Foundation Fieldbus Overview

By : Rajib Nag
Date: 30.11.2010

The information contained in this presentation is the confidential and proprietary property of Foster Wheeler Bengal Private Ltd.
and may not be used, copied, or reproduced in any manner without express written permission. The information is provided for
discussion purposes only. FWB makes no representation or warranty for the accuracy of the information, and reserves the right
to modify at any time, in whole or in part, based upon needs or objectives.
Agenda

 Overview
 Field wiring and Installation
 Control in the field device
 Selecting Field Devices
 Summary
What is Fieldbus?

Definition
A digital, two-way, multi-drop communication link among
intelligent field devices and automation systems.

Fieldbus

P
T

DCS
L
(Host)

If the Field bus technology follows Foundation Fieldbus H1 protocol the

Fieldbus system called Foundation Fieldbus H1
All Fieldbus system follows IEC 61158.
Microprocessors enable
better performance and
more functionality and
diagnostics and control in
the field devices
A Typical Plant from the past

DCS Proprietary Bus

4 - 20 mA 4 -20 mA 4 -20 mA

Information
A Plant with Fieldbus

Operator Interface

DCS High Speed Fieldbus

Information

Low Speed Fieldbus (31.25 Kbits/s)

Interoperable devices
Number of devices per segment

32 device are allowed per segment. However Based on

present device power consumption, Power conditioner
current limitation, resistance of wires and microcycle,
experience demonstrates that up to

16 Devices per segment can be

used
 Fieldbus Signal

I (mA)

17.5 18 mA (approx.)

Power 100 Ω 100 Ω Zeq = 50 Ω

Conditioner 1µ F 1µ F @ 31.25 KHz

V = 50 x 18 = 900 mV (approx.)
V (mV)

900 mV (approx.)
Signal Encoding
Fieldbus signals are encoded using the well-known Manchester Biphase-L
technique. The signal is called “synchronous serial” because the clock
information is embedded in the serial data stream. Data is combined with the
clock signal to create the Fieldbus signal as shown in the figure below. The
receiver of the Fieldbus signal as shown in the figure below. The receiver of
the Fieldbus signal interprets a positive transition in the middle of a bit time as
a logical “0” and a negative transition as a logical “1” .
-T/2 +T/2
1 Bit Time

Clock

1
Data 0

Manchester 1 0 1 1 0 0
Biphase-L
Encoding
Fieldbus Technology

Comparison to ISO OSI Model

USER LAYER USER LAYER

FIELDBUS MESSAGING
7 SPECIFICATION
APPLICATION LAYER
FIELDBUS ACCESS
SUBLAYER
PRESENTATION LAYER 6

SESSION LAYER 5

TRANSPORT LAYER 4

NETWORK LAYER 3

DATA LINK LAYER 2 DATA LINK LAYER

PHYSICAL LAYER 1 PHYSICAL LAYER

OSI MODEL FIELDBUS

Fieldbus Technology

USER LAYER USER LAYER

FIELDBUS MESSAGING
SPECIFICATION
FIELDBUS ACCESS
SUBLAYER

COMMUNICATION
STACK

DATA LINK LAYER

PHYSICAL LAYER PHYSICAL LAYER

Fieldbus Technology
 Physical Layer
The Physical Layer receives messages from the communication stack and
converts the messages into physical signals on the Fieldbus transmission
medium and vice-versa.

 Data Link Layer (DLL)

The Data Link Layer (DLL), controls transmission of messages onto the
Fieldbus. The DLL manages access to the Fieldbus through a deterministic
centralized bus scheduler called the Link Active Scheduler (LAS).

 Fieldbus Access Sublayer (FAS)

The FAS uses the scheduled and unscheduled features of the Data Link Layer
to provide a service for the Fieldbus Message Specification (FMS). The types
of FAS services are described by Virtual Communication Relationships (VCR)-
client/server, source/sink and publisher/subscriber.

.
Fieldbus Technology
• Client/server
The Client/Server VCR Type is used for queued, unscheduled, user initiated,
one to one, communication between devices on the Fieldbus. This is used for
operator initiated requests such as set point changes, tuning parameter access
and change, alarm acknowledge, and device upload and download.
• Source/sink
The Client/Server VCR Type is used for queued, unscheduled, user initiated one
to many, communication between devices on the Fieldbus. This is typically used by
Fieldbus devices to send alarm notifications to the operator consoles.
• Publisher/ Subscriber
The Publisher/Subscriber VCR Type is used for buffered, one to many
communications. The Publisher/Subscriber VCR Type is used by the field
devices for cyclic, scheduled, publishing of User Application function block
input and outputs such as process variable (PV) and primary output (OUT) on the
Fieldbus.
 Fieldbus Message Specification (FMS)
Fieldbus Message Specification (FMS) services allow user applications to send
messages to each other across the Fieldbus using a standard set of message
formats
Fieldbus Technology
 User Application
The Fieldbus Foundation has defined a standard User Application based on
“Blocks.” Blocks are representations of different types of application functions.
• Resource Block
The Resource Block describes characteristics of the Fieldbus device such as
the device name, manufacturer, and serial number. There is only one resource
block in a device.
• Transducer Block
Transducer Blocks decouple Function Blocks from the local input/output
functions required to read sensors and command output hardware. They
contain information such as calibration date and sensor type. There is usually
one transducer block for each input or output function block.
• Function Block
Function Blocks (FB) provide the control system behavior or control function
like AI, AO and PID etc
Fieldbus Technology

All layers must interoperate.

User Layer User Layer

Communication Communication
Stack Stack

Physical Layer Physical Layer

Fieldbus
 Fieldbus basic Benefits - I

 Physical
• Allow multi-dropping of
instruments
• Reduced wiring and installation
costs X
• Enables Multivariable
transmitters
• Reduced control room size
• Simplify installation
• Reduce number of drawings
• Simplify maintenance

X
 Fieldbus Benefits - II

 Functional
• Direct reading of variables in
Engineering Units
• Every reading contain information
on measurement health
• Remote access to device
calibration and diagnostics
• Control in the field
• Advanced diagnostics
• Easier maintenance
• Better plant performance
throughout its life
• Better immune to electromagnetic
interference
Fieldbus enables Multi-sensor applications

Process In
Fieldbus H1 - two wires
1 14 15 16
Catalyst Tube
1
2
3 Cooling
Fluid In
4
5
6
7 Cooling
Fluid Out
8

Up to 24
wires ! Process Out

Chemical Reactors
Electromagnetic Interference

DCS I/O
4-20 mA

HART
T/C

FF
Transients

Multi-Input
Capacitive Transmitter
(Fieldbus)
Coupled
All Cables with Shielded, Twisted
Pairs, Grounded at the DCS Noise per
4-20 mA
IEC Standards
(Light Industry)
Single-Input
mV Transmitter
(HART)

Electromagnetic Single-Input
Interference Radio Frequency Transmitter
Interference (4-20mA)
Thermocouple
Wired Direct
Electromagnetic Susceptibility Test Comparison
 Conventional
Conventional

Courtesy:
Courtesy:Cargill
CargillCorporation
Corporation
 Fieldbus
Fieldbus

Courtesy:
Courtesy:Cargill
CargillCorporation
Corporation
Conventional
Conventional

256
256 I/O
I/O
Fieldbus
Fieldbus
4,000
4,000
Fieldbus
Fieldbus ‘I/O’
‘I/O’
Agenda

 Overview
 Field wiring and Installation
 Control in the field device
 Selecting Field Devices
 Summary
 Segment Calculation
 Fieldbus Supports Multiple Topologies

Bus Topology

T1
H1 PS T T
S1 S2 S3 Sn

Tree or Chicken Foot Topology

S1
S2
T1
H1 PS T T S3

T1 +S1 +S2 + …. Sn<1900 m Sn

T1 - Trunk S1..n - Spur PS - Power supply,

H1- Fieldbus card, T-Terminator
Fieldbus Basic Architecture
High Availability System Design
 Voltage and Current

VPC

T V1 V2 V3 Vn
Power
Supply
Power
For VPS Iq1 Iq2 Iq3 Iqn T
Conditioner
Multiple
Segments

Maximum Voltage : 32 V
Minimum Voltage : 9 V

Total Current = Iq1 + Iq2 + Iq3 + ……... Iqn

Maximum current limited by the power conditioner.

Example: 500 mA
 Cable Length
• Total cable length should be less than 1900 m (shielded, 18
AWG, Type B)
• Connecting up to 16 devices in a powered bus, the Spur
length limit should be:

* 120 m with one device per spur

* 90 m with two devices per spur
* 60 m with three devices per spur
* 30 m with four devices per spur
• Length reduces with more devices in the network
Hazardous Area Installation
Method of Protection

Method of protection Zone 2 Zone 1 Zone 0

Ex d/ Exe Concept   
Intrinsic Safety - Conventional   
Approach (Entity Model)
Intrinsic Safety - FISCO Concept   
Intrinsic Safety - FNICO Concept   
Intrinsic Safety - High Power Trunk   
Concept
Ex d/Ex e - Concept

Division 2, Zone 2,1

Intrinsic Safety - Conventional Approach (Entity Model)

Division 1, Zone 2,1,0

Intrinsic Safety - Conventional Approach (Entity Model)

• Using an MTL Barrier as an Example

• More current = Less Volts

170
Available bus current
excluding voltage drop
Current (mA)

due to cable resistance

85mA

MTL5053 Load Line

(105 Ω )
9V
0
Voltage (V) 18
 Intrinsic Safety - Conventional Approach (Entity Model)

• So How Much Current do the devices need ?

• 3051
• 17mA
X2 = 34mA
• 3244
• 17mA 78mA
• Communication
Current Required
• 10mA X2 = 34mA

= 10mA
 Intrinsic Safety - Conventional Approach (Entity Model)

• Using an MTL I.S. Fieldbus Power Supply as an Example

• More current = Less Volts
• 1900m Cable resistance 84 Ω

170
Bus Load Line
Including 1900m of Cable
Current (mA)

(105 Ω + 84 Ω )

85

47

Current available 9V MTL5053 Load Line

for field devices 0 (105 Ω )
Voltage (V) 18
The Entity Model - Cable Length and Quality

• The Calculation.
• Current available =
Tx Minimum Lift
MTL5053 = 18V off voltage

(Open Circuit Output Voltage of the Power Supply) - 9Volts

(Source Resistance of the Barrier) + (Fieldbus Cable Loop Resistance)

1900m = 84 Ω
MTL5053 = 105 Ohms
The Main Issue
What types of Wire

“Typical” Length Restrictions With Existing Wire

Max
Type Description Size
Length
#18 AWG 1900 m
A Shielded , Twisted Pair
(.8 mm 2) (6232 ft.)
Multiple-Twisted-Pair with #22 AWG 1200 m
B Shield (.32 mm 2) (3963 ft.)
Multi-Twisted-Pair Without #26 AWG 400 m
C Shield (.13 mm 2) (1312 ft.)
Multi-core, w/o Twisted Pairs #16 AWG 200 m
D and Having Overall Shield (1.25 mm 2
) (656 ft.)
Intrinsic Safety - FISCO Concept
Intrinsic Safety - FISCO Concept

FISCO Requirement

• All instruments FISCO certified

• Power Supply must be FISCO certified
• Field cables must conform to the following specification:
– loop resistance must be between 15 and 150ohms/km
– loop inductance must be between 0.4 and 1mH/km
– loop capacitance must be between 45 and 200nF/km
– maximum length of each spur cable is 60m in IIC and IIB
– maximum length of each trunk cable is 1km in IIC or 5km in IIB
Intrinsic Safety - FISCO Concept

More Current Available

15V
Voltage

Current 110mA
Intrinsic Safety - FISCO Concept

• So How Much Current do the devices need ?

• 3051
• 17mA
X3 = 51mA
• 3244
• 17mA

•
107mA
8742C X2 = 34mA
• 12mA

• Communication
Current Required
• 10mA X1 = 12mA

= 10mA
Intrinsic Safety - FNICO Concept

Fieldbus Non-Incendive Concept

• Based on FISCO, the Fieldbus Intrinsically Safe Concept
• For Fieldbus in Zone 2 and Division 2 hazardous areas
• Complete field network is Non-Incendive EEx nL
• Live-workable throughout without gas clearance, just like Intrinsic Safety
• Easy to install, easy to document, easy to maintain.
Intrinsic Safety - High Power Trunk Concept

A new approach to solving hazardous area Fieldbus applications is based on

what some refer to as the “High Power Trunk” concept . Contrary to
FISCO/FNICO concepts, the High Power Trunk concept does not limit energy
on the Fieldbus trunk cable to intrinsically safe or nonincendive levels; rather,
the energy on the spur connections is limited to the instruments. This allows
end users to utilize the maximum number of devices on a segment while also
achieving maximum cable lengths and a distributed architecture. Depending on
the application, the protection (energy limitation) is accomplished in the field,
inside the junction box.
Intrinsic Safety - High Power Trunk Concept
Intrinsic Safety - High Power Trunk Concept

Fieldbus Barrier across Zones

Intrinsic Safety - High Power Trunk Concept
This concept provide following advantages
• Provide high power 30 V, 500 mA in the field means provide all advantages of
general purpose application in hazardous area.
• Number of instrument per segment increased up to 16 device.
• Total cable maximum length limitation increased to 1900m and maximum spur
length increased to 120m.
• Can be used in Class I, Division 1 hazardous area
• Live maintenance of spur (instruments) possible.
• Reduced control room size.
• High availability ensures as redundant power supply can be used.
• High level of diagnostic information regarding the physical layer available as
high power available.
• Compatible with FISCO & Entity field instruments
Summary –Comparison between various IS method

Entity IS FISCO Higher Power

Trunk
Maximum current output 80 mA 110 mA 500 mA
Number of device per segment 4 6 16
Total length of cable 1900m 1000m 1900m

Maximum spur length 120 m 60m 120m

Is live maintenance of Trunk Yes Yes No
permitted
Is live maintenance of Spur permitted Yes Yes Yes

Eliminate cable parameter calculation No Yes Yes (if instruments

are FISCO compatible)

Applicable hazardous area Class 1, Class 1, Class 1, Div 1

Div 1 Div 1
Segment allocation Philosophy
The instrument shall be grouped for segment allocation as below. This has
been followed in BP OCC project
• Segments will contain twelve (12) or fewer devices.
• An average loading of nine (9) devices per segment should be designed allowing
addition of three (3) future devices per segment for 25% spare capacity). However,
please note that it is acceptable to connect 10, 11 and 12 devices on some
segments as long as the overall spare is an average of three (3) devices per
segment and as long as the spare is reasonably evenly distributed.
• Segments should not contain more than two (2) control valves.
• Devices that require a function block cycle time of one (1) second should reside on
a segment with a total of not more than twelve (12) devices.
• Devices that require a function block cycle time of 0.5 seconds should reside on a
segment with a total of not more than six (6) devices.
• Devices that require a function block cycle time of 0.25 seconds should reside on a
segment with a total of not more than three (3) devices including maximum of 1
control valve.
Segment allocation Philosophy
• Level 1 critical valves will normally reside on segments where the only other
device on that segment is the measurement directly associated with the valve
controller. By exception, if there are 2 Level 1 valves on differing duties who both
result in the same loss, the 2 valves and their associated measurements may
reside on the same segment. Spared valves should not be allocated to the same
segment. Level 1 critical valves are defined as valves whose failure would result in
the total trip or shutdown of the plant or other major commercial loss ($5 million).
• Level 2 critical valves should reside on segments with no other level 1 or 2 control
valves. Level 2 critical valves are defined as valves whose failure would require
prompt operator action to save the plant from going to a shutdown state. The
remaining segment slots up to a maximum of 12 can be used.
• Level 3 critical valves should reside on segments with no level 1 control valves
and a maximum of 1 other level 2 or 3 control valve. Level 3 critical valves are
defined as valves whose failure does not result in any short term risk of total plant
shutdown. If a level 3 valve goes to the failure position, this does not require any
heroic operator action. The remaining segment slots up to a maximum of twelve
(12) can be used.
Agenda

 Overview
 Field wiring and Installation
 Control in the field device
 Selecting Field Devices
 Summary
An installation with Fieldbus: Control in the Controller

6 - Backplane
5 – H1 Card

H1
PS C
4 – Fieldbus
Power Supply
8 – Controller
Power Supply PS
7 - Controller
3 - Cable

TM

1 - Transmitter 2 - Valve
An installation with Fieldbus: Control in the Field

H1
PS C
4 – Fieldbus
Power Supply
PS
3 - Cable

1 - Transmitter 2 - Valve
Basic FF Function Blocks

• Discrete Input • P, PD Controller

• Discrete Output • Control Selector
• Analog input • Manual Loader
• Analog Output • Bias/Gain Station
• PID, PI, I Controller • Ratio Station
Advanced FF Function Blocks
• Pulse Input
• Complex Analog Output
• Complex Discrete Output
• Step Output PID
• Device Control
• Setpoint Ramp Generator
• Splitter
• Input Selector
• Signal Characterizer
• Lead Lag
• Deadtime
• Arithmetic
• Calculate
• Integrator(Totalizer)
• Timer
• Analog Alarm
• Discrete Alarm
• Analog Human Interface
• Discrete Human Interface
Why control in the field?
• Control in the field provides loop integrity, increasing
control loop availability and reliability.
• Control in the field provides better performance than
control in the DCS, reducing variability.

C o m p a r i s o n o f C o n t r o l i n D e l t a V a n d 3 0 5 1S F i e l d b u s T r a n s m i t t e r
( + /- 5 % L o a d D i s t u r b n a c e s a t 0 . 0 1 H z )

10 0

Control in 9 9 .5

DCS 99

Control in 9 8 .5

the field 98

9 7 .5
400 425 450 475 500 525 550 575 600 625 650 675 700 7 25
T im e
(s e c )
Agenda
 Overview
 Field wiring and Installation
 Control in the field device
 Selecting Field Devices
 Summary
Selecting Field Devices
For FF devices the required information should include but not limited to
the following:
• FF certification for passing the Interoperability Test Kit (ITK). Latest version is 6.0
• Hazardous area certification
• Function block requirements.
• Minimum power required.
• Device current draw (mA).
• Device in-rush current (mA).
• Device (lift off) minimum voltage.
• Block execution time.
• Polarity sensitivity.
• Link active scheduler (LAS) capability.
• Diagnostic requirements.
• Virtual communication relationships (VCRs).
• Device capacitance.
• Software revisions
Selecting Field Devices

Freedom of Choice !

TM

Allows digital instruments to be

connected onto a Fieldbus network and have
them communicate all available functionality
to each other and with the networked hosts.
Interoperability Tests among Field Devices

3244
Temperature

Fuji
3051
Pressure
8800
Vortex

Model 5300
Coriolis Transmitter
Interoperability between Field Devices and Hosts

3244
Temperature

3051
Pressure
8800
Vortex

Model 5300
Coriolis Transmitter
 Full Scale Fieldbus Architecture

Host Device
Web Browser

Firewall

HSE (High Speed Ethernet)

HSE Controllers
PLC HSE Field
Device
Field Mounted
Linking Device
Classic & HART I/O Fieldbus H1
H
1

H As-I/DeviceNet/DP
1

H1 Field Device
Summary
 A variety of applications may be implemented using the
function block capability of FF devices.
 Special attention should be paid to the unique
requirements of Fieldbus systems during design,
installation and checkout.
 Fieldbus brings dramatic savings in installation and
commissioning, but the real value is seen during plant
operation
Foundation Fieldbus Overview

Thank You