Andreas Agostin Installation Solutions

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Installation – Issues and SolutionsAndreas AgostinIndustrial Network Sales Specialist Asia PacificMTL Instruments Singapore, part of Cooper Crouse-Hinds

15.05.2013 Perth

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Introduction

Fieldbus is in use since 19981, yet still new for many customers today.

This presentation will look at the installation issues and the “lessons learned”, so that you can benefits from their experience.

1 Shell Malampaya is one of the early, larger projects. 1600 FF instruments are in use. The project produced first gas in Oct 2001. Source: J. Seaver, Shell Philippines Exploration B.V., “Malampaya Deep Water Gas-to-Power Project: Malampaya Subsea Development”, Offshore Technology Conference, 6 May-9 May 2002, Houston, Texas.

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Introduction� The pictures you will see are collected from “real”

projects; they are neither simulated nor “demo”.

� We will look at – Control room: cabinet design and wiring– Field: Wiring, field junction boxes, field device installation.

� Processes typically involve explosion protection methods “intrinsic safety” (I.S. / Ex i; energy limitation by a ‘barrier’) or “explosion proof” (Ex d; protection by explosionproof enclosure).Many examples use “IS” as this is a key product of my company and that is where I get involved.

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DisclaimerAll products shown serve as EXAMPLE only.In particular, problems shown in conjunction with a product

serve as example only.

The brand/make/model of the product serving as exampleis IRRELEVANT .

Problems highlighted serve as example only, are do in no way express problems with a particular product, model or brand.

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The conventional system

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Control room – Conventional wiring

2nd level 1st leveljunction box Marshalling

and barrierControl system

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Control room – Conventional wiring

Marshalling: to group AI / AO / DI / DO / etc

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Control room – Conventional wiring

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Control room – Conventional wiring� Long wires, standard length� Allows pre-fabrication of wire

(ferrules, mounting)� Conventional signals (4-20mA,

RTD, thermocouple, 0-5V/10V/24V) – slow, hardware filtered, length less important

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Field – Conventional wiring

� Quality (material)� Safety� Location / access� Weight/size, …

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Fieldbus versus conventional

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Control room – DCS wiring EXAMPLES

Fieldbus

Conventional

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Control room – DCS wiring EXAMPLESInstallations do not have

to look messy. They can be very nice, too.

Fieldbus

Conventional

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Control room – DCS wiring EXAMPLESFieldbus Conventional

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Control room – DCS wiring EXAMPLES

FieldbusFieldbus

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Control room – DCS wiring

Important:do not use individual wires to wire cabinet. Use fieldbus cable and shield properly.

Why?

Higher signal frequency – protect them against disturbances.Individual wires will cause crosstalk from one wire to another –communication faults can occur.

??

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Fieldbus CableRecommended:Type A cable: Shielded twisted pair

Other cable is possible, but there are limitations in terms of achievable cable distance and electromagnetic compatibility (EMC).

Fieldbus is a digital “high speed” (31kBit/s) communication, a current modulated signal superimposed on the DC power.

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Fieldbus Cable

Shielded pairprinciple

Foilshield

Foil plusbraidedshield

SWA

Not round – Not recommended

Ideally round – Recommended

Fillers (solid or fiber)

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Fieldbus Cable

SWA Multi-pair

Multi-pair (multi-trunk)

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Please not this way

Images obscured – Brand is irrelevant.

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Control room – DCS wiring

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Fieldbus system – Field wiring

??•• Parallel wiring Parallel wiring

(terminals)(terminals)•• special wiring special wiring

blocksblocks•• (daisy chaining)(daisy chaining)

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Fieldbus system – Field junction boxes

Principle of wiring distribution in junction box:all devices are in parallel

Source: FF AG 140 Rev. 1

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Fieldbus system – Field junction boxes

Please not this way

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Fieldbus system – Field junction boxes

Use dedicated wiring blocks with built-in electronic short circuit protection.

LEDs: - built-in s/c protection

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Good Wiring Practices� Test segment wiring before connecting components� Avoid damaging the wire when removing insulation� Ground the cable shield only at one point (at the control

room end)� Insulate the ungrounded end of the cable shield (at the

instrument)� Ground armor on both sides (potential equalization)� Use crimp ferrules

– Ferrule diameter must fit wire– Crimp tool must fit ferrule– Ferrule must fit terminals

� Maintain polarity and associated color codes throughout the segment

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Good Wiring Practices

� Lessons learned:� Torque screwdriver� Wire end ferrules� Right (!) wire strippers� Fieldbus tester

Harmswire strands

Chooseright size

AWG ..

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Fieldbus Design Tools(Examples)

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Project Procedure

Best practice:� Bench test

Functional tests and interoperability test� FAT� SAT

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Installation Guidelines� Cable Tests

– Experience has shown that new cable irregularities are so infrequent that it is more efficient to check cable after installation

� Cable Installation– Verify that cable is properly installed, bypassing impact

from wiring components� Segment Checkout

– Check of proper wiring of wiring components� Device installation

– Check of proper device installation� Loop checkout

– Functional test

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Installation tools

Portable fieldbus diagnostic test equipment(Handhelds)

� Measures relevant fieldbusparameters

� Establish baselineafter commissioning

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Handheld diagnostic tools

Handheld Diagnostic Tool

Device 1 Device 3 Device 2

T

Device Coupler& Terminator

(non-IS) Spurs

FFPST

FF Power Supply& Conditioner&Terminator

24VDC

HostComputer

H1 Interface

Connect at respective location to obtain accurate measurement.

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Handheld diagnostic tools

Handheld Diagnostic Tool

FFPST

FF Power Supply& Conditioner&Terminator

24VDC

HostComputer

H1 Interface

Fieldbus barrier

Device 1 Device 3 Device 2

Fieldbus barrier& Terminator

IntrinsicallySafe Spurs

T

Fieldbus

barrier

To measure at fieldbus barrier/IS segments, Handheld needs to be Ex i approved.Important since the galvanic isolation of fieldbus barrier impacts on measurement.

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Earthing/Grounding

� Grounding in the control room� One point grounding only� Continuous shield from control room to the field� Shield not connected at the field instrument

� Connect cable armor at both ends (potential equalization)

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Earthing/Grounding

Device 1 Device 3 Device 2

T

Wiring Block& TerminatorFFPS

T

FF Power Supply& Conditioner&Terminator

24VDC

HostComputer

H1 Interface

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Fieldbus barrier

Device 1 Device 3 Device 2

Fieldbus barrier& Terminator

IntrinsicallySafe Spurs

T

Fieldbus

barrier

Earthing/Grounding

FFPST

FF Power Supply& Conditioner&Terminator

24VDC

HostComputer

H1 Interface

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Local field junction box for 4 instruments. Rust prevented proper grounding, so that separate ground connection was required

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Field – Fieldbus wiring

Green: fieldbusRed: Power (Motors, etc)

For easy maintenance

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Troubleshooting

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Daisy chaining – not recommended

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Troubleshooting

Electrical welding can generate significant surges

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Bend radius too tight, Upward facing gland risks water ingress

Two cables into one glandprevents sealing of gland

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Water ingress caused corrosion of wire and terminals

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Cable jacket stripped back too far

Troubleshooting

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Wires coming out of ferrules

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Troubleshooting

Earth stud not connected – internal surge protectors not working

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Troubleshooting

Ground not connected

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Troubleshooting

Poor cable (shield) quality

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Troubleshooting

Grounding concept failure-prone

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Troubleshooting

Water marks, fungus inside junction box

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Troubleshooting

Wire squeezed by enclosure lid – water ingress

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http://forums.fieldbus.org/showthread.php?t=1298

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Conclusion

� Fieldbus is robust if the installation is adjusted to the requirements of a digital communication line

� Do not simply copy 4-20 methods� Use fieldbus smartly (e.g. eliminate marshalling)� Good wiring practices are more important than

on 4-20 due to bus structure� Train your installers on fieldbus practices

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Installation – Issues and SolutionsAndreas AgostinIndustrial Network Sales Specialist Asia PacificMTL Instruments Singapore, part of Cooper Crouse-Hinds

andreas.agostin@cooperindustries.comPh: +65 97585161