New tips and tricks to get value out of HART

发布日期: 2016 年 10 月 2 日
Jonas Berge 关注
Author, award-winning speaker, digital…
发布日期: 2016 年 10 月 2 日

The HART technology has many potential benefits but in most plants and for most
devices the smart features go unused. Plants struggle to put HART technology to
good use. This is a case of technology “Consumption Gap”. Often the original
intention of the project team was to use HART for continuous online device
diagnostics for predictive maintenance, monitor the auxiliary variables, as well as
for download and configuration management etc. Smart devices with diagnostics,
some multivariable devices, control system with smart I/O cards supporting HART,
even Intelligent Device Management (IDM) software part of an Asset
Management System (AMS) were specified. Yet, in most plants, for various reasons,
HART technology doesn't get utilized other than for commissioning with the
handheld field communicator - the control system only uses the real-time 4-20 mA
signal.284Sometimes
· 46 条评论 device commissioning is even done from the local display or
through USB. How can we close this consumption
评 gap to fully utilize the smart
features in all smart赞 devices? Here are my personal
论 thoughts: 分享
Figure 1 The Consumption Gap (from B4B: How Technology and Big Data Are
Reinventing the Customer-Supplier Relationship)
Many speak of HART and 4-20 mA interchangeably, saying HART when they really
mean 4-20 mA, but they’re not the same. They don’t realize digital HART is not the
same as analog 4-20 mA, so HART does not get designed and procured correctly,
not installed and commissioned correctly, not integrated and setup properly, not
maintained properly, and people don’t get trained. As a result the plant ends up
using only handhelds or laptop, missing out on the smart online capabilities.
To get value of HART there are a few things you’ve got to do to “Get Connected”,
to close the consumption gap. Here’s some simple HART engineering guidance to
make certain the digital communication works with the control system, multiplexer,
IDM software, and smart signal conditioners etc. If you are only going to use HART
with a handheld in the workshop you need not consider these pointers, but then
again, why limit yourself?

Figure 2 "Get Connected"

Training Required
You may have used 4-20 mA/HART for more than 20 years and think you know
everything about HART. However, having visited and helped many plants and
tracked various social media channels for many years I have noticed there are many
misconceptions. These misunderstandings are part of the reason why in the end
HART goes underutilized. For instance you may not know:
Resistor need not be exactly 250 ohm for the sake of HART
Smart valve positioner does not need resistor
Some control systems are affected by the HART signal and need an input filter
Some control systems affect the HART signal and need an output filter
When
284 ·a46Partial
条评论 Stroke Testing (PST) device is connected in parallel with a solenoid valve
you need a HART line conditioner
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论
 Cables have special capacitance requirements
If the line is noisy 4-20 mA works but HART does not
Max loop resistance is 600 ohm which limits series devices
You cannot connect DCS, handheld field communicator, wireless adapter, and smart
signal conditioner all at the same time due to master conflict
HART5 systems do not support HART7 devices
HART5 devices have the same diagnostics as HART7 devices
Some devices can be configured to operate as HART5 or HART7
Depending on if the device is configured to operate as HART5 or HART7 it will need a
different DD file
A HART input filter is not the same as a HART output filter
The triggered burst mode and event notification (sometimes referred to as report by
exception) functions are intended for WirelessHART not for 4-20 mA/HART
You can get 4-20 mA without a DD file but you cannot configure the sensor type and
other settings
If the loop resistance is too high, 4-20 mA may still work but HART may not communicate
HART compliant safety barriers are required
Therefore, if you are building a plant based on 4-20 mA, make sure to use
consultants, EPC contractors, and subcontractors trained in HART communication
to ensure certainty of outcome for the project. If not, the design, procurement,
installation, commissioning, integration, or setup will have shortcomings resulting in
the capabilities of HART not being accessible and cannot be utilized once the plant
starts up: a utilization gap.
If you are a plant owner, make sure to train plant personnel that will run and
maintain the automation system on HART to ensure certainty of continuity. If not,
the maintenance of the communication will have shortcomings resulting in the
capabilities
284 · 46of条评论
HART falling into disuse.
If you are an instrumentation
赞
& control engineer,
评 make sure to get 分享 trained on HART
so you are familiar with the above points. 论
Design Correctly
To get value out of HART it must be designed and specified correctly. In many
plants it was not, and as a result HART is not working properly and therefore
underutilized. Thus it is important to pay attention to network design, component
selection, and cable selection etc. When HART requirements are not considered in
the design, the analog 4-20 mA signal will work but the smart features cannot be
accessed and the benefits not reaped. There are additional design requirements for
multi-drop topology networks but it is rarely used and therefore not included here.
The HART communication application guide HCF_LIT-039 and the HART field
communication protocol technical overview HCF_LIT-20 include some design
guidelines as well as other useful information. The HCF_SPEC-054 specification also
includes several HART network design rules and examples. Since most don’t have
this document I have included some of those rules as well. Useful information is
also available on the HART Communication Foundation web site.
Physical Design
Some of the mistakes in physical network design that prevent HART from working
properly include:
Analog I/O cards in the control system or RTU chosen not supporting HART
communication pass-through
The 4-20 mA cable chosen does not meet HART communication requirements with
regards to capacitance and shielding
Too many devices in series in the design result in excessive 4-20 mA loop resistance and
voltage drop, allowing 4-20 mA to work but not HART communication
Cable too long
The safety barriers chosen are not HART compliant
The 4-20 mA cabling route planned too close to power cables resulting in noise pickup
allowing 4-20 mA to work but not HART communication
Cable shield connection not included in wiring diagrams and therefore not maintained all
the284way· 46from
条评论
the device through the junction box to the control system I/O
Device housing grounding not including in wiring评 diagrams and therefore not done
赞 论 分享
 Cable shield grounding not included in wiring diagram and therefore not done correctly
The control system analog inputs are affected by HART communication yet HART input
filters are missing in the design
The control system analog outputs are affecting the HART communication yet HART
output filters are missing in the design
Partial Stroke Testing (PST) device is connected in parallel with a solenoid valves for the
Emergency Shutdown (ESD) valves yet HART line conditioners are missing in the design
250 ohm resistor in valve positioner current loop design result in insufficient compliance
voltage
The field device chosen is not HART compliant
The field device chosen does not have a DD file
Noisy DC power supply
HART pass-through
If you are using 4-20 mA in a new control system such as DCS, PLC, or RTU make
sure analog input and analog output cards support HART communication and
comply with HCF_SPEC-054, as well as provide HART pass-through across the
higher level network. HART embedded in the I/O card is a lot easier to work with
than a separate multiplexer so make sure the I/O card has embedded support for
HART. For existing control systems not supporting HART pass-through, consider
installing WirelessHART adapters on selected instruments, but for any new systems
using 4-20 mA, make sure HART is supported right from the start.
Cable selection
Best practice is to use individually shielded twisted pair cable; typically single pair
between device and field junction box (“spur”) and multi-pair between field
junction box and marshalling cabinet (“trunk”). The minimum conductor size is 0.2
mm2 (#24 AWG) for cable runs less than 1,500 meters and 0.5 mm2 (#20 AWG) for
longer distances. Many plants don’t permit conductor size smaller than 0.75 mm2
(#18 AWG) anyway.
Make sure to specify individually shielded twisted pair cable as “shall be compliant
to the 284
HCF_SPEC-054
· 46 条评论 specification”
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Cable with polyethylene (PE) insulation is preferred because PE has lower
capacitance than PVC insulation. PE is also more stable electrically than PVC and
will not increase in capacitance as much over time to make sure communication
does not deteriorate a few years down the road.
“Low capacitance good-quality cable” is recommended in the HCF_SPEC-054
specification. This is true also for fieldbus and other digital communication. PE
insulated cable with mutual capacitance of 60 nF/km is available from several
manufacturers.
Additional cable requirements may apply depending on the hazardous area
classification and local regulations etc.
Loop resistance
Calculate the voltage drop for the current loop to ensure that the loop supply
voltage from the I/O card is sufficient for all the devices in the loop such as
transmitter, positioner, indicator, signal conditioner, and wireless adapter, plus
sufficient voltage to overcome loop wire resistance. The loop resistance or voltage
drop is different for each type of device and also depends on options such as
indicator. Calculate the loop cable resistance based on cable length and wire cross
section area (gage) including both the positive and negative conductor of the wire
pair. The maximum loop current may be as high as 23 mA (during sensor failure)
depending on the transmitter type and options.

Figure 3 Calculate the loop voltage drop to ensure the power supply is
sufficient for the device, accessories, and cable
If a device will be replaced with a new model having higher voltage drop, or an
accessory is added in series such as an indicator, signal conditioner, wireless
adapter, or HART output filter, first calculate to make sure the voltage is sufficient.

Figure 4 Typical example of two-wire transmitter load limitation

For example, if the max loop current is 23 mA and the device requires a minimum of
12 VDC on its terminals to operate, and the voltage source from the AI card (with
internal284250
· 46 ohm
条评论 shunt resistor) is 15 VDC, the maximum permitted loop resistance
for the cable is (15-12)/0.023 = 130 ohm. If评there are other loads in the loop those
must also be taken赞into account. 论 分享
Table 1 and Table 2 Resistance of IEC 60228 size and AWG size copper cable

The maximum loop resistance permitted for HART communication as per

HCF_SPEC-054 is 600 ohm. This puts a maximum distance limitation on the wires.
Remember:
A 250 ohm shunt resistor is not required for the current loop to a smart valve
positioner
The shunt resistor for a transmitter need not be exactly 250 ohm for the sake of
HART communication. For HART communication anything from 230 ohm to 600
ohm will do. Some analog input cards require a precision 250 ohm resistor for the
sake of the analog 4-20 mA signal, but many receiving devices use other shunt
resistor values.
Loop capacitance
Capacitance of the loop is contributed by the device and the cable
Recommended maximum capacitance for a device as per HCF_SPEC-054 is 5 nF.
Determining the max allowable cable length is a complex iterative calculation based
on the so called 65 microsecond rule for the time constant of the capacitance and
resistance of the loop. By using the chart provided below the max cable length can
be estimated without the complex iterative calculation:

Figure 5 Maximum cable distance for single device 5 nF, 250 ohm shunt resistor
The chart also makes it clear that by using low capacitance (PE insulation) cable
with large conductor cross section, additional distance limitations are not imposed.
A full 1.5 km is possible. However, if high capacitance (PVC insulation) cable with
small conductor cross is used the distance will be limited. Many plants don’t permit
conductor size smaller than 0.75 mm2 (#18 AWG) anyway. PE insulation cable with
mutual capacitance of 60 nF/km is available from many vendors.
Additional cable requirements may apply depending on the hazardous area
classification and local regulations etc.
284 · 46 条评论
Example: Single device,赞
5 nF device capacitance,
评 250 ohm shunt resistor
分享
论
Cable Capacitance: 180 nF/km
Conductor Resistance: 49 ohm/km (22 AWG)
From the 65 microsecond-rule chart, at conductor resistance of 49 ohm/km along
x-axis, and up to cable capacitance of 180 nF/km (between the 164 and 230 lines),
the maximum length on the y-axis is approximately 1 km. If there is higher loop
resistance or capacitance due to additional components in the loop, the distance
will be shorter.
Safety barriers
Intrinsic safety barriers have to be HART compatible passing communication
through the barrier between safe side to hazardous area in both directions without
attenuating the HART signal. Make sure to specify barriers for 4-20 mA input and
4-20 mA output must be able to pass through HART communication and “shall be
compliant to the HCF_SPEC-054 specification”
All intrinsic safety rules apply. They are not covered here.
Cabling route planning
4-20 mA/HART signal wiring must be kept separate from power cables. This must
be taken into account in the design stage when planning the cable tray and
conduit layout and cable routing. 4-20 mA/HART signal wiring is routed together
with other signal wiring including fieldbus and other data communication. If signal
wiring has to cross power cables, they should only do so at a right angle. Make sure
to document the cable routing to ensure it gets done at the time of installation.
Shield connection
The cable shield must be maintained all the way from the field device to the control
system I/O card. That is, the shield of the spur from the device to the junction box
must be joined to the shield for the trunk from the junction box through the
marshalling cabinet all the way to the I/O card. Note that the shield shall not be
connected to the device housing when a single point grounding scheme is used.
This is the recommendation in the HCF_SPEC-054 specification. Make sure to
include the shield connection in all wiring diagrams and loop diagrams to ensure it
gets done at the time of installation. This is the same as fieldbus and other digital
communication.
284 · 46 条评论
Housing grounding
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论
The device housing shall be connected to ground through a large cross-section
conductor. Without it the EMI/RFI protection will not work. Make sure to include the
device housing ground connection in all wiring diagrams and loop diagrams to
ensure it gets done at the time of installation. This is the same as for fieldbus and
other digital communication.
Shield grounding
The shield shall be grounded at the DCS I/O card. Note that the shield shall not be
connected to the device housing when a single point grounding scheme is used.
This is the recommendation in the HCF_SPEC-054 specification. Make sure to
include the shield ground connection in all wiring diagrams and loop diagrams to
ensure it gets done at the time of installation. This is the same as for fieldbus and
other digital communication.
Input filters
If you are installing a new system using 4-20 mA, specify analog input cards
supporting HART pass-through and compliant to HCF_SPEC-054 as well as having
internal low-pass filters to ensure the analog reading is not disturbed by HART
communication.
Some systems do not have low-pass filters internally on their inputs and therefore
require external HART input filters to be added to make sure the reading will not be
disturbed when a HART multiplexer, handheld field communicator, or laptop with
HART interface is connected.

Figure 6 Some analog inputs require external HART filter

The external HART filter for analog inputs is a capacitor properly encapsulated for
easy installation and reliability.

Figure 7 HART filter capacitor for analog input (Courtesy P+F)

284 · 46 条评论
The HART filter is installed near the field wiring terminals of the DCS AI card. If
intrinsic safety barriers
赞 are used, the HART评filter shall be installed between
分享 the AI
论
card and the barrier.
Some specialized compressor surge controllers do not have filters on their inputs
and may react to HART communication. Confirm with the compressor controller
manufacturer if adding HART filter to the controller input is advisable for the
specific application.
Output filters
If you are deploying a new system with 4-20 mA, specify analog output cards
supporting HART pass-through and compliant to HCF_SPEC-054 as well as not
affecting the HART communication.
Some control systems have analog outputs which short-circuit the HART signal or
they rapidly change the analog signal which interferes with the HART signal. The
AO card may also include feedback circuitry which may report the HART signal as a
fault. Such systems therefore require external HART output filter to be added to
ensure HART communication with a HART multiplexer, handheld field
communicator, or laptop with HART interface is not affected or cause nuisance
alarms. The HART filter is installed near the field wiring terminals of the DCS AO
card. If intrinsic safety barriers are used, the HART filter shall be installed between
the AO card and the barrier.

Figure 8 Some analog output cards require HART filter

The DCS AO card must have a sufficiently high compliance voltage to overcome the
combined voltage drop across the valve positioner, HART filter, and loop wiring.
Take the HART output filter into consideration when checking the loop resistance.

Figure 9 HART filter for analog output (Courtesy: Fisher Controls)

Some 4-20
284 · 46mA
条评论simulators (loop calibrators) also require a HART output filter
Line conditioners 评
赞 论 分享
A Partial Stroke Test (PST) device can be connected in parallel with a safety
shutdown valve solenoid. A 250 ohm resistor (typically 1/4 W) is generally not
suitable for currents more than 22 mA (approximately 1/8 W dissipation). The
current for the solenoid is too high for a resistor. In this case use a HART line
conditioner instead. This is similar to fieldbus.

Figure 10 Some discrete outputs require HART line conditioner

Make sure the line conditioner is compliant to HCF_SPEC-054.

Figure 11 HART line conditioner (Courtesy: Fisher Controls)

Device HART compliant
Devices which have not been tested and registered by the FieldComm Group (FCG)
or earlier HART Communication Foundation (HCF) may not be fully compliant with
the HART specifications. This may result in the device not communicating properly
with the system and software preventing device configuration or diagnostics
management, monitoring of auxiliary variables, and causing of nuisance alarms etc.
Therefore make sure to specify devices which are tested and registered by FCG or
earlier HCF. Which devices have passed the interoperability testing can be checked
on the HCF website. This is the same as fieldbus and other digital communication.

Figure 12 HART certificate of registration

Therefore, don’t just specify “HART” for the device but also specify it shall be
registered. That is, specify “Device shall be HART Registered”
Device DD
You don'284t·need DD files for 4-20 mA but you do need DD files for HART
46 条评论
configuration and diagnostics. Without a DD file it is not possible to properly
configure or diagnose
赞 a device. Setting up 评 of
论
instrument diagnostic分享alarm
management filters in the control system and IDM software also becomes very
challenging. Therefore make sure to specify devices which come with DD files.
Which devices come with a DD file can be checked on the HCF website. This is the
same as fieldbus and other digital communication.
Therefore, don’t just specify “HART” for the device but also specify it must come
with a DD file. That is, specify “Device shall come with DD file”.
Loop power supply
The loop power supply must be free from ripple and noise. An old, faulty, or
overloaded power supply may be a source of noise. The power supply ripple/noise
should be less than 2.2 mV RMS. Make sure to specify “shall be compliant to the
HCF_SPEC-054 specification”
Network Arrangement
Some of the mistakes in logical network arrangement that prevent HART from
working properly include:
Connecting more than two masters
Connecting two masters of the same master class
Device using burst communication interfering with IDM software
Unpolled device addressed
Master conflict
Do not connect more than two HART masters on a loop and make sure the two
masters are not of the same master class. That is, one primary master and one
secondary master. The primary master is usually the permanently connected host
such as DCS I/O card or a HART multiplexer. The secondary master is usually a
portable, temporarily connected, “visitor host” such as a handheld field
communicator, laptop with interface, or documenting calibrator. If two or more
masters of the same class are connected the communication will fail.
Table 3 HART masters and their class

Conflicts
284 may occur when smart signal conditioners are used because there may be
· 46 条评论
a need for three masters: DCS I/O cards, smart
评 signal conditioner, and handheld
field communicator.赞For instance, if the DCS论has HART enabled I/O分享 cards (primary
master) the smart signal conditioner must be configured as secondary master to
avoid conflicts, but this would in turn prevent the use of a handheld field
communicator (secondary master). The same applies if a HART multiplexer is the
primary master or a laptop with interface is the secondary master. Smart signal
conditioners are usually not used when a DCS or multiplexer is used as a primary
master with continuous polling.
A smart signal conditioner will not be receiving any PV if there is a conflict with
another master For instance, a HART to analog converter will set the analog output
to an failure alarm output (< 4 mA or > 20 mA) causing “Bad PV” in the receiving
input card, and shutdown of the control loop. Therefore, particular attention should
be given to the master class configuration when smart signal conditioners are used.
Burst communication
Do not use burst communication for devices connected to a control system or
multiplexer because the burst communication will cause diagnostics and auxiliary
variable monitoring etc. to slow down. Burst communication may also cause many
communication error alarms in the IDM software.
Unpolled address
Use a HART version 7 (HART7) host to ensure all devices are detected. Version 5 of
HART (HART5) only permitted address up to 15. Therefore older system software
and handheld field communicators do not support polling of addresses up to 63,
and will therefore not be able to detect newer devices such as wireless adapters
which use default addresses above 15.
Integration Planning
Some of the mistakes in integration planning that prevent HART from being put to
good use include:
Devices not supporting command 48
DD files not provided with devices
HART7 devices not supported
Polling too slow
Command
284 ·48
46 条评论

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For devices not supporting the standard HART command 48 it is not possible for
the IDM software alarm management function to intelligently filter the instrument
diagnostic alarms from the devices. Therefore it is important devices support
command 48. Many HART5 devices do support command 48, but it was not
mandatory so not all HART5 devices support it. Command 48 was made mandatory
in HART7. HART5 devices have the same diagnostics as HART7 devices, but
without command 48 it is challenging to put the diagnostics to good use. Make
sure to specify devices “shall support command 48”.
Note: HART5 systems don’t support HART7 devices, so only specify HART7 devices
if you have a HART7 compatible system.
DD files
You can get the 4-20 mA signal without a DD file but you cannot configure the
device from IDM software without a DD file, for example temperature sensor type
and many other settings in a device that may be required to get a correct
measurement. Not all devices come with a DD file. These devices may have to be
configured form a local display or by proprietary software. Make sure to specify
devices “shall be provided with DD files”.
HART7
HART5 systems cannot support HART7 devices
Some devices can be configured to operate as HART5 or HART7 – essentially two
different devices so have two DD files.
Note: HART5 systems don’t support HART7 devices, so only specify HART7 devices
if you have a HART7 compatible system.
Polling
Early warning to operators of impending process problems resulting from device
failure requires the instrument diagnostic alarm monitoring to be fast. If the polling
time is set longer than a minute, intermittent problems may be missed and the time
left for operators to respond too short. Therefore set the polling time as short as
possible.
The triggered burst mode and event notification (sometimes referred to as report
by exception) functions are intended for WirelessHART not for 4-20 mA/HART.
284 · 46 条评论
Therefore use polling for 4-20 mA device diagnostics.
赞 评 分享
论
Devices configured for burst communication may interfere with diagnostics polling.
Therefore do not configure devices for burst communication.
Procure Correctly
To get value out of HART, the components must be procured correctly. It is up to
engineering to correctly specify a device, software, and other infrastructure
components, but it is up to procurement to ensure vendors comply with the
specifications. The lowest bidder’s component may not comply and this could
jeopardize the ability to utilize HART capabilities. When HART requirements are not
considered in the procurement, the analog 4-20 mA signal will work but the smart
features cannot be accessed and the benefits not reaped.
Some of the mistakes in procurement that prevent HART from being put to good
use include:
System analog I/O cards not supporting HART pass-through
The 4-20 mA cable not meeting HART requirements
The safety barriers not HART compliant
The field device not HART registered
The field device not provided with DD file
DC power supply not HART compliant
Devices not supporting command 48
HART7 devices not supported in system
Design engineers will specify a system supporting HART pass-through with HART7,
cable, safety barriers, and power supply meeting HCF_SPEC-054 requirements,
devices which are registered, supporting command 48, and come with DD files etc.
At the time of procurement it is important to verify the bids received meet these
requirements. That is, procurement should not specify or accept any old 4-20 mA
system, 4-20 mA cable, 4-20 mA safety barriers, DC power supply, or any HART
device.284 · 46 条评论
http://www.hartcommproduct.com/inventory2/index.php?action=list
评
赞 论 分享
Rather than specifying all the characteristic parameters, impedances, voltage levels,
signal levels, and noise levels etc. for cables, devices, and other components it is
easier to simply specify “shall be compliant to the HCF_SPEC-054 specification”
Integrate Properly
To get value out of HART, devices must be integrated correctly. In many plants they
were not, and as a result HART is underutilized. When HART requirements are not
considered in the system integration, the analog 4-20 mA signal will work but the
smart features cannot be accessed and the benefits not reaped.
Some of the integration mistakes that prevent HART from being put to good use
include:
DD files not loaded on DCS
DD files not loaded on IDM software
DD files not loaded on portable tools
Wrong DD file
Load DD files on DCS
The DCS may also be using DD files. For instance, the DD files may be used when
configuring the filtering of the diagnostics in HART command 48 in order to display
each diagnostics as human readable text (see section on Tailoring the application).
Therefore make sure DD files for all device types and versions are loaded on the
DCS to ensure the device is fully integrated.
Some DCS may not use standard DD, but instead use an internal system specific file
created for each device type and version for device diagnostics alarms
management and other functions. In this case, make sure these files are loaded.
Any internal files should be auto-generated by the system from the DD files when
the DD files are loaded. This is the same as for fieldbus and other digital
communication protocols.
Load DD files on IDM software
The IDM software uses DD (EDDL) files to display all the configuration options and
diagnostics
284 · 46etc.
条评论Without the DD file loaded it is not possible to configure sensor
type and many other settings or perform sensor
评
trim and other functions which
must be done before赞 the 4-20 mA/HART device论 is operational. That分享is, without
loading DD on the software the device cannot be made to work correctly. There will
be a 4-20 mA signal, but it may not be correct until the device is properly
commissioned. Therefore make sure DD files for all device types and versions are
loaded on the IDM software to ensure the device is fully integrated.
Some DCS may not use DD or EDDL, but instead use DTM driver software. In this
case, make sure these programs are installed for all devices and versions. In my
personal opinion FDT/DTM has several drawbacks so the plant is better off using
only EDDL.
Load DD files on portable tools
The portable tools like a handheld field communicator or laptop software for a
HART interface also use DD (EDDL) files to display all the configuration options and
diagnostics etc. Without the DD file loaded it is not possible to configure sensor
type and many other settings or perform sensor trim and other functions which
must be done before the 4-20 mA/HART device is operational. That is, without
loading DD on the portable the device cannot be made to work correctly. There will
be a 4-20 mA signal, but it may not be correct until the device is properly
commissioned. Therefore make sure DD files for all device types and versions are
loaded on the IDM software to ensure the device is fully integrated.
Correct DD file
Some devices are available in HART5 or HART7 version, or can be configured to
operate as either HART5 or HART7 to be compatible with both HART5 and HART7
systems. Depending on if the device is configured to operate as HART5 or HART7 it
will need a different DD file. If the device is configured to operate as HART7 but the
HART5 DD has been loaded, the system cannot access the device features.
Tailor Specifically
To get value out of HART, each device must be configured specifically for its
service, and settings are also required for each tag in the DCS and IDM software,
especially to make use of the diagnostics. In many plants this was not done, and as
a result HART is underutilized.
When instrument diagnostics alarm management is not considered in the setup,
the benefits
284 · 46 of
条评论diagnostics cannot be reaped. HART provides no wiring reduction or
savings. The value from HART is purely from diagnostic monitoring and other
intelligent device management.
赞 It is therefore
评 important to engineer
论 分享the instrument
diagnostic alarm management functionality in the devices and systems to make
sure the diagnostics monitoring works.
Some of the mistakes in configuration that prevent HART from being put to good
use include:
Instrument diagnostic alarm management not engineered and configured
Analog output tight-shutoff configured to 0 mA
Instrument diagnostic alarm management
Many 4-20 mA/HART devices have dozens of different instrument diagnostic
alarms. Simple devices like pressure and temperature transmitters just a few, but
advanced devices like valve positioners and flow meters many more. When
multiplied by hundreds or thousands of devices in a plant there is a potential for
instrument diagnostic alarm flooding unless the instrument diagnostic alarm
management system is engineered properly.
When too many instrument diagnostic alarms are sent to the wrong person
becoming a nuisance, the diagnostics polling will soon be turned off. The plant can
no longer benefit from the potential advantages of device diagnostics.
The ISA108 group is developing standards and technical reports as guidance to
IDM in general and instrument diagnostics alarm management in particular. In the
mean time the “Device Diagnostics Deployment and Adoption Guide” found here
can be used:
http://www.eddl.org/DeviceManagement/Pages/DeviceDiagnostics.aspx
The steps in engineering instrument diagnostics alarms management are detailed
in that guideline and will not be repeated here. This is similar to fieldbus and other
digital communication. The steps are:
Categorize instrument diagnostics alarm severity for each device type
Identify criticality to the process for each device tag
Configure system and devices
FAT to verify correct system configuration for alarm management and reports
284 · 46 条评论
Tuning of device diagnostics to fit the application
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 Rewrite maintenance procedures to include the IDM software
Customized training
Do not postpone the instrument diagnostic alarm management engineering and
configuration until after plant startup for the run & maintain team to sort out. They
may not have the same resources as the project team. Work with the EPC
contractor and system vendor to get this engineered and setup before the plant
starts up. It is part of the project responsibility. Indeed the planning portion
including categorization of instrument diagnostics alarm severity and criticality
ranking of devices etc. shall be performed at an early stage of the project after the
CHAZOP such that it can be configured in the system well before device
commissioning.
Not all faults in the device are equally severe. Some diagnostics is predictive or
advisory in nature, meaning the device still functions. Some HART devices may
have standard support for NE107 to categorize the instrument diagnostic alarms
but most don’t because it is a new feature and it is optional. Therefore, make sure
to specify a DCS which is also able to categorize instrument diagnostic alarms for
command 48 internally.
Configure the system to filter the instrument diagnostic alarms for each device. For
each instrument diagnostic alarm in each device there is a bit in HART command
48. Configure the severity for each alarm such as Failed, Maintenance, or Advisory.
This in turn controls how the system routs this instrument diagnostic alarm, for
instance to the operator, or only to the instrument technician. This configuration
work is greatly simplified if the diagnostics for each device is displayed in the DCS
engineering software as human readable text rather than cryptic bit numbers.
Therefore make sure to specify a DCS which uses information from the device DD
file to list the possible instrument diagnostic alarms from the device. If the system
is not directly using the DD files, it can instead auto-generate whatever internal
system files from the DD using some utility. Manually creating such internal system
files or waiting for the system vendor to do it can cause delays. Learn more about
internal system files from appendix 3 in the “Device Revision and Lifecycle
Management Guide” found here:
http://www.eddl.org/DeviceManagement/Pages/DeviceRevisionManagement.as
px 284 · 46 条评论
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Figure 13 Each diagnostic in command 48 can be mapped to a status signal
Some 4-20 mA/HART devices now support NAMUR NE107 status signals
(“Condensed Status”) for instrument diagnostics alarm management. It may be a
good idea to buy devices which support standard commands 523-527 such that
when systems support NAMUR NE107 status signals for 4-20 mA/HART devices in
the future, the installed base of devices already has this functionality. However, not
many such devices are available today so it cannot be made a requirement.
Note that the NE107 implementation for HART doesn’t have priority for each
device. This will have to be supported by the system in a way specific to the system.
It is important to configure the priority appropriately for each device, because all
devices are not equally critical. Some devices are more critical than others and this
must be taken into account in instrument diagnostic alarm management.
Also note that some HART devices have some form of NE107 but the
implementation is not according to the HART “condensed status” standard
commands for NE107 which means it will not integrate with systems using the
standard commands. Therefore, verify if standard commands 523-527 are used in
the device or not.
Analog output tight-shutoff
Don’t configure control system tight-shutoff output current to 0 mA because this
turns off the smart valve positioner and any wireless adapter and other accessories
in the loop preventing diagnostics and HART communication.
The tight-shutoff current setting in the DCS shall be somewhere in the range 3.6-
3.8 mA to ensure the positioner still performs diagnostics and devices plus
accessories are able to communicate.
Test Thoroughly
To get value out of HART, the HART integration must be tested during the system
Factory Acceptance Test (FAT). For many plants it was not, and as a result HART is
underutilized. When HART requirements are not considered in the FAT, the analog
4-20 mA signal will work but the smart features cannot be accessed and the
benefits not reaped.
Some of284the
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omissions in FAT that prevent HART from working properly include:
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Device interoperability / integration test not论performed
 Instrument diagnostic alarm routing test not performed
Interoperability/integration
During system FAT connect one of each 4-20 mA/HART device type. Open each
device type in the IDM software to make sure the DD file for the type and version of
the device has been loaded and that the device displays correctly. Download a
device configuration to make sure the download is error free. This is similar to what
is done for fieldbus and other digital devices.
Instrument diagnostic alarm routing
For each device type, simulate instrument diagnostic alarms of different severity
such as Advisory, Maintenance, and Failure and make sure they are routed to the
right person such as operators or instrument technicians as defined in the design
stage.
Install Correctly
To get value out of HART it must be installed correctly. It is up to engineering to
correctly design cable routing and grounding schemes etc, but it is up to the
installation contractor to ensure the design is followed. If cables are routed and
grounded differently this could jeopardize the ability to utilize HART capabilities.
The HART signal is small, only 1 mA. If there is noise on the wire due to poor
installation, the diagnostics, secondary (SV), tertiary (TV), and quarternary (QV)
variables will stop coming. There will be no updates to the system and
communication alarms will be generated. A smart signal conditioner may output <
4mA or > 20 mA which may cause a nuisance trip. Such issues will not be noticed
when using a handheld for device configuration and commissioning, but once
continuous monitoring is used it will be evident. Make sure to install properly. In
many plants the installation was not done correctly, and as a result HART is
underutilized. When HART requirements are not considered during installation, the
analog 4-20 mA signal will work but the smart features cannot be accessed and the
benefits not reaped.
Remember, when using a 4-20 mA/HART device with a WirelessHART adapter the
wiring must still meet the HART requirements because HART is still communicated
across the wires, if ever for a very short distance between the device and adapter.
Some of284the mistakes in installation that prevent HART from working properly
· 46 条评论
include: 评
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 Cable shield connected to device
Inadvertent contact between shield and grounded metal objects
Cable shields not maintained in field junction box
Signal cables routed in same tray as power cables
Cable looped too tight damaging shield
Device housing not grounded
Junction box not grounded
Signal cables and power cables coiled together
Shield and conductor insulation damaged
Cable jacket and shield stripped off unnecessarily
Multi-pair cable overall shield not grounded
Cable armor not grounded
The HCF_SPEC-054 specification includes several HART shielding and grounding
recommendations. Since most don’t have this document I have included some of
those rules below complemented with additional pointers. These are the same as
for fieldbus and other digital communication.
Don’t ground shield at device
Do not connect the shield or drain wire to ground in the device housing. Ground
the shield only in a single point, at the power supply. Only connect signal wires at
the device. Isolate the drain wire using shrink tube or tape. This is the
recommendation in the HCF_SPEC-054 specification. Some plants have other
practice.
Insulate shield at device
Do not leave the shield or drain wire “flying” as it may come in contact with the
device housing.
Cut the284shield
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inside the device housing. Isolate the drain wire and shield using
shrink tube or tape赞to make sure it does not评论come in contact with 分享 grounded metal
parts. For armored cable, make sure shield drain wire is not touching the cable
armor.
Maintain shield in junction boxes
Do not ground the shield in the junction box. Do not leave ‘flying’ shield or drain
wire as it may touch other wires or grounded metal parts.
The shield shall be continuous from system panel, through junction box, up to the
device (but not connected to the device).
If two cables are joined, make sure the junction (splice) also joins the shields of the
two cables.
Route signal cables in separate tray from power cables
Do not lay communications signal cable in the same tray as power cable.
Route signal cable and power cable in separate tray. If signal cable and power cable
is laid in the same tray, maintain maximum possible separation, keeping power
cable and signal cables on separate sides of grounded metal dividing wall.
The plant designer is responsible for designing separate trays for signal cables and
power cables. Installer is responsible for laying cable in the assigned tray.
Don’t loop cable too tight
“Pig tails” are permitted but must have a sufficiently large radius to not damage the
internal shield. Do not loop/bend cable too tight – it can damage the shield
reducing noise immunity. Cable trunking / wire troughs / trays are usually too
narrow to permit looping of the cable. Do not turn corners in cable trays and on
cable ladders too tight.
Observe cable minimum bend radius, which is cable type dependent. For armored
cable it can be space taking. Use proper cable tray bend, cross, and tee pieces to
allow cable to round corners with wide radius.
Ground device housing
Without a ground connection the device EMI/RFI suppression will not work
Make sure the device housing and junction box is safety grounded to the plant
284 · 46 条评论
structural steel with a low impedance connection to ensure personnel safety and
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EMI/RFI suppression. It is particularly important for those devices where surge
protection is used.
Ground junction boxes
Make sure the junction box is safety grounded with a low impedance connection.
When using plastic junction boxes and metal cable glands, these glands must be
connected to the safety ground bar inside the junction box, typically using a metal
plate inside junction box.
Don’t coil signal cables and power cables together
Do not coil signal cables and power cables together inside the device terminal
compartment, for example, in separately powered devices such as Coriolis and
magnetic flow meters, etc.
Keep cables short, jacket on, shielded, and separated
Don’t damage shield and conductor insulation
Do not damage shield and conductor insulation when cutting and stripping cable.
Do not use a knife to cut the cable jacket – it might damage the shield and
conductor insulation causing short circuits and reduced noise immunity. Do not use
a hacksaw to cut the tube armor or steel wire armor (SWA) – it might damage the
inner jacket, shield, and conductor insulation, the cable will no longer be
waterproof, cause short circuits, and reduced noise immunity
For cable jacket use a cable jacket/sheath stripper which only cuts the jacket
without damaging underlying layers. For tube armor use a pipe/tubing cutter which
only cuts the tube armor without damaging underlying layers. For SWA use a wire
cutter to cut strand by strand which only cuts the armor without damaging
underlying layers.
Don’t strip off more than necessary
Do not remove shield or jacket for cable running in cabinet or junction box - bare
shields (and drain wire) of different cables will touch and may cause ground loops.
Do not untwist the twisted pair.
Maintain shield and jacket as far as possible, close to the connection terminals.
Ground284overall shield for multi-pair cable
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Do not leave overall赞 shield on multi-core cable
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On multi-core cable, the shield shall be grounded in the power supply end. Make
sure overall shield does not touch any of the individual pair shields.
Ground the cable armor
For armored cables, do not leave the cable armor floating
For armored cable, the metal cable gland must make contact with the amour of the
cable at the device and in the junction box. If plastic cable glands are used at the
junction box, or the junction box is plastic, the cable armor shall be grounded to
safety ground bar. Ground the armor in multiple points: before cable enters
marshalling cabinet, in cable tray, and in the field junction box.
Other good installation practices
Normal good installation practices apply; these are the same as for any wiring:
Do not pull cable with too much force
Make sure cable glands are tight
Seal unused conduit entries
Use correct size ferrule/fork and tool
Do not cram wires in device terminal compartment
Do not over/under-tighten screws
Make sure covers are tight
Do not tighten cable-tie too much
Label wires
Observe polarity
Commission Correctly
To get value out of HART it must be commissioned correctly. In many plants it was
not, and284as· 46a条评论
result HART is underutilized.
When HART requirements are not considered 评
at commissioning, the analog 4-20
mA signal will work赞but the smart features 论cannot be accessed and分享the benefits not
reaped.
Some of the mistakes in commissioning that prevent HART from working properly
include:
HART communication not checked during loop check (loop test)
Digital integration not verified
HART communication check at loop check (loop test)
Although it is critical to perform a 5-point look check for the 4-20 mA current loop
to verify scaling and linearity etc. at 4 mA, 8 mA, 12 mA, 16 mA, and 20 mA, as well
as < 3.6 mA and > 21 mA to verify NAMUR NE 23 functionality, it is also important
to verify the HART communication. Use a loop calibrator with HART communication
capability or a handheld field communicator to communicate with the device while
it is on the current loop to ensure communication is error free. For instance,
monitor the four dynamic variables (PV, SV, TV, and QV) for some time. This verifies
the design and installation is done correctly, so digital communication will be
reliable.

Figure 14 HART-enabled loop calibrator (Courtesy Fluke)

This is similar to fieldbus and other digital communication
Digital integration verification
Also as part of the loop check, open up each device in the IDM software. This
verifies the communication is enabled and working from the system end, and that
the DD file matches the device type and version actually installed in the field. For
instance, open the device on its diagnostics page to make sure the device is fault
free. If there is any problem like an incorrectly wired temperature sensor this will be
revealed too. This is the same as for fieldbus and other digital communication.
Change
284 ·Work
46 条评论Practices

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Just devices with diagnostics alone are not enough. Also having IDM software
won’t do it because if nobody looks at the software, the diagnostics and software is
useless. Getting into the habit of using the IDM software as part of the daily routine
is an important step. It is a culture change. This is the same as for fieldbus and
other digital communication.
Some of the work practice mistakes in that prevent diagnostics from being put to
good use, include:
Instrument diagnostic alarm summary and log not reviewed daily
Device diagnostics not reviewed before going to the field
Not rewriting Standard Operating Procedures (SOPs)
Review instrument diagnostic alarms
Instrument technicians must make it a point to review the instrument diagnostic
alarm summary and log every day to see what is happening to the instruments in
the field. By acting on predictive diagnostics, outright failures can be avoided. Also,
routine inspection of devices results in technicians spending precious time on
devices which need no service while a device that needs service gets no attention.
By using the IDM software technicians can instead focus on the device which need
their attention.
Check the software first
When operations say a device is not working, instrument technicians must make it
a point to check the software first, before going into the field to take a look,
because many times it turns out to not be a device problem. By checking the IDM
software first, many unnecessary field visits resulting in no action taken can be
avoided.
Rewriting Standard Operating Procedures (SOPs)
The work procedures related to instrumentation such as inspection, replacement,
calibration and other tasks have to be rewritten to include the use of the IDM
software. But most importantly, getting into the habit of checking the software first
is a culture change.
Maintain
284 · 46Properly
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To get value out of HART the installation must be maintained in good condition to
ensure the HART communication continues to work error free. In many plants this is
not done, and as a result HART is disabled for one device after another as
communication deteriorates, so as to avoid communication alarms. The analog 4-
20 mA signal will work but the smart features can no longer be accessed and the
benefits not reaped. When HART communication stops working, digital
communication troubleshooting should instead be done to bring it back online.
The issues that develop over time preventing HART from working properly include:
Cable shield grounded at device by somebody not knowing it shall not be connected at
the device
Inadvertent contact between shield and grounded metal objects due to moisture or dirt,
or at device replacement
Excessive loop resistance due to corroded terminals or added series device like an
adapter
Device replaced with a device which is not HART-enabled
New source of noise
Moisture in device compartment or field junction box
Loose connections due to vibration
HART signal attenuation due to increased capacitance in aging cable or stray capacitance
Device replaced with a device which is not the correct HART protocol version
Device replaced with a device which has not been configured correctly
Additional master connected causing master conflict
Shield damaged
Shield continuity compromised
Housing ground disconnected at device replacement or due to corrosion
284 · 46 条评论
Field junction box ground poor connection due
评 to corrosion
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When HART communication alarms start appearing, don’t just disable HART
communication. Instead troubleshoot the communication to fix the problem. If
HART communication is disabled, the benefits of HART are lost and only analog 4-
20 mA remains.
Monitor network health
Communication errors are usually only alarmed if there are three unsuccessful
attempts in a row. Therefore monitoring communication Packet Error Rate (PER) is a
good way to detect deteriorating communication much earlier, before alarms start
ringing. Check communication statistics for lost packages from time to time. The
control system may have built-in communication diagnostics, or external HART
analyzer software can be used. This is just like fieldbus and other digital
communication.

Figure 15 Messages sent and messages received should match

Maintain installation integrity
Anybody that works on maintenance of instrumentation and in field junction boxes
must be familiar with the additional requirements of digital HART over and above
those of analog 4-20 mA. If not, they may make mistakes like connecting the cable
shield to the ground screw on the device. They may not take care to prevent
contact between shield and grounded metal objects at device replacement. They
may forget to ground the device housing.
Make sure there is no moisture or dirt in device compartments or field junction
boxes, and terminals are not corroded, that connections have not come loose due
to vibration, including ground connections. Look for shield damage and shield
continuity. Check for noise.
Management of change
There are several considerations when replacing a device or making other changes.
HART communications should also be taken into consideration. When a device is
replaced, make sure it is a HART-enabled device, that it has a supported protocol
version, that it is tested and registered, supports command 48, and that it comes
with a DD file. Make sure it is configured correctly with regards to communication
and diagnostics.
284 · 46 条评论If a HART master device like a wireless adapter or signal
conditioner is added, make sure there is no评master class conflict. If another series
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device is added in the loop, like an adapter or field indicator, make sure the voltage
is sufficient.
Make sure sources of noise are not introduced. Make sure new cable is laid in the
correct trays. Be mindful of new sources of noise being introduced in the plant such
as variable speed drives (VSD) / variable frequency drives (VFD).
Troubleshooting
Troubleshooting digital HART is different from troubleshooting analog 4-20 mA.
You can’t troubleshoot HART with a multimeter. Refer to this to troubleshooting
guide for HART and other field communication:
http://www.eddl.org/SiteCollectionDocuments/TechPapers/ag_Field%20Commu
nication%20Troubleshooting.pdf
Manage Properly
To get value out of HART the system needs proper administration. In many plants
the system is not kept up to date with new devices, and as a result HART is
underutilized.
When HART requirements are not considered throughout the long run & maintain
phase of the lifecycle, the analog 4-20 mA signal will work but the smart features
cannot be accessed and the benefits not reaped.
When a failed device is replaced by a different model or version this new device
must be registered and must come with DD files
The system administration mistakes preventing HART from working properly
include:
System not kept up to date with new device types and versions
Device replaced with a device for which DD or other internal system files are not available
Keep system up to date
Make sure to load the DD files for new device types and versions on the control
system and IDM software such that they are ready to accept new devices. Without
the DD284files the devices cannot be configured or diagnosed. This is the same as
fieldbus and other digital communication. Without DDs loaded the IDM software
· 46 条评论
will fall into disuse.赞DD files are easy to download
评 from the Internet.分享Because DD
论
files are not programs, it is possible to load DD files for dozens of versions of
dozens of device types from hundreds of device manufacturers on the system
without conflicts or burdening the computers. This way a DD-based system is ready
for all kinds of devices. Some systems have DD wizard that automatically
distributes the DD to all workstations in the system when the loaded on the server.
Some system suppliers offer update services which loads DD files onto the system
automatically as they become available.
There is IDM software which uses DTM driver software instead of DD. In the case of
FDT/DTM it is necessary to make sure that the DTM for the device is available for
the particular Windows version used by the IDM software (FDT frame). Because
DTMs are software programs, DTMs for all kinds of devices cannot be installed in
advance as DLL conflicts may result and the burden on the computers excessive.
Instead instrument technicians need the skills to install DTM software as and when
new device types and versions are installed in the plant. Instrument technicians
may need ‘administrator’ level password to install the DTM program. The DTMs
must be installed on all workstations used to access devices one by one. Use only
certified DTMs and only DTMs from the original device manufacturer, not third-
party DTMs. Many DTM programs require a license key to unlock full device
capabilities. Make sure all DTMs are available for the new Windows version before
upgrading Windows.
Make sure DD files are available
When a failed device is replaced by a different model or version the new device
must be registered and must come with DD files. Not all HART devices have DD
files, so an important first step is to make sure a device comes with DD files before
purchasing it.
Get Connected
By designing according to the rules, procure correctly, installing and commissioning
correctly, integrating and setup properly, maintaining properly, and training people,
HART will work and can be put to good use not only with a handheld field
communicator at commissioning but also with IDM software.
If you are not getting the most out of your HART devices, get a field
communications
284 · 46 条评论expert to conduct an audit to identify gaps. If your next project
involves 4-20 mA/HART, get a field communications expert involved. Well, that’s my
personal opinion. If赞you are interested in how
评 the digital ecosystem分享
论 is transforming
process automation click “Follow” by my photo. Click “Like” if you found this useful
to you and share it with others if you think it would be useful to them.
Mike Glass 3 个月
Instrumentation and Controls Expert | Owner, Orion Technical Solutions | Trainer, Mentor | Husband, Father, Fishe…
Great article! It’s sad how many plants fail to take advantage of the technology they’ve paid for.
Training (or lack there of) seems to be the leading cause.
We need more coverage of the kinds of issues in this very detailed and informative article. Great
work!
赞· 回复
Dan Weise 4 个月
Sales support and training
It might be 7 years old by now, but I just linked another forum thread about HART issues to this
page. It is the definitive HART troubleshooting document out there.
赞· 回复 1 次回应
杜刚 2年
上海辰竹仪表有限公司 - 高级工程师
Very detailed and wonderful article! I have been reading your articles recently and have benefited
a lot. Thank you,Jonas!
赞· 回复
Mirko Torrez Contreras 2年
Associated Technical Consultant at PITC/PICC
An outstanding guide about all things HART. With the usual attention to details that has become
a trademark of Jonas's posts.
赞· 回复 1 次回应
Rishikesh Tiwari 3年
Proposal Engineer at Rockwell Automation
Thanks for such informative article
赞· 回复 1 次回应
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