Fieldbus Foundation – India Committee & ISA South India ... · PDF fileFieldbus...
Transcript of Fieldbus Foundation – India Committee & ISA South India ... · PDF fileFieldbus...
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
3© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference
p p p j
06-Feb-2010 3
Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Basic Engineering
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
4© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 4
Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Basic Engineering
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.
5© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 5
Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Basic Engineering
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
6© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 6
– 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
7© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 7
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………
8© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 8
Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Basic Engineering
No of Devices in High power Trunk concept is High. Hence in Hazardous
9© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 9
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
10© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 10
TerminatorD
Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Basic Engineering
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
11© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 11
Fieldbus Engineering in Green Field Plants
P D i
An EPC's Perspective – Basic Engineering
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
12© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 12
Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Basic Engineering
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
13© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference
Redundancy requirement of H1 card, FFPS, etc
06-Feb-2010 13
Fieldbus Engineering in Green Field Plants
I t B i E i i
An EPC's Perspective – Basic Engineering
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
14© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 14
Fieldbus Engineering in Green Field Plants
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
15© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference
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
16© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 16
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
17© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 17
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
2010 FFIC-Chennai Conference
18© 2010 Fieldbus Foundation
06-Feb-2010 18
Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Detailed Engineering
19© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 19
Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Detailed Engineering
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
20© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 20
Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Detailed Engineering
21© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 21
Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Detailed Engineering
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
22© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 22
Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Detailed Engineering
23© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 23
Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Detailed Engineering
Minimum Specification for FF Devices
24© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 24
Fieldbus Engineering in Green Field PlantsAn EPC's Perspective Detailed EngineeringAn EPC's Perspective – Detailed Engineering
Final Documents after Award of Contract
25© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 25
Fieldbus Engineering in Green Field PlantsAn EPC's Perspective Detailed EngineeringAn EPC's Perspective – Detailed Engineering
Wiring Document
26© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 26
Fieldbus Engineering in Green Field PlantsFieldbus Engineering in Green Field PlantsAn EPC's Perspective – Detailed Engineering
System SpecificationSystem SpecificationConfigurationRedundancyCommunication Protocol FDT/DTM, EDDLMacro cycle scheduleyOSI Reference ModelDiagnosticsHost Test Kit 4 2Host Test Kit 4.2
27© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 27
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)
28© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 28
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
29© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 29
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
30© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 30
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
31© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 31
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
32© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 32
Automatic documentation & schedule prints
Fieldbus Engineering in Green Field Plants
Affect on Conventional Project Schedule due to FF
Fieldbus Engineering in Green Field PlantsAn EPC's Perspective – Project Control
33© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 33
Fieldbus Engineering in Green Field PlantsAn EPC's Perspecti eAn EPC's Perspective
Advantages in FF Technology
34© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 34
Fieldbus Engineering in Green Field PlantsAn EPC's Perspective
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
35© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 35
Fieldbus Engineering in Green Field PlantsAn EPC's Perspective
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.
36© 2010 Fieldbus Foundation
2010 FFIC-Chennai Conference06-Feb-2010 36