NeSSI Gen 2 Status of the Sensor Actuator Manager (SAM): Overcoming - PowerPoint PPT Presentation

1 NeSSI™ Gen 2 Status of the Sensor Actuator Manager (SAM): “Overcoming the Perception of Complexity” Patrick Lowery 1/26/2009 www.circortech.com

2 GEN 2 Bus is Done! � Two options, one based on open standard � Multi-drop, hot-swappable � Deterministic, auto-fault tolerant � Multi-variable data capabilities � Self diagnostics and asset management � An entire IS CANbus solution package is literally weeks away from IS certifications!! www.circortech.com

Challenge A “Complete Solution” was required: The ability to integrate pressure, temperature, flow, other multi-variable sensors, valve control and ALL of the associated equipment, power supplies, and cables that are needed. The GEN 2 bus lays the groundwork for more sophisticated low-powered sensors for the next phase of GEN 3. But how can the end user implement today? www.circortech.com

The Embedded SAM ABB PGC-5000 style implementation shown Siemens Maxum GC has a version also www.circortech.com

5 What if a Smart GC is not available? www.circortech.com

6 What if a non Smart GC is not available? � Must have some sort of “bus master” � “Missing Link” that could stop implementation of GEN2 in the field outside of Smart GC’s (or other analyzers w/ embedded SAM’s) � Must have the Sensor Actuator Manager or “SAM” � Lesson from the past (GEN1): � Must have the entire solution figured out & available � Must overcome the strong perceptions in the industry � Too complex to understand by the norm � More expensive than traditional methods www.circortech.com

7 Myth Busting � “Too complex” � The core value proposition of GEN2 is to provide information from SHS to act proactively to avoid process down time � If the core value is information, must put sensors on the SHS � This has been accomplished by many end users with the GEN 1.5 methodology � PLC or Industrial PC with analog I/O and digital I/O www.circortech.com

8 Myth Busting www.circortech.com

9 Myth Busting www.circortech.com

Original SAM definition � Going back to the original NeSSI™ Gen 2 draft, SAM was defined roughly as a device which needed to have the following features: � Graphical HMI � Local (short range) Wireless � Maintenance Tool � Host to the IS Sensor/Actuator (GEN2) Bus � Gateway to an Ethernet LAN and DCS/maintenance systems � Must support multiple communication protocols � OPC � HTTP � FF, etc. � Software Applets for Sample System Repetitive Tasks (Application Interface) � Provides “Open” Development Space for Custom Software” www.circortech.com

Myth Busting � The main problem with the “ideal” NeSSI vision of SAM is one must � Develop such a product, $$$ � Direct connections to the DCS require � Data historians � Firewalls � OPC gateways � Non volatile memory and automatic backup � Robust network security � Must circumnavigate the plethora of different corporate security IT issues � Quote from one of the NeSSI visionary founders at ExxonMobil, “ ExxonMobil is locked down tighter than the National Security Agency ” www.circortech.com

Realistic Definition of SAM � CIRCOR has made a “bridge” to link GEN2 bus to the SAM � Bridge between C1D1 (Zone 1) and C1D2 (Zone 2) for CAN communications � Integrated analog I/O to digitize 4-20mA devices � Obtains inventory of all CAN networked devices using electronic data sheets � Monitors total system “inventory” and health � Has a basic application interface that can pass alarm triggers and set points down to devices and pass alarms and data up to GC � GC is not the sample system master per se, but a data server � Future upgrade path for CAN device metadata to provide system configuration data up to HMI at GC interface or “stand alone SAM” � Still need a corporate IT approved link to the DCS www.circortech.com

13 13 CIRCOR CIM76 www.circortech.com

14 CIM76 and SMART Module AVAILABLE FOR CONNECTION TO ABB FIBER CANopen, PROFINET, ETHERNET, AND MODBUS www.circortech.com

Myth Busting � Too Expensive � Today, in order to build an “analog sensor” you must: � convert an analog signal to digital � Implement calibration and DSP algorithms � Re-convert into analog � Commonly must use expensive DAC’s and amplifiers � Also must commonly provide galvanic (mini-transfomer) isolation to prevent ground loops � To implement digital sensors � Only need to convert analog sensor to digital � Convert core TTL logic level information into a “bus structure” � Off the shelf chips exist today for many bus flavors � CANbus is the flavor of choice because • Inexpensive, 200M+ CAN chips sold per year • Easy to implement • Open standard • Off the shelf tools • Can be linked to many industrial fieldbuses www.circortech.com

Myth Busting � Too Expensive � Cost comparison of GEN1.5 (using distributor list price) to GEN2 system (using CIRCOR list price of CANbus device) These benefits are based on a 1 stream GC system, w/ bypass with all of the minimally needed sensing points to avoid a system failure or filter blockage, using a ProfiNET enabled PLC (digital cost also includes a very expensive, triple fault tolerant power supply) www.circortech.com

17 PLCs: Good or Bad? � What is the difference between a PLC, hybrid controller, and RTU? � Really nothing nowadays � All are based on solid state logic, FPGA and have solid state backup memory � The are the only link allowed to the DCS in most plants outside the GC � Come with seamless HMI and programming tools � Ladder logic has evolved to “function block” programming, internationally standardized � Therefore they are good, but is some cases not preferred if Smart GC is available www.circortech.com

18 PLCs: Good or Bad? � Using the CIRCOR CIM76 module � Sample system configuration I/O comes preloaded for many PLC automation programs: � Allen Bradley � Siemens SIMATIC � Honeywell � Modicon � All sample system CAN and analog nodes come pre- loaded with ranges, ID’s, alarms, and graphics into the PLC application programming interface � Analytic techs/engineer/chemist will not need to become expert in industrial automation � Companies can pick the PLC and HMI of their choice www.circortech.com

19 PLC Alternatives � Industrial PC’s � Not preferred in some circles due to: � Expense � Size � MTBF (many moving parts) • PLC MTBF is much much longer � PLC is therefore the SAM of choice by the majority of users and fits the reality of the market www.circortech.com

20 Summary � The GEN 2 book should be closed � The SAM is the smart GC or a PLC (maybe an industrial PC) � IS CANbus will become an open international physical layer � Free and other tools are available today to configure any type of CAN device � IS CANbus backbone can be used for CANopen and Devicenet application layers � CIRCOR can link this to any industrial fieldbus � Let’s move onto the fun stuff, GEN3!!! www.circortech.com