Fieldbus Foundation India Marketing Committee

Foundation Fieldbus Engineering

Consultant Perspective

Mistry Harendra G.
Chief Engineer - Instrumentation

Aker Powergas Pvt. Ltd., Mumbai, India

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2008 Fieldbus Foundation

Foundation Fieldbus Engineering?

Is not Hard or Difficult
It is Little Different

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

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
2008 FFIMC - Automation 2008-Mumbai

2008 Fieldbus Foundation

Fieldbus Concepts

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

Segment Topology

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

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

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

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

Reallocate device to
same segment

Yes

All device of control loop

in same segment?

NO

NO

Yes
Yes

Reallocate one
device to another
segment

Perform Preliminary
segment calculation

Does segment contain

3 control devices?
NO
NO

Add monitoring only

FF device to existing
segment

NO

Does segment contain

more than 8 devices ?

Does calculation
validate segment?
Yes

Does segment contain

more than 8 devices ?

Yes

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

Yes

Reallocate one
device to another
segment

NO

Preliminary segment
assignment
complete

END

Segment fully loaded

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

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

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

Final Segment Design

START

Preliminary Segment
Assignment
complete
Finalise Trunk &
Spur length

Develop list of critical

control valve

Does segment contain

critical control valve?

Yes

Perform Final
segment calculation

Re-assign all other

control element to
another segment

No
No

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

Yes

Re-assign device to
another Segment

Yes

Monitoring only
Device(s)?
No

Does calculation
validate segment?

Yes

Segment assignment
complete

Device(s) away from

junction Box
END

No

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

Finalise Segment
Route
2008 FFIMC - Automation 2008-Mumbai
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2008 Fieldbus Foundation

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

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

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

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

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]

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2008 Fieldbus Foundation

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

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

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

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

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
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2008 Fieldbus Foundation

P&ID

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

Datasheet

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2008 Fieldbus Foundation

Segment diagram

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2008 Fieldbus Foundation

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

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

Junction box Wiring Diagram

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

Loop Diagram

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2008 Fieldbus Foundation

Segment Loop Diagram

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

Segment Validation Report

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2008 Fieldbus Foundation

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

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

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

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

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

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation

Questions ?

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2008 Fieldbus Foundation

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

2008 FFIMC - Automation 2008-Mumbai

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2008 Fieldbus Foundation