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PROFIBUS AUDIT for ‘FLOUR MILL’ at Northern Saudi

Plant Location:

Flour Milling Company Hail, Northern Saudi

 

PROFIBUS network with SIEMENS S7-300 PLC and ET200 RIO and Micromasters running on 500 kbps. The total number of slaves is 84 and the network is separated into segments with 3 Repeaters.
 
Segment 1 is consisted of all the RIOs (25 Devices).
 
Segment2 is consisted of all the Micromasters together (29 Devices).
 
Sements 3 & 4 are having a mixture of weighers and HMIs.

PROFIBUS Network Test:

The company have asked for ASM Process Automation service to check the healthiness of the PROFIBUS network.
 
Looking at segment 2 visually, you can see that is has many drawbacks such as:
 

  • The number of devices per segment is almost reaching the limit.
  • Connecting this number of Micromasters together in series will generate HIGH noise that affects the PROFIBUS signal.
  • All these Micromasters are connected together with less than 1 meter of cable. Although the Baudrate is not 1500 kbps, adding this to the previous factors counts.
  • Any cable issue (short circuit, wire break, wrong termination) will take down the whole segment.

 
network_test

Checking with the Analyzer:

So Profitrace was used to check how the signal would look like on that segment. To compare, the 1st pic is for the segment 1 that contains the RIOs and the 2nd pic is for segments 2 with the Micromasters

 

Analyzer

 

Analyzer2

ASM Recommendations:

Ammar Atta the ASM Engineer had a meeting with the plant manager and the department’s heads to discuss the recommendations.

 

They want to use the PROFIHUB to separate that segment into smaller ones, so they benefit from isolating the sensitive devices, rewiring the short cables and to making it easy to troubleshoot.

 

ASM_recommendations

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P.O. Box 51736, Mahmud Al Himsi street
Building no:3249, Abhur Al Janubiyah,
Jeddah 23731, Saudi Arabia,
info@asm.net
Fax :
+966 11 491 1104
JEDDAH
+966 55 66 20210
KHOBAR
+966 59 566 3333
RIYADH
+966 11 491 1104
DUBAI
+971 45 149 230
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