fieldbus foundation – india marketing committee fieldbus ... · pdf filedavid brown...

1© 2009 Fieldbus Foundation

2009 FFIEUC-Mumbai Conference

AuthorDavid BrownBechtel Corporation CAT Engineering Specialist

AuthorDavid BrownBechtel Corporation CAT Engineering Specialist

Fieldbus Foundation – India Marketing Committee

Fieldbus FoundationEnd Users Council Conference-2009

On Site Support of the Reliance JERP Project

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© 2009 Fieldbus Foundation

Fieldbus Foundation Topic –

Segment Design

Assigning Devices to Segments

Physical Layer

Segment Pre-Commissioning

Team Cooperation

Lessons Learned

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Fieldbus Foundation Topic – Segment Design Based on Loop Severity

Implementation of Fieldbus into the project was based on FF AG181 rev 2.0 guideline for valve Criticality from the beginning of the project. During the design some units relaxed the use of criticality 1 & 2 on new loops. After installation started loops that were changed or added used the loop severity approach.

The Segment Design Risk Assessment is an operability review process performed prior to FOUNDATION™ fieldbus (FF) Segment design.

The purpose of the design review is to evaluate the impact of FF associated failures to determine segment design(s) that minimize process risks.

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Fieldbus Foundation Topic – Segment Design Based on Loop Severity

A process severity ranking is determined for control loops leading to segment design recommendations made in relation to risk ranking and good engineering design practices.

The design intent for control loops with higher risk is to minimize the number and type of devices on a segment, reducing the process risk, to facilitate ease of isolating control loops with high process severity ranking during troubleshooting and maintenance, and increasing reliability.

The analysis may also identify control loops that should not be FOUNDATION™ fieldbus due to loop control criteria.

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Fieldbus Foundation Topic – Assigning Devices to Segments

The FF AG181 guideline was used to start with and based on this and experiences from the design team the segments are laid out based on the following guidelines.

Spur lengths set to 90 meters with a maximum of 120 meters

Total segment less than 1900 meters

The Interim Junction Boxes located to minimize the number of Home Run Trunk cables from the field to the PIB’s

The Barrier Junction Boxes located to meet the spur length

Critical devices on the same segment within the wiring limits

For some segments used two barrier JB’s to maintain the loop integrity

This required detailed drawings that showed device locations

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Fieldbus Foundation Topic – Physical Layer

Physical Layer Connectivity Equipment Used on the Reliance Project

With the size of the plant being a logistic issue along with the different environmental areas the Hybrid Segment, High Powered Trunk, concept was utilized.

Allows for Intrinsic Safety circuits to be located in the field

Uses standard FF Barriers for Intrinsic Safety function

Utilizes standard FF power supplies for up to three FF barrier interfaces per segment.

Allows for longer segment distances

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Fieldbus Foundation Topic – Hybrid High Power Segment

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Fieldbus Foundation Topic – Hybrid High Power Segment

9© 2009 Fieldbus Foundation


Fieldbus Foundation – India Marketing Committee

Fieldbus FoundationEnd Users Council Conference-2009

Pre-Commissioning and Validation of FF Segments Improves Start-Up

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Fieldbus Foundation Topic – Project Issues

With FOUNDATION™ Fieldbus systems getting larger, more devices and segments, some of the common project issues become scheduling nightmares.

– Segment check-out such as the right device in the right place.

– Segment validation of the physical hardware and signals.– At present it can take up to 15-20 minutes per device to

commission on each segment using the standard DCS.

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Fieldbus Foundation Topic – Solution

New schemes are being developed to shorten the Commissioning and Validation process.One such scheme is being used on a couple of Mega projects.

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The scheme uses the following equipment along with data from the INtools data base.The use of devices such as the 375 Field Communicator used as the LAS and read/write of the following information.

– TAG Name– Device Address– Checking on DD and software revisions

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FBT- 6 FOUNDATION™ Fieldbus physical layer tester

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Fieldbus Foundation Topic – SolutionScopemeter for checking signal quality and measure resistance and capacitance on the segment

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FOUNDATION™ Fieldbus power supply for powering the portion of the segment being tested Line to 24 vdc power supplyCoupler block for connecting up the devices to the segment being tested

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Basic Segment Testing LayoutTrunk

Spurs Spurs

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Field Junction Box with CouplerField Junction Box with Coupler

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Five pair Trunk cable in instrument cabinet

Single pair for testing

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Interim Junction BoxInterim Junction Box

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Field Barrier Junction Box

Barrier Isolation

Trunk Input Terminals

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Field Barrier Junction BoxField Barrier Junction Box

Field Device Spurs

Field Device Spurs

BarriersBarriers

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Fieldbus Foundation Topic – Data Collection

Data collection Process:With a Fluke Scopemeter or a DVM check for shorts

Signal to signalSignal to shield

Power up the segment with test FF supplyConnect the 375 and power up and select Foundation Fieldbus operation

Allow 375 to be LASCheck Livelist for devices and address

Once Livelist is established connect the FBT - 6 and validate segment physical operation and store data.

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Fieldbus Foundation Topic – Data Collection

After the FBT – 6 data has been stored use the 375 to complete the data review and update.If the address for the devices are located in the parking area you will need to change each device to the listed address in INtools and then check the TAG along with the revisions.After all the data has been checked and recorded along with the devices updated you have completed the Validation and Pre-Commission.

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Fieldbus Foundation Topic – Data

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FBT - 6 Spread Sheet

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Fieldbus Foundation Topic – Team Cooperation

The worlds largest FF project has presented several challenges.

During construction with the wiring and installation

Start-up with finding compatibility issues with different devices

Issues during normal operation requiring upgrades

Through all of the challenges Team work has been the prime reason for the plant being were it is today. Everyone from Reliance, EPC’s such as Bechtel and others along with the Vendors like Invensys have worked together to identify the root cause and fix the Issues.

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Fieldbus Foundation Topic – Lessons Learned

Lessons Learned from the project:Training is the key to success during

construction and start-up

Communications between all parties is a must to meet the schedules and find resolutions to issues

Device interoperability must be known before installation of devices. Any new device that does not have a minimum of one year run time needs very detailed testing before accepting.

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QuestionsQuestions

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