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28 November 2012 1
Foundation Fieldbus Implementation
EPCM Perspective
Rajiv Gupta
28 November 2012 2
Indian experience in FF
Indian Oil & Gas industry is on the forefront of adopting new
technologies and Foundation Fieldbus is one of them
Many large grass root Refinery and Petrochemical plants in
India are using FF today
EIL is part of this evolution in the country as leading EPCM
Implemented FF technology in utility plant in 2003 itself
First grass root Refinery with control in field FF in 2007
FF is de facto choice for all EIL projects
EIL has extensively implemented FF in major projects:
BORL, GGSRL, MRPL, BCPL, OPAL, KRL, GAIL, NRL,
BPCL, IREP, Offshore and KPPC Aromatics
Many plants have more than 1000 segments
28 November 2012 3
FIELDBUS ENGINEERING
• FIELDBUS IN INSTRUMENTATION DESIGN BASIS
• FIELDBUS IN P&IDS
• FIELDBUS FIELD DEVICES
• HOST SYSTEM
• FFPS (FOUNDATION FIELDBUS POWER SUPPLY)
• FIELDBUS CABLES
• SEGMENT DESIGN
• FIELDBUS JUNCTION BOX
• PACKAGE PHILOSOPHY
• INTEGRATED ASSET MANAGEMENT SYSTEM
• FAT, PRE COMMISSIONING AND COMMISSIONING
• BENEFITS
• WAY FORWARD
28 November 2012 4
Fieldbus based system in which units & devices
Type of Fieldbus: Foundation Fieldbus or Profibus PA
Type of hazardous area protection for Fieldbus:
IS (Entity), FISCO, FNICO (or FISCO ic),
High-powered trunk, Flameproof
Control functionality location
Redundancy requirements
FIELDBUS in Instrumentation Design Basis
28 November 2012 5
For licensed units FF implementation is discussed in
Technology Transfer reviews & Fieldbus devices & loops are
identified in P&IDs
Fieldbus devices are not used in sequence, interlock and
shutdown system loops.
Number of close loops per Fieldbus segment. (Rest could be
used for open loops.)
Fieldbus devices shall not be used in special loops e.g. anti-
surge control etc.
For special instruments for which Fieldbus devices are not
available/ limited availability, Smart or conventional type
transmitters are used.
Using Fieldbus is advantageous in loading gantry, Coriolis
flow meters, BTD/RTD monitoring of motors
Not practical in Offsites
WHERE TO USE FIELDBUS
28 November 2012 6
Showing FIELDBUS in P&ID’s
A different line style/Solid bubble is used for the connection between fieldbus devices
28 November 2012 7
Showing FIELDBUS in P&ID’s
ISA 5.1 2009 includes depiction of FF which is
expected to be adapted universally
28 November 2012 8
• Interoperability test (ITK latest revision) clearance
• Polarity sensitivity
• Capability to become device link master
• Power supply
• Current drawn by field devices
• Certification code for hazardous area protection
• Function blocks requirement
• Function blocks execution time
• Diagnostic requirement
• Number of link objects
• VCRs available
• Software revisions
FIELDBUS FIELD DEVICES
28 November 2012 9
Foundation Fieldbus is supported by all major DCS
vendors. Following information is used for segment
design and system loading
o Maximum number of segments per H1 card,
o Maximum number of devices per segment in H1 card,
o Maximum number of function blocks per H1 card
HIST compliance as per FF-569
Host must support ‘off-line configuration’ using
information from the device Capabilities Files.
Redundancy requirement in H1 interface card, power
supplies to be specified. Redundant H1 card is
recommended.
Support for advanced diagnostics
HOST SYSTEM
28 November 2012 10
Power supplies are designated as per the Fieldbus
Foundation Physical Layer Profile Specification:
Type 131: Non-I.S. Power supply intended for feeding an
I.S. barrier. Output voltage depends on barrier rating.
Type 132: Non-I.S. Power supply not intended for feeding
an I.S. barrier. Output voltage is 32 V DC maximum.
Type 133: I.S. Power supply. Complies with the
recommended I.S. parameters.
Appropriate type selected as per hazardous area protection
FFPS (POWER SUPPLY for FF)
28 November 2012 11
FFPS should be powered from redundant bulk power
supplies
Over current protection shall be provided for each feed to
FFPS
Not more than 8 FFPS may be connected together with
common Bulk Power Supply feeder
Failure or faults in any of the redundant FFPS shall be
annunciated in the host system. A common alarm for all
FFPS in a single cabinet may be used
FFPS (POWER SUPPLY for FF)
28 November 2012 12
Cable type A as per IEC 61158-2 used. EIL has developed
Standard Specification for procurement
Fieldbus cable are unique in colour and easily
distinguishable from non-Fieldbus cables. Recommended
colour:
For intrinsically safe (entity) and FISCO application:
Orange with blue longitudinal stripes.
For safe area, FNICO, and flameproof application:
Orange with black longitudinal stripes.
For high powered trunk application: Trunk cable orange
with black longitudinal stripes. Spur cable shall be
orange with blue longitudinal stripes.
Cables had to be imported for earlier projects however now
indigenous vendors are developed
FIELDBUS CABLES
28 November 2012 13
Drawings/ documents required for segment design:
P&IDs,
Instrument location plans,
Fieldbus devices specifications (maximum current drawn from
bus, minimum voltage required, block execution time etc.),
FFPS Specifications
Cable specifications (particularly loop resistance in case of
FISCO/ FINCO / High powered trunk applications).
Response time of different loops as per project specifications
(including process licensor’s requirement, if any),
Host-system documentation showing configuration rules or
restrictions.
SEGMENT DESIGN
28 November 2012 14
Separate segments for unrelated process units and area
Separate segments for parallel process streams / trains
Devices used for same functions in same location/
equipment on different segments
All devices for the same loop on the same segment
PROCESS CONSIDERATIONS
28 November 2012 15
Stainless Steel, ingress protection of IP 65. Canopy for junction boxes located in open areas.
More than one wiring/ terminal block housed in one junction
box to avoid large number of JBs. For wiring blocks with 4-6
spur connections, 2-3 wiring blocks housed in one junction
box
Maximum 12 spurs preferred due to similarity of engineering and optimum size.
For junction boxes with 2 and 3 wiring/ termination blocks, 3 and 4 pair cables used respectively, keeping one spare pair.
Inactive spare fieldbus trunk cables may be terminated on conventional terminal block inside junction box
JUNCTION BOXES
28 November 2012 16
Hardware, software for all fieldbus instrumentation up to FFPS (excluding FFPS) is included in package vendor/ contractor scope.
Guideline for segment design are given to package vendor/ contractor. Package vendor/ contractor shall furnish the number of segments and provide all internal hardware for the segments up to fieldbus junction box.
Number of segments to be worked out early before
procurement.
PACKAGE PHILOSOPHY
28 November 2012 17
Available concepts for hazardous area protection
analysed and High Power Trunk chosen. Also
implemented FISCO, Flameproof and FISCO ic
High power trunks preferred due to uniformity of
design, area classification and length of trunk, higher
distance of field devices.
EIL has implemented Control in Field
12 spur FFJB to have identical design and optimum
size of FFJB. Also reduces spur lengths
Early Grouping of signals for segment design based
on equipment layout and fine tuned as per actual
locations
3D modelling of FFJB’s
EIL experience in FF engineering
28 November 2012 18
Early ordering of FFJB by identifying segments up to
6 spurs early and considered spare FFJB’s in each
category
20-25% spare capacity for field devices in each
segment.
Single pair trunk cables used for HPT. Few spare
segment cables laid to accommodate additions during
commissioning
Integrated Asset Management System for advanced
diagnostics of Positioners needs to be ensured which
leads to limitation of vendors since in FF the AMS
can’t be independent.
EIL experience in FF engineering
28 November 2012 19
Implementation Challenges & Benefits
The FF device integration was tested in FAT by requesting
the field instruments in DCS vendor works during FAT
Difficulty in getting timely field device data for DCS
configuration and segment design
The DD version mismatch with supplied data/web
download and actual supply
Mismatches between FF and Non FF during loop
modifications, HAZOP. Consider spare instruments
During commissioning electronic module was changed to
ensure min voltage
The FFJB changed to have more spurs for field additions
28 November 2012 20
Implementation Challenges & Benefits
Net reduction in copper use.
Reduction in control room hardware and terminations
Further cost reduction after indigenisation of cables and JB
The reduction in diameter of trunk cables results in ease of
construction, faster construction and more space in
duct/trays/MCT’s, also adds aesthetics
Faster commissioning due to segment wise loop checking
WAY AHEAD
Indigenisation of FF cables and FFJB
More vendors for FF barriers
Vendor interface programmes for advanced diagnostics
28 November 2012 21
THANKS
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