A study and the evaluation of real time performance of Samancor’s Profibus network

Abstract

The field buses, and particularly the ‘PROFIBUS’, are currently widely used in automation systems, with the intention to automate industrial applications. It is of the utmost importance that one should understand how these systems operate, because failure to understand may result in improper applications, which can ultimately lead to intense network problems and, consequently, lead to potential catastrophic failures in industrial equipment, as well as compromising the health and safety of the people. This research was the performance evaluation of SAMANCOR PROFIBUS network that controls the chrome manufacturing plant. The problem with the network was that it was failing intermittently. These network failures resulted in loss of production, loss of throughput, compromised quality, downtime due to reworks, high costs in energy used to rework, and equipment damage or failure. One of the OBJECTIVES of the research was to carry out a performance evaluation of the PROFIBUS network in terms of the possible electromagnetic interference (EMI) within the plant’s PLC network. This topic emanated from the network service providers that kept insisting that the network was unstable, due to possible electromagnetic interference caused by possible high voltage cables running next to the plant network cables. This assumption was without fact, and hence the research was conducted. The QUANTITATIVE research method was used to conduct the research, where simulation of the plant network, using external parameters, were used to carry out the research. Furthermore, experiments were conducted and the physical measurements were performed on the network, where parameters derived from these measurements were used to compare the two networks. In essence, the network was tested under known configurations. The manner in which the network was simulated was that of stepping up the electrical current from the external device, and recording the response of the network. A stand-alone network rig was built and used to carry out the tests, and the results were compared with those obtained from the plant network.