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Fieldbus Foundation – India Committee &

ISA South India Section

Fieldbus FoundationFieldbus FoundationFFIC + ISA Fieldbus Foundation Conference-2010

Date : 6th February 2010 ( Saturday)Date : 6th February, 2010 ( Saturday) Time : from 09:00 am to 05:30 pm. Venue : IIT Convention Centre

Gajendra Circle, IIT Campus, Adayar Chennai

K.Ibrahim Raja B.Sc, B.Tech(MIT)

Adayar, Chennai.

j@ Present : Principal Engineer ,

Chennai

Previous : Manager, Engineers India Ltd New Delhi

© 2010 Fieldbus Foundation

2010 FFIC-Chennai Conference

Ltd, New Delhi

06-Feb-2010 1

Fieldbus Engineering in Green Field PlantsAn EPC's Perspective

B i E i iBasic Engineering

Detailed EngineeringDetailed Engineering

Installation

Commissioning

2© 2010 Fieldbus Foundation

2010 FFIC-Chennai Conference06-Feb-2010 2

Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Basic Engineering

Basic EngineeringBasic Engineering

Decision on Technology : Conventional or Foundation Fieldbus/ Profibus/ As-i BusConcept : FISCO, FNICO, High Power Trunk, ExdComplying to International Standards

C GIEC, AG standards, etcProcess Design (Identifying loops, symbol)Identify Registered InstrumentsControl assignmentCable routing, Control room location

Based on above, Design basis / Std Spec for FF shall be prepared for the project



p p p j

06-Feb-2010 3


Conventional Technology

⇒ Topology⇒ Transmission method

- One to One- 4 - 20 mA DC analog

Conventional Technology

⇒ Transmission method⇒ Transmission direction⇒ Signal type

P t l t d di ti

- 4 - 20 mA DC analog- One way- Single signal

⇒ Protocol standardisation⇒ Remote setup of field devices⇒ Self diagnostics

- Internationally standardised- Not possible- Information cannot be obtained

from field devices




Foundation Fieldbus Technology

⇒ Topology - MultidropO l Di it l

Foundation Fieldbus Technology

⇒ Transmission method⇒ Transmission direction⇒ Signal type

- Only Digital - Bi-directional- Multiplex signalg yp

⇒ Protocol standardisation⇒ Remote setup of field devices⇒ Self diagnostics

- Intenationally standardised.- Possible- Information can be obtained⇒ Self diagnostics Information can be obtained

through HHT or separate maintanence systems.




As-i Busbit level (push buttons limit switchesbit level (push buttons, limit switches, etc.)

ProfiBusSupport analog signals and Master -Slave comm through RS485comm through RS485

FieldbusDigital replacement of 4-20 mA Conventional signalsConventional signalsA Digital, 2 way, Multi-Drop communicationAs per IEC 61158 and ISA S50H1 LAN(31.25 kbps), HSE (100 Mbps-H1 LAN(31.25 kbps), HSE (100 MbpsBackbone), Peer –to- Peer communication Supports Intrinsic SafetyIn India, MRPL, HPCL, Reliance, Essar



– Proved

Fieldbus Engineering in Green Field PlantsAn EPC's Perspective – Basic Engineering

Foundation Fieldbus is a digital, two-way, multidrop communication link among intelligent measurement and control devices.

Conventional DCS : 2-wire, loop powered, one way communication,

Fieldbus Network Concept : 2 way, loop IS di ti i t l ipowered, one way communication,

single data, multi cabling till control room

power, IS, diagnostic, signature, plugging detection, single cabling, Inter operable,

Plug & Play

Diagrams courtesy of the Fieldbus Foundation, www fieldbus org



www.fieldbus.org

Fieldbus Engineering in Green Field Plants

Concept

Fieldbus Engineering in Green Field PlantsAn EPC's Perspective – Basic Engineering

Based on Area classification, Concept to be decided

– FISCO : As per IEC 60079-27, 1 k / 4 d i / 12 4V@120 A (Z 1 IIC) 1 9 k / 9 d i / 13 1@250 A1 km/ 4 device/ 12.4V@120 mA (Zone 1,IIC), 1.9 km/ 9 device/ 13.1@250 mA (Zone 2, IIB), Spur length 60 m

– FNICO : As per IEC 60079-27, 500 m/ 6 device/ 12 4@180 mA (Zone 2 IIC) 500 m/ 8 device/ 13 1@320 mA500 m/ 6 device/ 12.4@180 mA (Zone 2,IIC), 500 m/ 8 device/ 13.1@320 mA (Zone 2, IIB), Spur length 60 m

– High Power Trunk : As per ISA S 50.021700 m/ 12 Devices/ 24 V DC@ 500 mA (Zone 1 / 2), IS Device, IS Barrier, Exd1700 m/ 12 Devices/ 24 V DC@ 500 mA (Zone 1 / 2), IS Device, IS Barrier, Exd Terminator, Exe Junction box, etc.

– See the comparison Curve Contd………




No of Devices in High power Trunk concept is High. Hence in Hazardous



area based Refinery, this concept is selected.

Fieldbus Engineering in Green Field PlantsAn EPC's Perspective Basic Engineering

D D

Typical Fieldbus Segment Configuration (Topology)

An EPC's Perspective – Basic Engineering

ControlRoom

Spurs

“Home Run” Cable (Trunk)

I.S. Barriers (optional)A. Bus with Spurs

• requires layout design• requires taps

ControlRoom

Terminator

(Trunk)• difficult to change

B. Daisy Chain

Control D

D D D

I.S. Barriers (optional)

• requires layout design• difficult to change• difficult to maintain

RoomD

“Home Run” Cable (Trunk)

D

Junction Box& TerminatorI.S. Barriers

(optional)C. Tree• conforms to present practices• wiring savings are realized only

in “home-run” cable D



TerminatorD


Internation Standards for Foundation Fieldbus

ISA 50.02 Part 2 Fieldbus Standard for use in Industrial Control system, Part 2 : PhysicalLayer Specification and Service Definitiony p

AG-181 System Engineering GuidelinesAG-140 Application Guidelines for 31.25 kbps & wiring

systemsystemIEC 61158-2 Digital data communication for measurement and

control fieldbus for usein Industrial Control system Part 2 to Part 6

IEC 600079-27 Electrical apparatus for explosive gas atmosphere- FISCO and FNICO




P D i


Process Design

FF implemented for Complete p prefinery except Complex loops, Special loops (say Anti-Surge, BMS), Interlock & Shutdown loopsId tif th b lIdentify the above loopsSegregation of Critical/ Semi-Critical/ Non-Critical loopsDeciding the package philosophyDeciding the package philosophyRepresenting in PID




Instrument Design : Identify the FF Registered Instruments & Non-FF Devices (such as Process Analysers, F&G detectors)

Layout Design : Location of control room, Cable routing

Control Design : No of control loop in one segmentMacrocycle time based on Scan timeField control or DCS control if so for which loopRedundancy requirement of H1 card, FFPS, etc



Redundancy requirement of H1 card, FFPS, etc

06-Feb-2010 13


I t B i E i i


Importance Basic Engineering

Basic engineering is Must. If not, it will end up as follows,Basic engineering is Must. If not, it will end up as follows, Revise the Process design due to philosophy changeRevise Instrument & JB Location drawingAff t C bl h d l MTO JB MTOAffect on Cable schedule, MTO, JB MTO, Revise Instrument Specification, Re-orderRevise FF segment Table, Revalidation, Rework on DCS engineeringRework, Additional Manhour, Schedule affect




D il d E i i

Fieldbus Engineering in Green Field PlantsAn EPC's Perspective – Detailed Engineering

Detailed Engineering

Finalising FF Segment PhilosophyPhilosophyTag mark-up in Layout & Junction Box Location DrawingFF Segment designOptimizing the segment & ReviseOptimizing the segment & Revise LayoutFF Segment Validation –PreliminaryPreparation of InstrumentPreparation of Instrument specificationFF Segment Validation – FinalSystem SpecificationWi i



Wiring06-Feb-2010 15

Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Detailed Engineering

Finalising FF Segment Philosophy g g p y

Concept : High Power TrunkB i (A ISA S 50 02)Basis (As per ISA S 50.02):

a) Spur length – 100 m, Trunk length – 1700m, Min Oper Device Voltage – 9.5 V, Min Oper Field Barrier Voltage – 17 V, Max Device Current –20 mA, ,

b) Macro Cycle time – 1000 msec, Schedule – 70%, Un Sch-30%, Execution time – 32 msec,

c) Scan time – P, F, DP - 500 msec, T, L, Analyser – 1000 msec

Max Open loop per segment – 12 device For Close loop,

a) 1 Close loop (500 msec scan) – 1 Close loop+ 6 Open loops



b) 1 Close loop (1000 msec scan) – 1 Close loop+ 10 Open loops

Fieldbus Engineering in Green Field PlantsAn EPC's Perspective Detailed EngineeringAn EPC s Perspective – Detailed Engineering

FF Segment Philosophy Table- Distance based



Fieldbus Engineering in Green Field PlantsAn EPC's Perspective Detailed EngineeringAn EPC's Perspective – Detailed Engineering

Tag mark-up in Layout & Junction Box Location Drawing



06-Feb-2010 18


FF Segment designFF Segment design

Based on Philosophy Table & Layout, Segment to be designedp y y , g gPreparing FF Segment Table Validating segment in term of Voltage loading using reputed validation software segment checkervalidation software segment checker, Validating segment based on cycle time loading Optimizing the segment & Revise Layout




Preparation of Instrument specificationPreparation of Instrument specification

Which function blocks are required?Which function blocks are required?Timing for block execution LAS Backup Designationp gDD Files, CFF Files – RevisionFirmware Revisions ITK 4.61Details in http://www.fieldbus.org




Minimum Specification for FF Devices




Final Documents after Award of Contract




Wiring Document




System SpecificationSystem SpecificationConfigurationRedundancyCommunication Protocol FDT/DTM, EDDLMacro cycle scheduleyOSI Reference ModelDiagnosticsHost Test Kit 4 2Host Test Kit 4.2



Fieldbus Engineering in Green Field PlantsAn EPC's Perspective Detailed EngineeringAn EPC s Perspective – Detailed Engineering

AI 110AI 110

PID 110

“Loop 110” period(Macrocycle) of ti

AO 110

H t I t f i l LAS

Cyclic Functions Acyclic Functions- Control Functions - Alarms and Events

- Maintenance and Diagnostic InformationP I ti

executionHost Interface incl. LAS

- Program Invocation- Permissive- “View Data” Communication- Trend Information- Configuration & Downloads

AI- Function Block Execution (3244)

Cyclic Communication between Devices

PID- / AO- Function Block Execution (DVC5000)



yand / or Controller

Acyclic Communication

Fieldbus Engineering in Green Field PlantsAn EPC's Perspective - Installation

Tradition Installation ArrangementAn EPC s Perspective - Installation

thController

JunctionB

otherJunction Boxes

I/OTerminations

I/OInterface

4-20 mA or Analog

BoxTerminations

Significant Costs:• wiring• I/O cards

Marshaling

• I/O cards• cables• terminations• IS barriers• marshaling

IS (Exi)Barriers



Fieldbus Engineering in Green Field PlantsA EPC' P ti I t ll tiFoundation Fieldbus Installation

An EPC's Perspective - Installation

Controller

Cost savings:• wiring• I/O cards &

cablesJunctionBox

H1 I/O

H1 I/OInterface

Controller

Similar I/O Cards

cables• terminations• IS barriers• marshaling

Reduced Wiring

FewerTerminations

H1 I/OTerminations

H1 Fieldbusall-digital

Marshaling H1 Fieldbusall-digital

Fewer IS barriers

IS (Ex i)Barriers

FewerTerminations



Fewer IS barriers

Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Installation

Control roomL I/O L

350 device control room with traditional

Less I/O, Less

Space Required architecture

Uses one I/O

module for up to

350 device control room with field-basedmodule for up to

32 devices

field-based architecture using fieldbus



Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Commissioning

Fieldbus is practical, today!Instead of two person for one device In FF commissioning one personInstead of two person for one device. In FF commissioning one person for multiple device InteroperabilityNetworking capability of FF allows user to commission an Device in minutesPossible of source of error is less for FF device. Hence calibration is not required or very lessDue to less no of cabling in marshalling, verfication during commissioning

is very less

Fieldbus will lead to cost & Time savingsEnhanced device capability advantagesEnhanced device capability advantagesSlashed installation time & cable costs i.e 6-8 hours reduction for particular installationAutomatic documentation & schedule prints



Automatic documentation & schedule prints


Affect on Conventional Project Schedule due to FF

Fieldbus Engineering in Green Field PlantsAn EPC's Perspective – Project Control



Fieldbus Engineering in Green Field PlantsAn EPC's Perspecti eAn EPC's Perspective

Advantages in FF Technology




Step towards FF Technology:Step towards FF Technology:Status of FF Implementation in India

5 Years Back -for Non Critical Open Loopsfor Non Critical Open Loops3 Years Back -for all Open Loops 2 Years Back2 Years Back -for all Open loops & Non Critical

Close LoopsToday For all loopsToday - For all loops except Complex & Shutdown loopsSoon, All Existing will revamped to FF




C l iConclusion

Foundation FieldbusFoundation Fieldbus Technology, despite being a step change, requires Team work Training in FF andwork, Training in FF and mind set to take the challenge for successful project executionexecution.

