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1 © 2008 Fieldbus Foundation 2008 FFIMC - Automation 2008-Mumbai Mistry Harendra G. Chief Engineer - Instrumentation Fieldbus Foundation – India Marketing Committee Foundation Fieldbus Engineering Consultant Perspective Aker Powergas Pvt. Ltd., Mumbai, India

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Page 1: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 2: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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© 2008 Fieldbus Foundation

2008 FFIMC - Automation 2008-Mumbai

Is not Hard or DifficultIt is Little Different

Foundation Fieldbus Engineering?

Page 3: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 4: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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© 2008 Fieldbus Foundation

2008 FFIMC - Automation 2008-Mumbai

Fieldbus Concepts

Page 5: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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© 2008 Fieldbus Foundation

2008 FFIMC - Automation 2008-Mumbai

Segment Topology

Page 6: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 7: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 8: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 9: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 10: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 11: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 12: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 13: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 14: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 15: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 17: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 21: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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© 2008 Fieldbus Foundation

2008 FFIMC - Automation 2008-Mumbai

Loop Diagram

Page 22: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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© 2008 Fieldbus Foundation

2008 FFIMC - Automation 2008-Mumbai

Segment Loop Diagram

Page 23: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 25: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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

Page 26: Foundation Fieldbus EngineeringID’s Plot Plan ... Foundation Fieldbus Implementation Philosophy / Guideline

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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)