Cooper Industries: Confidential

New approaches deliver safer, more reliable networks in hazardous areasRoger HightonMTL Instruments

2

Foundation Fieldbus

w Major Oil and Gas companies use or standardize on Foundation Fieldbus technologys BPs Exxon Mobils Petronass Petrobrass Qatar Petroleums Reliances Saudi Aramcos Shells …

3

Foundation Fieldbus

w World’s largest Petrochemical plants use Foundation Fieldbuss Shell Nanhai (China)s BP Secco (China)s Reliance JERP (Jamnagar Export Refinery Project)

(India)s Qatar Gas II (ME)s Qatar Petroleum/Shell Gas to Liquid plant (ME)s Saudi Aramco Khursaniyah, Hawiyah and Rabigh (ME)

Options for non-fieldbus systems

Ex i Intrinsic Safetys Very safe, allows ‘hot’ workings Need IS interfaces, design expertises Ex ic/Ex nL non-incendive for Zone 2

applicationsEx d Flameproof/Ex e Increased Safetys Widely used, good experience, simples Only ‘cold’ working permitss Ex nA non arcing for Zone 2 applications

Options for fieldbus systems

Intrinsic Safetys Retains live-working benefits common to all IS circuitss FISCO addresses device limitations of ‘Entity’ solutions Some limitations on cable length and number of devices in IICs Live work trunk and spurss FNICO/FISCO ic provides more power in Zone 2 applications

Flameproofs No Ex limitation on number of devices per segments How to disconnect one device without de-powering segment?s Not preferred for fieldbus – there are better options

Combination techniquess Fieldbus Barrier (high energy trunk; IS spurs)s Ex nA non arcing trunk Ex ic/Ex nL non incendive for Zone 2s No live work on trunks Live work on spurs/devicess Option of live connection/disconnection of fieldbus barrier module

6

Topologies

Safe Area Zone 2 Zone 1 & Zone 0Zone 1

Ex dEx nL/icEx nA FISCOor Ex i*

FISCOor Ex i

Instrument located in …

InstrumentProtection

method

Non-Ex

NI HET for Z. 2FNICO/

FISCO icNon-Ex

FISCO orEx nL/ic

Ex d FISCO HET

#

*: With Spur Connector. #: Grey Megablock either in Zone 2 or with Ex d box in Zone 1. Yellow Megablock in Ex e box in Zone 1.= no live maintenance. = Live maintenance allowed. %: For live maintenance, ensure Ui ≥ U0.

Entity

%

Topology to use… Note: NI = Non-incendive (Ex nA); HET = High Energy Trunk)

7

High Energy Trunk FISCO

Topologies for IS fieldbus devices

8

Applications - High Energy Trunk

9

Applications - High Energy Trunk

l Solution for any Zone, any Gas Groupl Compatible with Entity and FISCO field devicesl Capable of long cable runsl Trunk power can be redundantl Multiple-unit enclosure options availablew Popular in large oil refining and petrochemical complexess e.g. Reliance Jamnagar Export Refinery Project

• >13,000 FF instruments• >3,600 segments

10

Applications - FISCO

11

Applications - FISCO

w IEC 60079-27 FISCO standardw Suits users who like fully Ex i systemsw Eliminates the need to calculate cable parameters (!)w Reduces safety documentation to a list of devicesw Allows addition of devices without a review of safety

documentationw Cable runs limited s typically fieldbus trunk 2/3 distance of Fieldbus Barrier

w Popular in medium size petrochemical plants, chemical plants, upstream oil and offshore. s e.g. Shell Bonny Island terminal

• >5,000 FF instruments

‘Physical layer’ expectationsw Users request:s Higher Reliability

• Redundancy• Simplification

s Safety• Removal of risks from inadvertent/unskilled maintenance• Use of intrinsic safe where possible in hazardous areas

s Ease of use• Flexible hardware solution

s Maintainability• ‘Pluggable’ modules• User-friendly, ergonomic construction

12

13

‘High Energy Trunk’ concept

FISCO or Entity fieldbus devices

FIELD

CONTROL ROOM

Zone 1Division 2

GAS DUST

Zone 1/0Division 1

Zone 21

Zone 21/20

Control system

Redundant FF power supply

Live-workable Ex i spurs

Fieldbus barriers

High energy Ex e trunk

14

High Energy Trunk Practical Solution

Live Ex de disconnect switches: allow replacement of a faulty fieldbus barrier

Separate terminator: segment still terminated even if any of the fieldbus barriers removedSurge protection: often required since built-in SP’s are only basic (for very small surges)Wiring, ducting: clean wiring required to avoid wrong maintenance

Ex e wiring block under plastic cover: allows opening compartment to access switches

Wiring blocks: Required for incoming field wiring as terminals on FBB are not replaceable

15

High Energy Trunk Practical Solution

Number of terminals:Spur: + / - / Shield of FBB to + / - / Shield of Surge Protector. There are 12 spurs = 72Spur: + / - / Shield of Surge Protector to + / - / Shield of screw terminal. There are 12 spurs = 72Trunk: + / - / Shield of FBB to + / - of Ex de switch. There are 3 Trunks = 15Trunk: + / - of Ex de switch to + / - / Shield of Ex e terminals. There are 3 Trunks = 15Total = 72 + 72 + 15 + 15 = 174 terminals = 174 Potential points of failure

New-Generation ‘High Energy Trunk’ architecture

“Live pluggable”

Fieldbus Barrier modules

Spur surge protector (optional)

Pluggable Terminator

Trunk terminals

Pluggable trunk surge protector

(optional)

Trunk Terminal Assembly

(TTA) housing

Screw-secured,

pluggable spur

terminals

17

Pluggable modules aid maintainability

17

Fieldbus Terminator and Trunk Surge protector modules plug into dedicated sockets in the ‘Trunk Terminal Assembly’

• May be removed and replaced while under power without ‘gas clearance’

18

Retro-fittable components add flexibility

w Many details are still unconfirmed during FEED:w Which fieldbus spurs require surge protection?w How many spurs are required per field junction box?

w Ability to retro-fit surge protection and barrier modules adds flexibility during the design and construction process

19

Smaller field enclosures lead to significant savings in infrastructure and installation costs

Replace this...

“Honey, I shrunk the Fieldbus Barrier”

950mm

430mm

.....with this

Every module and circuit within the shaded area is live-

workable in the hazardous area

Mixing circuits that can be live-disconnected in a hazardous area with those that can’t leads to unnecessary risks during field maintenance – which is

why all circuits and modules in the main enclosure compartment are designed to be interruptible while powered.

Reducing maintenance risk

Non-live workable circuits are confined within the Trunk Terminal compartment and protected by a cover

21

Summary

w Compact, modular constructionw No interconnecting wiring inside main enclosure

compartments Eliminates complexitys Higher reliability

w Integrated, pluggable surge protections Flexible to users’ needss Suitable to retrofit

w All modules hot/live-pluggables No additional isolating switches requireds Reduces risk of explosion due to wrong operation

22

FISCO

FISCO power supply

FIELD

CONTROL ROOM

Live-workable Ex i spurs

FISCO fieldbus devices

24Vdc24Vdc

Live-workable Ex i trunk

GAS DUST

Control system

Zone 1 / Div1Hazardous Area

Zone 21Hazardous Area

23

FISCO

Features of FISCO:w Trunk and Spurs are intrinsically safew High reliability (typically higher than high energy trunk concept)w Typically 12 instruments (typically limited by cycle time)w Most economic concept for any number of instrumentsw Verification of intrinsic safety documented by FISCOw No mix of protection methods – Safest technology of all

Considerations:w FISCO supply is singlew Cable distance shorter than with High Energy Trunks Use thicker cable to compensate voltage drop

w Mainly used for FISCO instruments, not Entitys Study1 showed that 93% of instruments are FISCO certifieds Use spur connector to connect to Entity instruments/Zone 0

1 http://forums.fieldbus.org/showthread.php?t=2205

FISCO Power Supply Redundancy

w Increasingly specified for critical process applications requiring high system availability

w Recommended in Fieldbus Foundation Engineering Guide, AG181s “Fieldbus Power Supplies/Conditioners should be

redundant…” (Clause 5.2.2)w Power supply redundancy significantly increases availability

of the fieldbus segment, and hence of the overall control system

25

Redundant FISCO power supply

FIELDZone 1

CONTROL ROOM

24Vdc24Vdc

Fieldbus control system (DCS)

Bulk power input

Intrinsically safe FISCO Fieldbus devices

Intrinsically Safe Field wiring hub

Intrinsically Safe trunk and spurs(1 segment of 4)

Redundant FISCO

Redundant FISCO power supplies

Ø On power-up, output is defaulted to FISCO A

Ø On detected failure of FISCO A or corresponding Supply Arbitration Module, FISCO B is selected

Ø Failure notification is given (open-circuit alarm)

Ø LEDs indicators identify failed module, to allow replacement under power

FISCOPower Supply

A

FISCOPower Supply

A

SAM

A

SAM

A

FISCOPower Supply

B

FISCOPower Supply

B

SAM

B

SAM

B

IS H1 to Field

Failure alarm

HAND-SHAKINGHAND-SHAKING

SAM = Supply Arbitration

Module

Host Control System

H1

IS Megablock

IS field instruments

27

Redundant FISCO

w Change-over is bumplessw FF-831 specifies behaviour of fieldbus network when

power supply drops to 0Vw Fieldbus devices are required to survive the complete

collapse of the bus for 500usw If the change-over coincides with a data packet, data will

simply be retransmitted (mechanism of Foundation fieldbus protocol)

w Fieldbus communication “as usual”w No loss of controlw No loss of data

28

Redundant FISCO

First application to use Redundant FISCO:BP Angola Block 31

29

Conclusion

w With Advanced High Energy Trunk and Redundant FISCO, alternative concept continue to co-exist

w High Energy trunk becomes safer and more reliablew FISCO remains the safest topology, and strengthens its

position as the most reliable.

30

Thank you! Questions?

Roger HightonMTL InstrumentsGreat MarlingsButterfieldLuton, LU2 8DLUK+44 1582 723633rhighton@mtl-inst.comhttp://www.mtl-inst.com