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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Mistry Harendra G. Chief Engineer - Instrumentation
Fieldbus Foundation – India Marketing Committee
Foundation Fieldbus EngineeringConsultant Perspective
Aker Powergas Pvt. Ltd., Mumbai, India
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Is not Hard or DifficultIt is Little Different
Foundation Fieldbus Engineering?
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Foundation Field bus Implementation guideline documentClient specification / ITB requirementsFieldbus type (i.e. General, Entity,FISCO, FNICO, High Power Trunk etc)Network/segment Topology selection Critical loop defination and applicationLoop response timeSegment design consideration / guidelineHardware PlanningDevice requirementsFF Cable typeRedundancySpare RequirementsControl assignmentsPackage supplied FF instrument interfaceEngineering documents format templatesDCS (HOST) system requirementsNaming convention
Preliminary Engineering
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Fieldbus Concepts
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Segment Topology
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Preliminary Segment Design
Documents/Input required for Preliminary segment designP&ID’sPlot Plan / Equipment LayoutApproved Foundation Field bus Implementation guidelineHazardous area classification
Segment design constraintsField bus type (Safe, FISCO, FNICO or High Power Trunk)Voltage drop calculationCurrent calculationSignal attenuation calculationSegment execution time.Segment criticality Rating Spare capacity
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Preliminary Segment Design
Preliminary Segment Assignment
(Control loop)
Preliminary Segment Assignment
(Monitoring only)
Reallocate device to same segment
All device of control loop in same segment?
Does segment contain 3 control devices?
Reallocate one device to another
segment
Add monitoring only FF device to existing
segment
Does segment contain more than 8 devices ?
Does segment contain more than 8 devices ?
Reallocate one device to another
segment
Segment fully loaded
P&ID and Plot plan available
START
Generate Preliminary Trunk &
spur cable length
Is any spur>120?Is segment >1900m?
Perform Preliminary segment calculation
Does calculation validate segment?
Preliminary segment assignment complete
END
Yes
NO
Yes
NO
Yes
NO
Yes
NO
Yes
NO
Yes
NO
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Final Segment Design
Documents/Input required for Final segment designP&ID’sInstrument Location PlansCable tray Layout / Plot Plan / Equipment LayoutApproved Foundation Field bus Implementation guidelineHazardous area classificationControl NarrativesComplex Loop Narratives List of Critical Control Loops List of Loops requiring Loop execution times faster than 1 second. I/O Lists
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Final Segment Design
Re-assign all other control element to another segment
Does segment contain critical control valve?
Develop list of critical control valve
Re-Route Trunk or re-assign entire loop
START
Finalise Number of wiring blocks
Finalise Trunk & Spur length
Does calculation validate segment?
Segment assignment complete
END
No
Yes
Yes
Review Instrument Location plans
Device(s) away from junction Box
Monitoring only Device(s)?
Finalise Segment Route
Perform Final segment calculation
Re-assign device to another Segment
Preliminary Segment Assignment
complete
Re-assign device(s) to another segment
Yes
Yes
NoNo
No
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
H1 card quantity FF Power supply conditioner card quantityFF Cable quantityNumber of FF junction boxFF termination block / FF Barriers QuantitySurge protector quantityTerminators quantity
Hardware planning
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Device certified for latest interoperability testing Device approved by the Fieldbus Foundation and carry the Foundation fieldbus“Check Mark” logo.Device Description (DD) and Common File Format (CFF) files available. Device have link master capabilities.Device have required function block (AI, PID, AO etc) and execution time.Device minimum operating voltage, current and power consumption.Device should be polarity insensitive.Capable of performing continuous advanced diagnostics, self-test function, provide specific diagnostic information, on-line automation procedures (e.g.calibration) from the DCS, support peer to peer communicationFF device and its function blocks shall be tested and certified by the DCS vendor
Field Device Requirements
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Function blocks shall be downloadable into the devices by the system.Device certified for plant hazardous area. Device used in hazardous area should have
Field Device Requirements
Ci[nF] + Ccable [mH]>=Co [nF]Li[mH] + Lcable[mH]>=Lo [mH] Pi [mW]<=Po [mW]Ii [mA]<=Io [mA]Ui [V]<=Uo [V]
Safety Parameter of Device
Safety Parameter ofI.S. Barrier
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Cable
Trunk cable can be multi-pair (as per project requirement).Fieldbus Cable is to be unique in color (e.g. Orange with blue strips for I.S. segment)Cable should be armoured for outdoor installation in cable tray
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Sufficient space to accommodate termination block / field barrier, surge protector, conventional terminal, isolation switch (for field barrier isolation) etc.Material i.e. Stainless steel, GRP etcInactive spare Fieldbus trunk pairs shall be terminated on conventional terminal blocksComplete box should certified for hazardous area installation i.e. EExe etcWire capacity size 12 – 24 AWGConventional terminal block to be provided suitable for wire size 12 – 24 AWGShort circuit protection & surge protection to be provided with each spur
Junction Box
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
List of Conventional documents required modification as per Foundation fieldbus engineering
System Conceptual drawingP&IDDatasheet Instrument index / DCS I/O listJunction box wiring diagramLoop wiring diagram / Segment Wiring diagramManufacturer documentation
Newly added documents for Foundation fieldbus engineeringFoundation Fieldbus Implementation Philosophy / GuidelineInstrument Segment/Network DiagramSegment validation reportOff line configuration data document
Documentation
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
P&ID
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Datasheet
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Segment diagram
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Following input to be provided for DCS engineering. Tag No.Calibration range and UnitFlow range and UnitOutput typeTransmitter ModelNode Address (To be provided by DCS vendor)Device Type Device Class (Basic / Link master)Device RevisionDD RevisionCFF RevisionPID Function Required
Off line configuration data document
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Junction box Wiring Diagram
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Loop Diagram
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Segment Loop Diagram
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Segment Validation Report
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Redundant Power feeder to bulk power supplyRedundant Bulk Power supplies with battery backup (Min. 30 minutes)Redundant system controller power supplyRedundant system controllersRedundant Foundation Fieldbus H1 cardRedundant Foundation Fieldbus power conditionersRedundant controller should not share the same back planeRedundant H1 card should not share the same back planeRedundant FF power supply should not share the same back planeRedundant Link Active scheduler
Redundancy
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Segment shall be designed for 25% spare capacity- FFPS supply current : 25% spare current capacity- FF Spur Terminals (wiring block) : 25% spare spur terminal capacity- Spare capacity in segment bandwith (i.e. Function block capacity, Number of
VCR, Macrocycle time etc) 25% spare pair in trunk cable or minimum 1 pair as spare.20% installed hardware spares in Host System (H1 card, FFPS etc)40% spare capacity in Bulk power supply
Spares
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Engineering Tips
Include Segment Validation in system vendor’s scope. Consider critical complex loops under conventional I/OConsider FF multiplexer temp transmitter for non-critical temperature monitoring loops e.g. column, furnace, reactor, etc.Make use of FF-type multivariable transmitter & save on pipe penetration.Redundant LAS in Redundant H1 card (if available), other wise one of the field devices in segmentDon’t mix devices with different macro cycle time on same segment.Close co-ordination between engineer, designer and programmer (DCS vendor)Off line configuration data should be available from device vendor.Simple closed loop devices on same segment with PID controller in valve positioner. No control in TransmitterComplex loop controllers / control strategy in Host system controllerPackage supplied FF instruments wire to plant FF junction boxSystem vendor’s Installed Sites and Project sizes
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Questions ?
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© 2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Must have standard system Product (Hardware, software etc) InteroperabilityMust be certified for FF Host Interoperability Support Test (HIST)Host system Fieldbus FunctionalityMust support FF field device DD and CFF files.System should have a configuration tool capable of on-line and Off-line configurationSupport Implementation of the FF function blocks in field devices.System should support Redundant hardware and Bump less transfer for high availabilityTroubleshooting, Maintenance should be possibleShould have dedicated advanced Diagnostics and computer based maintenance system.Must have Asset Management software and Advanced Process Control Must have third party interface capability
Host System Requirements (Minimum)