FF Engineering Harendra Mistry 26 9 2008

Fieldbus Foundation India Marketing Committee
Foundation Fieldbus Engineering

Consultant Perspective
Mistry Harendra G.
Chief Engineer - Instrumentation
2008 FFIMC - Automation 2008-Mumbai 1
2008 Fieldbus Foundation
Foundation Fieldbus Engineering? Is not Hard or Difficult It is Little Different
Preliminary Engineering
Foundation Field bus Implementation guideline document
Client specification / ITB requirements Fieldbus type (i.e. General, Entity,FISCO, FNICO, High Power Trunk etc) Network/segment Topology selection Critical loop defination and application Loop response time Segment design consideration / guideline Hardware Planning Device requirements FF Cable type Redundancy Spare Requirements Control assignments Package supplied FF instrument interface Engineering documents format templates DCS (HOST) system requirements Naming convention
Fieldbus Concepts
Segment Topology
Preliminary Segment Design Documents/Input required for Preliminary segment design

P&IDs Plot Plan / Equipment Layout Approved Foundation Field bus Implementation guideline Hazardous area classification
Segment design constraints

Field bus type (Safe, FISCO, FNICO or High Power Trunk) Voltage drop calculation Current calculation Signal attenuation calculation Segment execution time. Segment criticality Rating Spare capacity
Preliminary Segment Design

START
P&ID and Plot plan available Preliminary Segment Assignment (Monitoring only) Preliminary Segment Assignment (Control loop) Generate Preliminary Trunk & spur cable length
Yes
Reallocate device to same segment
All device of control loop in same segment?

Yes Yes
NO
Is any spur>120? Is segment >1900m?

NO
Reallocate one device to another segment
Does segment contain 3 control devices?

NO NO
Perform Preliminary segment calculation
Add monitoring only FF device to existing segment

Yes
Does calculation validate segment?

Yes
Does segment contain more than 8 devices ?

NO
Does segment contain more than 8 devices ?

NO
Yes
Reallocate one device to another segment
Preliminary segment assignment complete
END
Segment fully loaded
Final Segment Design Documents/Input required for Final segment design

P&IDs Instrument Location Plans Cable tray Layout / Plot Plan / Equipment Layout Approved Foundation Field bus Implementation guideline Hazardous area classification Control Narratives Complex Loop Narratives List of Critical Control Loops List of Loops requiring Loop execution times faster than 1 second. I/O Lists
Final Segment Design

START
Preliminary Segment Assignment complete Develop list of critical control valve Finalise Trunk & Spur length
Does segment contain critical control valve?

No
Yes
Re-assign all other control element to another segment

No
Perform Final segment calculation
Review Instrument Location plans Re-assign device(s) to another segment

Yes
Does calculation validate segment?

Yes
Re-assign device to another Segment

Yes
Segment assignment complete
Monitoring only Device(s)?

No
Device(s) away from junction Box

No END
Re-Route Trunk or re-assign entire loop Finalise Number of wiring blocks
Finalise Segment Route 2008 FFIMC - Automation 2008-Mumbai 9
Hardware planning
H1 card quantity FF Power supply conditioner card quantity FF Cable quantity Number of FF junction box FF termination block / FF Barriers Quantity Surge protector quantity Terminators quantity
Field Device Requirements

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 communication FF device and its function blocks shall be tested and certified by the DCS vendor
Field Device Requirements

Function blocks shall be downloadable into the devices by the system. Device certified for plant hazardous area. Device used in hazardous area should have Safety Parameter of I.S. Barrier Uo [V] Io [mA] Po [mW] Lo [mH] Co [nF] Safety Parameter of Device Ui [V] Ii [mA] Pi [mW] Li[mH] + Lcable[mH] Ci[nF] + Ccable [mH]
<= <= <= >= >=
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
Junction Box
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 etc Inactive spare Fieldbus trunk pairs shall be terminated on conventional terminal blocks Complete box should certified for hazardous area installation i.e. EExe etc Wire capacity size 12 24 AWG Conventional terminal block to be provided suitable for wire size 12 24 AWG Short circuit protection & surge protection to be provided with each spur
Documentation List of Conventional documents required modification as per Foundation fieldbus engineering
System Conceptual drawing P&ID Datasheet Instrument index / DCS I/O list Junction box wiring diagram Loop wiring diagram / Segment Wiring diagram Manufacturer documentation
Newly added documents for Foundation fieldbus engineering

Foundation Fieldbus Implementation Philosophy / Guideline Instrument Segment/Network Diagram Segment validation report Off line configuration data document
P&ID
Datasheet
Segment diagram
Off line configuration data document

Following input to be provided for DCS engineering.
Tag No. Calibration range and Unit Flow range and Unit Output type Transmitter Model Node Address (To be provided by DCS vendor) Device Type Device Class (Basic / Link master) Device Revision DD Revision CFF Revision PID Function Required
Junction box Wiring Diagram
Loop Diagram
Segment Loop Diagram
Segment Validation Report
Redundancy
Redundant Power feeder to bulk power supply Redundant Bulk Power supplies with battery backup (Min. 30 minutes) Redundant system controller power supply Redundant system controllers Redundant Foundation Fieldbus H1 card Redundant Foundation Fieldbus power conditioners Redundant controller should not share the same back plane Redundant H1 card should not share the same back plane Redundant FF power supply should not share the same back plane Redundant Link Active scheduler
Spares
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
Engineering Tips
Include Segment Validation in system vendors scope. Consider critical complex loops under conventional I/O Consider 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 segment Dont 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 Transmitter Complex loop controllers / control strategy in Host system controller Package supplied FF instruments wire to plant FF junction box System vendors Installed Sites and Project sizes
Host System Requirements (Minimum)

Must have standard system Product (Hardware, software etc) Interoperability Must be certified for FF Host Interoperability Support Test (HIST) Host system Fieldbus Functionality Must support FF field device DD and CFF files. System should have a configuration tool capable of on-line and Off-line configuration Support Implementation of the FF function blocks in field devices. System should support Redundant hardware and Bump less transfer for high availability Troubleshooting, Maintenance should be possible Should have dedicated advanced Diagnostics and computer based maintenance system. Must have Asset Management software and Advanced Process Control Must have third party interface capability
Questions ?

FF Engineering Harendra Mistry 26 9 2008

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FF Engineering Harendra Mistry 26 9 2008

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Fieldbus Foundation India Marketing Committee

Foundation Fieldbus Engineering

2008 FFIMC - Automation 2008-Mumbai 1

2008 Fieldbus Foundation

Foundation Fieldbus Engineering? Is not Hard or Difficult It is Little Different

2008 FFIMC - Automation 2008-Mumbai 2

2008 Fieldbus Foundation

2008 Fieldbus Foundation

2008 FFIMC - Automation 2008-Mumbai 4

2008 Fieldbus Foundation

2008 FFIMC - Automation 2008-Mumbai 5

2008 Fieldbus Foundation

Preliminary Segment Design Documents/Input required for Preliminary segment design

Segment design constraints

2008 Fieldbus Foundation

Preliminary Segment Design

Reallocate device to same segment

All device of control loop in same segment?

Is any spur>120? Is segment >1900m?

Reallocate one device to another segment

Does segment contain 3 control devices?

Perform Preliminary segment calculation

Add monitoring only FF device to existing segment

Does calculation validate segment?

Does segment contain more than 8 devices ?

Does segment contain more than 8 devices ?

Reallocate one device to another segment

Preliminary segment assignment complete

Segment fully loaded

2008 FFIMC - Automation 2008-Mumbai 7

2008 Fieldbus Foundation

Final Segment Design Documents/Input required for Final segment design

2008 FFIMC - Automation 2008-Mumbai 8

2008 Fieldbus Foundation

Final Segment Design

Does segment contain critical control valve?

Re-assign all other control element to another segment

Perform Final segment calculation

Review Instrument Location plans Re-assign device(s) to another segment

Does calculation validate segment?

Re-assign device to another Segment

Segment assignment complete

Monitoring only Device(s)?

Device(s) away from junction Box

Re-Route Trunk or re-assign entire loop Finalise Number of wiring blocks

Finalise Segment Route 2008 FFIMC - Automation 2008-Mumbai 9

2008 Fieldbus Foundation

2008 FFIMC - Automation 2008-Mumbai 10

2008 Fieldbus Foundation

Field Device Requirements

2008 FFIMC - Automation 2008-Mumbai 11

2008 Fieldbus Foundation

Field Device Requirements

<= <= <= >= >=

2008 FFIMC - Automation 2008-Mumbai 12

2008 Fieldbus Foundation

2008 FFIMC - Automation 2008-Mumbai 13

2008 Fieldbus Foundation

2008 FFIMC - Automation 2008-Mumbai 14

2008 Fieldbus Foundation

Newly added documents for Foundation fieldbus engineering

2008 Fieldbus Foundation