Design Benefits - Fieldbus Foundation · Design Benefits from ... Saving of Cable & Cabinet ......

1 1 The Future is Digital

The Future is

Digital

Design Benefits

Arasu Thanigai Pepperl+Fuchs

On Behalf of FF Marketing Society

2 2 The Future is Digital .

Design Benefits from

Applying Foundation Fieldbus

Bus structure and Wiring

Loop Integrity

Going digital

available verification tools

Majority vendor support

Flexible hazardous area realization

Eliminating Marshalling


User Benefits - Life Cycle Savings

Saving of Cable & Cabinet

Small # of instruments (control in

field)

HPT / HPT-IS / FISCO / iC

Engineering

FAT/SAT

Smaller System Footprint

Cost saving in plant life cycle

FAT,SAT Renewal

Operation

Maintenance

Installation Design

OPEX Savings CAPEX Savings

Expand operator’s aspect

Down-Time reduction by diagnosis

Asset management

Improvement of maintenance work

–Remote maintenance work, Automatic

maintenance work

–Application of diagnostics

Small # of instruments to be checked

software change in field instruments

download


Fieldbus Project Costs

Estimated Project Savings – Materials/Field Devices: Marginal Increase

– Installation Labor: Significant reduction

– Commissioning: Significant Reduction

– Design time: Significantly reduced

– Overall Capital Savings

– Savings will be realized if the project is

planned as a fieldbus project and the

information is shared with all levels of the

organization!


Conventional 4-20mA Design

Ethernet TCP/IP

Ethernet/TCP/IP Internet/Intranet Work

station

Operations Maintenance

PC/VME Management

Ex

-Multiple IS Barriers

-Multiple cables


Foundation Fieldbus Design Benefits in wiring and infrastructure -Common Power Supply

-Common Bus cable

Ethernet TCP/IP

Operations Maintenance

PC/VME Management

Ethernet/TCP/IP Internet/Intranet Work

station

Fieldbus EX Fieldbus

H1

Common Bus

FF Power

Supply


Conventional wiring 2nd level 1st level

junction box

Multicore cables


Fieldbus system wiring

……

……

.

80 Segments > 900 Instruments

1

80

Fieldbus

power

supplies

Control system


Benefits in hardware

Less barriers, no marshalling,

less I/O cards, less wiring,

smaller control room

Fieldbus Conventional


Benefits-wiring and termination savings

marshalling cabinet

marshalling cabinet

distributor

For 10 instruments

500m 5000 m cable 800m cable

2 terminations 20 terminations

20 terminations

20 terminations 11 terminations

FF Power

Supply


Benefits by Concept

Foundation Fieldbus is realized by

connecting many instruments on the same

segment

allowing various hazardous area methods on the

same segment (e.g. Ex d and Ex i using Fieldbus

barriers)

providing intelligent field instruments regardless

their function, whether temperature, ON/OFF

valves, flow, pressure, etc.

using standardized device configuration methods

DD and EDDL


Benefits by Concept

reduced cabling (wiring)

reduced infrastructure and components involved

eliminate the variety of isolators and converters

needed for DI/DO/AI/AO/RTD/etc

no marshalling required for grouping

DI/DO/AI/AO/RTD/etc

provide high levels of diagnostics, not just Lead

break /Short circuit

Get rid of manufacturer-dependent configuration

tools


Benefits by Higher Integrity

Foundation Fieldbus combines all components of

the control loop (e.g. AI, PID, AO) on the same

cable pair (segment)

Conventional: A “loop” is often considered the

arrangement of equipment between DCS and

field device (I/O card, isolator, field instrument,

cabling).

It is usually not the “logical” loop (e.g. AI, PID,

AO).


Design – Perception of single loop integrity

DCS

CPU: Performs PID function

4-20mA

4-20mA

HMI

non

Ex

Ex

non

Ex

Ex

IS barrier

(Intrinsic safety)

for wiring into

hazardous area


Design - Single loop integrity on FF

Redundant H1 card

DCS

HMI

Redundant - IS

Device Coupler


Benefits by Bus structure

Foundation Fieldbus enables single Loop

Integrity – AI, PID and AO on the same cable

– Major components are redundant • FF H1 card (host)

• Redundant FF power supply

– In conventional (particularly I.S.), more components

are involved, so more prone to failure

→ Fieldbus is less prone to failure


Benefits by Being Digital

Digital communication increases signal

transmission accuracy – Analogue loop: A/D (sensor to device) – D/A (device to

cable) – A/A (signal isolator / I.S. barrier) – A/D (DCS)

– D/A (DCS) – A/A (signal isolator / I.S. barrier) – A/D

(cable to device) - D/A (device to actuator)

– Fieldbus loop: A/D (sensor to device) - D/A (device to

actuator)

(Note that all transmission and DCS calculation is all-

digital)

→ Higher accuracy by design


Benefits – Design Validation

Easy verification of segment power distribution using

software tools

Effect of temperature

Individual loop calculations (with individual voltage and

current parameters) are not required

Spur calculations negligible (spur voltage drop is < 0.1V)

Segment loading factors

• Proper segment design for various zones of applications

Documentation

19 19 The Future is Digital . 19

Single

Many Vendor support – Power Supply

Redundant,

Multi-segment

FISCO - IS

High Power IS

20 20 The Future is Digital . 20

Many vendor support – Device couplers

Zone 2

Zone 1

Ex me

Zone 1/0

IS

Zone1

Fieldbus barriers

Ex me [ia]


Validation Benefits at Hazardous area applications design

Fieldbus signal:

Ex parameters standardized – FISCO: 17.5V, 380mA, 5.32W (IEC 60079-27)

– Entity: 24V, 250mA, 1.2W (FF-816)

Verification of intrinsic safety

Eliminated using FISCO – I.S. achieved by following the design rules

Simplified for Entity using High Power Trunk

(Fieldbus barrier / HPT-IS) – Point-to-point connection (spur)

– Max. 120m spur length allows to calculate worst case

cable parameters, reducing the verification to a simple

comparison


Engineering Benefits - Flexible Hazardous area design

Design criteria covered by IEC61158-2

Further supported by AG 181 ( rev 3.1)

Project applications vary based on – Length of the trunk and spur cable

– Number of devices to be connected

– Level of redundancy required

– Amount of diagnostics information required

All these applications requirements are met by

designing the fieldbus with the appropriate

hazardous area concepts


User Benefit : Design guidelines


User Benefit : Choices of IS Approach at Hazardous locations

High power ( Exe + IS )

High Power IS

Refer AG 181-3.1

-Limited Power

-High Power


User Benefit : Choices of IS Approach at Hazardous locations

Example IIC Gas Group application


Design Benefits – Flexibility in IS design Limited Power – ENTITY / FISCO Power

Zone 1

V = 12.4V

I = 120mA ~11V

FISCO IIC FF

Power Supply

IS Verification

Eliminated

- -

IS Spurs


Zone 1

Ex e

Ex ia (FISCO + Entity)

Fieldbus barrier

HPT Power

supply

Design Benefits – Flexibility in IS design High Power Trunk – Exe + IS

IS Verification

Eliminated / Simplified

V = 30V

I = 500mA

IS Spurs

~11V


Design Benefits – Flexibility in IS design High Power Trunk - IS

DART Segment Protectors

HPT –IS Power supply protected by

DART

IS Verification

Simplified

--------

Zone 1

V = 22.4V

I = 360mA IS Spurs

~11V


Device Couplers

Design Benefits – Flexibility in Bringing the same HPT to different hazardous areas

Zone 2

Ex d

19..32V

230VAC

Ex e

Ex ia

Fieldbus

barrier

Zone 1 Zone 1

Ex ic


Benefits by selecting relevant Hazardous area approach

Flexibility to handle changes and additions late in the

project

Selecting the cost effective solution

Reducing the hardware

Future expansion

Additional features


Benefits by Eliminating Marshalling

Fieldbus is designed with “spares” provisions (spare spurs,

spare trunks)

Signals do not need to be grouped by type

(AI/AO/DI/DO/RTD/…), and can simply be connected to

any segment

Change a on/off valve to electric actuator to control

valve late in the project without changing I/O cards,

drawings, wiring, etc

Adding further non-control related signals (e.g. for

monitoring) does not require infrastructure

Adding signals does not require change of cabinet

drawings

Fewer intermediate wire connections in the panel

simplifies drawings


Summary

The main benefits in the design phase are: Faster and easier to design Reduced time in validation Higher accuracy (digital data throughout) Reduced components Less prone to failures Multivendor Support Greater flexibility while selecting hazardous area

concepts based on the project needs Diagnostics are integrated and reduces design

and commissioning time

Design Benefits - Fieldbus Foundation · Design Benefits from ... Saving of Cable & Cabinet ......

Documents

Transcript of Design Benefits - Fieldbus Foundation · Design Benefits from ... Saving of Cable & Cabinet ......