Maintenance
tools
7 November 2009
Maintenance Strategies
Maintenance
ad y
lr e
e da
ccu rr
eo
ai lur
F
Failure already occurred

Repair
Failure causes production
loss
Potentially very high
costs
Time based Condition based

On a schedule When required
8 November 2009
Maintenance
ad y
lr e
e da
ccu rr No failure yet
eo
ai lur
F
No failure yet
Repair Preventive
High and regular
maintenance costs

9 November 2009
Maintenance
ad y
lr e
e da
ccu rr No failure yet
eo
ai lur
F
Repair Preventive Predictive

In time before
failure occurs
(Condition: Warning)

10 November 2009
Device Maintenance Effort
Process
Interface; 6%
Failure;
4%
Preventive
Zero Drift; 6%
Routine check;
35%
Re-ranging; 20%
Failure suspect, but no

problem found; 28%
Repair
63% of time is spent investigating problems that do not exist.

On Fieldbus, the fieldbus diagnostic module will alert you
when maintenance is needed, and will keep quiet if not. Predictive
Source: ARC Advisory Group, Intelligent Devices Provide Foundation for Operational Excellence ARC Strategies, January 2003.

11 November 2009
Why Predictive Intelligence?
100%
Condition of Assets
Too Late
0%
Time to Fail

12 November 2009
100%
Condition of Assets
Prediction gives you

enough time to make
proper decision and to Too Late
prevent abnormal
situations
0%
Time to Fail
Conditions: OK
(Alarms) Needs maintenance soon
Needs maintenance now
13 November 2009
100%
Condition of Assets
Prediction gives you

enough time to make
proper decision and to
prevent abnormal
situations
0%
Time to Fail
Conditions: OK
(Alarms) Needs maintenance soon
Needs maintenance now
14 November 2009
Typical Problems

15 November 2009
Case study: faults in operation
Water in junction box, cable or device:
Increasing number of retransmissions

Indication of shorts to shield
Can be a combination of both

16 November 2009
Bend radius too tight, Upward facing gland risks water ingress
Two cables into one gland

prevents sealing of gland Foundation Fieldbus Seminar Malaysia
17 November 2009
Corroded terminals:

Increase of FF noise
18 November 2009
Short to shield on fieldbus trunk:
Indication of short to shield

Increasing number of retransmissions on all
devices

19 November 2009
Short to shield on fieldbus spur (wiring block):
Indication of short to shield

Increasing number of retransmissions on this
specific device or on the devices of this wiring
block

20 November 2009
Short to shield on fieldbus barrier spur:
Indication of short to shield only on Handheld

tester (due to galvanic isolation of fieldbus
barrier)
Increasing number of retransmissions on this
specific device or on the devices of this fieldbus
barrier

21 November 2009
Bad wiring technique
Welding, variable frequency drives (VFD), Motors,

machinery:
Increase of HF noise
22 November 2009
Cable jacket stripped back too

far can cause instrument
malfunction:
Water ingress
Wires shorted to housing
Corrosion
Tearing wires (increasing
resistance)
Increasing number of
retransmissions
Signal amplitude rises
Increase of FF noise
Can be a combination of
above

23 November 2009
Fieldbus terminator missing:
All signal amplitudes rise (best indicator)

Increased noise in all frequency bands
Increasing number of retransmissions (usually on all
devices)
One or more devices drop off the bus (may or may not
come back)
Note: likely to be the terminator in the field, not on the

baseplate (soldered, controlled environment)
24 November 2009
Wires coming out of ferrules:
Trunk:
Spur: Devices drop off (may or may not return)
Device drops off (may or may not return) Signal amplitude sometimes ok, sometimes high
Increasing number of retransmissions Increasing number of retransmissions
25 November 2009
Problem indicated by Diagnostic Module

26 November 2009
Warning or alarm levels exceeded?

27 November 2009
On which segment?

28 November 2009
Whats the problem on the segment?

29 November 2009
Alarm Identification
Name and Description Corrective Action
Device Signal Level High-High Alarm If only one device high: check:
1. alarm limits have not been wrongly set,
Device Signal Level High Alarm
2. device operation.
If several/all devices on segment check:
1. for only one terminator on segment
2. for failed terminator.
Device Signal Level Low Alarm If only one device low: check
1. alarm limits have not been wrongly set,
Device Signal Level Low-Low Alarm
2. spur cabling, spur and device connections
are tight
3. for water in spur cable or device
4. device operation.
If several/all devices on segment low check:
1. for more than two terminators on
segment, check that terminator switches
on the fieldbus barrier are set to off.
2. for water in devices, junction boxes and
cabling.

And what does that mean, what is the cause of the alarm?
30 November 2009
In the device manager, you:
Compare actual vs historical data
See information about each device
See alarms of physical layer of device Foundation Fieldbus Seminar Malaysia
31 November 2009
All data is communicated via FF, allowing full
Integration into all host software packages.
Example: Trending of noise and voltage levels in the historian.

32 November 2009
Example: Noise level trending
Alarm level (critical)

Noise
Warning level
2008 2009 2010 2011 2012
Warning and alarm levels are set so that there is sufficient

time to fix the problem e.g. during a regular shutdown
33 November 2009
On-line monitoring
24VDC
FFPS FF Power Supply

Host & Conditioner Fieldbus barrier
T
Computer &Terminator & Terminator
F809F Fieldbus
DM Diagnostic Module
Fieldbus
Fieldbus barrier
T barrier
Intrinsically
H1 Interface Safe Spurs
Device 1 Device 2 Device 3
Permanently installed at the fieldbus power supply in the control room.

34 November 2009
Portable diagnostic tools
24VDC
Host Fieldbus barrier

Computer FFPS FF Power Supply & Terminator
T & Conditioner
&Terminator Fieldbus
Fieldbus barrier
T barrier
Intrinsically
H1 Interface Safe Spurs
PDI
Portable
Diagnostic
Instrument
Device 1 Device 2 Device 3
To measure at fieldbus barrier, PDI needs to be Ex i approved.

Important since the galvanic isolation of fieldbus barrier impacts on measurement.
35 November 2009
Typical measured parameters
DC voltage
Indicates correct function of power supply/conditioner
Instrument supposed to operate from 9V onwards
Shield short (+ or connected to shield/ground/screen)

Easy to measure and understand
Further measurements can identify location
Signal level
Minimum level is specified by Fieldbus specification
Low or high levels on all devices suggests incorrect bus termination
If only one device, suggests problem on single spur

36 November 2009
Typical measured parameters
Noise
Maximum level is specified by Fieldbus specification
Tri-band measurement helps to identify source
LF: bulk supply
IF: fieldbus device
HF: induction from outside the network
Retransmissions / Retransmission rate

Good measurement of physical layer health
Measured in absolute retransmissions and in % of total transmissions
(rate)
Re-tries can obscure faulty device or network
http://forums.fieldbus.org/showthread.php?t=1298
Follow link to access Fieldbus Forum posting on physical layer problem
(see summary on next page)
37 November 2009
http://forums.fieldbus.org/showthread.php?t=1298

38 November 2009
Amount of diagnostic information
Fieldbus Diagnostic Modules can provide a

multitude of data and information
Not every maintenance technician is a fieldbus
expert
Tools must match the employee skills

39 November 2009
The various solutions

40 November 2009
The various solutions
Differentiators:
- Physical Interface
(FF H1 / FF HSE / RS485 / Contact)
- Measurements
- Level of detail
- User Interface
(H1 Host integration / DTM / OPC)

41 November 2009
Conclusion
Key Three:
Foundation Fieldbus communication is very
robust
If you do your installation right, you avoid many
problems down the road
Online-diagnostic of the physical layer is an add-
on that can help you to identify problems before
they cause a failure

42 November 2009
Any Questions?
Andreas Agostin contact:

+65 9758 5161
aagostin@mtlsing.com.sg

43 November 2009
www.fieldbus.org
44 November 2009

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Fieldbus FoundationTM

Bus diagnostics and

Foundation Fieldbus Seminar Malaysia

Plant life cycle

Foundation Fieldbus Seminar Malaysia

Plant life cycle

Engineering Installation Commissioning & Operation &

Plant life cycle

Proper engineering ensures that the plant works as

Plant life cycle

Plant life cycle

Commissioning should be done

Plant life cycle

In large installations with hundreds of bus segments, it

There are voices suggesting to use such tool for

Failure already occurred

Time based Condition based

Time based Condition based

Repair Preventive Predictive

Time based Condition based

Failure suspect, but no

63% of time is spent investigating problems that do not exist.

Foundation Fieldbus Seminar Malaysia

Foundation Fieldbus Seminar Malaysia

Prediction gives you

Prediction gives you

Foundation Fieldbus Seminar Malaysia

Water in junction box, cable or device:

Increasing number of retransmissions

Foundation Fieldbus Seminar Malaysia

Two cables into one gland

Increasing number of retransmissions

Short to shield on fieldbus trunk:

Indication of short to shield

Foundation Fieldbus Seminar Malaysia

Short to shield on fieldbus spur (wiring block):

Indication of short to shield

Foundation Fieldbus Seminar Malaysia

Short to shield on fieldbus barrier spur:

Indication of short to shield only on Handheld

Foundation Fieldbus Seminar Malaysia

Welding, variable frequency drives (VFD), Motors,

Cable jacket stripped back too

Foundation Fieldbus Seminar Malaysia

Fieldbus terminator missing:

All signal amplitudes rise (best indicator)

Note: likely to be the terminator in the field, not on the

Foundation Fieldbus Seminar Malaysia

Foundation Fieldbus Seminar Malaysia

Foundation Fieldbus Seminar Malaysia

Foundation Fieldbus Seminar Malaysia

Foundation Fieldbus Seminar Malaysia

Alarm level (critical)

2008 2009 2010 2011 2012

Warning and alarm levels are set so that there is sufficient

FFPS FF Power Supply

Device 1 Device 2 Device 3

Permanently installed at the fieldbus power supply in the control room.

Foundation Fieldbus Seminar Malaysia

Host Fieldbus barrier

Device 1 Device 2 Device 3

To measure at fieldbus barrier, PDI needs to be Ex i approved.

Shield short (+ or connected to shield/ground/screen)