Automation 2011
Name : Jigish JepalJob Title : Executive ManagerCompany : Yokogawa India Limited
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
Presentation Points
Key Points in Fieldbus Project
Typical early (before ~2004) FF project execution and lesson Learned
Present day (after 2004) FF project execution
Fieldbus project execution methodology
Fieldbus project execution procedure ‐ example
Fieldbus project support tools
Fieldbus segment design guideline and segment check tools
Engineering tools
Factory Acceptance Test procedure
Site Acceptance Test procedure
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
Key Points in Fieldbus Project (1/2)
Understanding of Difference of FF System from Conventional System
・Technology・Design & Engineering・Design & Engineering ・FAT / SAT Methodology ・Installation ・Commissioning ・Device Functions
Establishment of FF Project Execution Methodology
・Project Handling Procedure
・Design and Engineering Procedureg g g・Design Documentation・Design Information Exchange Scheme
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
Key Points in Fieldbus Project (2/2)
Common Understanding of FF System among Users/EPC/Licensers andVendorVendor
Assignment of Experienced Engineers in Project Team
Confirmation of Device Interoperability and Availability of AuxConfirmation of Device Interoperability and Availability of Aux. Equipments; Power Supply /Exi Barrier/Terminator etc.
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
Typical early (before ~2004) FF project execution and lesson Learned
Conventional I/O Basis
Feed Phase Engineering Phase Site Activity Phase
Feed Generation & Debug SATDetailed Design Commissioning
Spec. FreezeKOM
FATBasic Design
Shipping
Feed Phase
SAT &
FF Basis
Engineering Phase Site Activity Phase
FF Knowledge Device InteroperabilityExperienced Engineers Resource
Feed
Spec. FreezeKOM
FATBasic Design Generation & DebugDetailed Design SAT &
Commissioning
Shipping Risk at Site
PJT Execution Procedure
Design Documents
Device& Aux.Equipment Selection
Segment DesignDevice Grouping PID Allocation
Device Interoperability
FAT/SAT Procedure
Service & Maintenance Tool
p g
© 2011 Fieldbus FoundationFFIC : Automation 2011 ‐Mumbai
‐ Device Grouping, PID Allocation‐Macrocycle, Cable Length :Trunk & Spur
Problems observed in earlier stage of Project
Present day (after 2004) FF Project Execution
Feed Phase
FF Basis
Engineering Phase Site Activity Phase
Feed
Spec. FreezeKOM
FATBasic Design
Generation & DebugDetailed Design SAT & Commissioning
ShippingRisk at Site
Feed
Feed Phase
FATBasic Design
Generation & DebugDetailed Design SAT & Commissioning
Engineering Phase Site Activity Phase
Spec. FreezeKOM Shipping
•Fieldbus Tutorial
Design and Engineering Tools & ProcedureBenefits to Customer•Fieldbus Tutorial
•FF Technology Introduction•FF Project Execution Guide•FF Segment Design Guideline•Functional Design Specification•Segment Check Tool
•System Engineering Guide• Better Engineering Tool
•FAT Procedure•SAT Procedure
•Minimize Human Errors•Prevent Re‐works•Shorten PJT Schedule
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
•Device&Aux.Equip. Selection Guide
Fieldbus Project Execution Methodology
Project KOM Main frame of FF project execution procedure is same as conventional I/O
FF t d i i Basic Design
Hardware Design
system. FF segment design in basic design phase is a key element in the FF project execution.
Each work item needs somechanges and additions toimplement FF technology
Software Design
Needs to set up
implement FF technology.
System Staging& Internal Test
FAT
Needs to set up•FF system project coordination procedure
•Design information exchange schemeFAT methodology is FAT
Delivery
exchange scheme gydifferent from theconventional I/O system.
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
Fieldbus Project Execution Procedure : Example (1/3)
MilestoneDeliverables by Customer Deliverables by System Vendor
Kick Off1) Project Execution Plan2) PJT Organization
1) PJT Schedule2) PJT Organization Kick Off ) g
3) PJT Schedule4) QA/QC Plan5) Technical & Commercial Proposal 6) Bill Off Materials (BOM)
2) PJT Organization3) Inquiry Specification4) FF Design requirements
Basic System design ‐ FF Segment Design Philosophy
FF System Design Specification‐ FF Segment Design Specification
1) Instrument Index
H/W Design Specification1) DCS System Configuration 2) DCS H/W E i t S
2) I/O Point List3) Loop Drawing
2) DCS H/W Equipment Spec3) Equipment Dimension4) Power Supply/Grounding5) Subsystem/Aux.Equipment
Hardware Design Design Requirements for;1) Console&Aux. Cabinet 2) Subsystem 3) Aux.Equipment
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
A
Fieldbus Project Execution Procedure : Example (2/3)
MilestoneDeliverables by EPC Contractor Deliverables by DCS Vendor
FF Design Information1) D i Li & T
A
1) H/W Design Specification& Drawig
2) BOM f H d
1) Device List & Type2) FB Assignment3 Device Grouping4) Expected Cable Length5) Cable Specification
2) BOM of Hardware3) I/O Card Assignment4)Typical Loop Configuration
FF Segment Detail Design
1) Complex Loop Schematics) i f l & Material Order & Manufacturing
S/W Design Specification1) Control Functions 2) MMI F ti
2) Narrative of Complex Loop&FB3) Sequence& Interlock Logic4) Graphic Sketch5) Subsystem Communication Spec
Software Design 2) MMI Functions3) Alarm Function4) Access/Security Functions5) Graphic/Logging 6) Subsystem Interface
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
B
Fieldbus Project Execution Procedure : Example (3/3)
MilestoneDeliverables by EPC Contractor Deliverables by DCS Vendor
)
B
1) Communication Point List
1) JB Schedule for Marshalling Rack2) Wiring Details3) Installation Details
1) Loop Drawings 1) Communication Point List2) Graphic Display Data3) Logging Formats4) Group Display Assignment5) Trend Assignment
2) Terminal Assignment ofMarshalling Rack
S/W Generation
System Staging
l
FAT
Internal Test
FAT Procedure
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
Delivery
Fieldbus Project Support Tools (1/2)
FeedPhase
Engineering Phase
Site ActivityPhase
Project Execution Phase
Support Tools Category
General Specification of FF
FF Tutorial
FF Technology Introduction
General Information
General Information
General Information
X
X
XFF Technology Introduction
FF Segment Design Guideline
FF PJT Execution Guideline
System Engineering Procedure
General Information
Design Guideline
Procedure & Manual
Design Guideline
X
X
X
X
X
X
X
X
Segment Check Tool
Engineering Tool
Device&Equip. Selection Guide
Design Tool
Engineering Tool
Design Guideline
X
X
X
X
X
FAT Guideline
SAT Guideline
Start‐up & Service Manual
Training Manual
Design Guideline
Design Guideline
Procedure & Manual
Manual
X
X
X
X
X
X
X
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
Training Manual
Quotation Guideline
Manual
Quotation Guideline
X
X
Fieldbus Project Support Tools (2/2)
FF Segment Design Guideline
Device&Equip. Selection Guide
SAT Guideline
General Specification FF in DCS
FF Tutorial
FF Technology Introduction
Plant/ Process
I & C System AFE FDS SAT Commissioning OperationInstallation
SAT Guideline
Start‐Up & Service ManualFF Segment Design Guideline
FF PJT Execution Guideline
System Engineering Procedure
Segment Check ToolProcess Design
System Design
AFE FDS SAT Commissioning OperationInstallation
Site Activity Phase
Device&Equip. Selection Guide
FAT Guideline
SAT Guideline
Training Manual
Quotation/ClarificationsFeed Phase
FATH/W Design & Manufacturing
Gen./Debug
Detailed Design
g
Quotation Guideline
Basic Design
FF Segment Design Guideline
S/W Design/ Configuration
FF Segment Design Guideline
FF PJT Execution Guideline
System Engineering Procedure
SWIFT Plus Engineering Tool
i & i S l i G id
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
Engineering PhaseDevice&Equip. Selection Guide
FAT Guideline
SAT Guideline
Fieldbus Segment Design Guideline
Table of Contents
1. General1.1 FF Segment Design Methodology
2. Basic Segment Design2.1 Hazardous Area Classification
4. Segment Execution Time4.1 Macrocycle Time4.2 Scheduling
2.2 Redundancy 2.3 Segment Loading 2.4 Spare Philosophy
3. Wiring Design
5. Control Assignment
6. Application Specific Design 6.1 Control Valve Fail State6 2 ESD Valve Status Equalization3. Wiring Design
3.1 Topology3.2 Cable Length3.3 Cable Type 3 4 Power Consumption
6.2 ESD Valve Status Equalization6.3 Risk Assessment For Control
Loops7. Documentation
3.4 Power Consumption3.5 Minimum Operating Voltage
7.1 Segment Drawing7.2 Loop Configuration Drawing
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
Fieldbus Segment Check Tools
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
Typical Engg. Tool
INtools RDB CustomerDB
MS‐Excel Engg.
Source Documents
Instrument Index Module
MS Excel/ Access
ggDB
Export (INtools)
Cross link
Source ocumentsP&IDControlNarrativesetc.
Meeting Typical FAT Text DB
Auto generationEngg. Tool
Meeting
Typicalloops
Typical FAT Text DB
Typical Loops
oopsmarking on P&ID
w/generic tag numbers
DCS DBDCS DB w/target tag numbers
Builder (DCS)
Export (DCS)
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
Factory Acceptance Test Procedure
Device List Verification
DD File And Capabilities File Verification
Fieldbus Application Verification
: Connection of Function Blocks
H1 Communication Scheduling Chart Verification
Connection Test with Actual Field Device ( by Using Representative Model)( y g p )
Segment Functional Test for Selected Segment
with Actual Field Devices
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
Site Acceptance Test Procedure
Confirm Physical Connection of the Field Devices
Download Configuration Data to Field DevicesDownload Configuration Data to Field Devices
Loop Connection Check
Verify Voltage at Device Terminals
Observe and Check Signal WaveObserve and Check Signal Wave
Verify Loop Operation ( LAS Redundancy Check etc.)
Adjust Loop Parameters
Arrangement of Proper Site Organization for Site Activities
Note
(SAT & Commissioning) Prepare Tools for Troubleshooting at FAT/ SAT (Bus Monitor, Volt Meter and Oscilloscope)
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
Thank You
Fieldbus FoundationIndia Committee
21st September, 2011
© 2011 Fieldbus Foundation
FFIC : Automation 2011 ‐Mumbai
www.fieldbus.org
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