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