2 Installation - Issues and Solutions

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11 Successful Implementation & Improved Operation

Installation Issues and Solutions

Andreas AgostinIndustrial Network Sales Specialist Asia PacificMTL Instruments Singapore, part of Cooper Crouse-Hinds

22.02.2012 Kuala Lumpur


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Introduction

Fieldbus is in use since 19981

, yet still new formany customers today.

This presentation will look at the installation issues

and the lessons learned, so that you canbenefits from their experience.

1 Shell Malampaya is one of the early, larger projects. 1600 FF instruments are in use. The project produced first gas in

Oct 2001. Source: J. Seaver, Shell Philippines Exploration B.V., Malampaya Deep Water Gas-to-Power Project:

Malampaya Subsea Development, Offshore Technology Conference, 6 May-9 May 2002, Houston, Texas.


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Introduction

The pictures you will see are collected from realprojects; they are neither simulated nor demo.

We will look at Control room: cabinet design and wiring

Field: Wiring, field junction boxes, field device installation.

Processes typically involve explosion protection methods

intrinsic safety (I.S. / Ex i; energy limitation by a barrier)

or explosion proof (Ex d; protection by explosionproof

enclosure).

Many examples use IS as this is a key product of my

company and that is where I get involved.


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Disclaimer

All products shown serve as EXAMPLE only.In particular, problems shown in conjunction with a product

serve as example only.

The brand/make/model of the product serving as example

is IRRELEVANT.

Problems highlighted serve as example only, are do in no

way express problems with a particular product,

model or brand.


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The conventional system


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Control room Conventional wiring

2nd

level 1st

leveljunction box Marshalling

and barrierControl system


7/5377 Successful Implementation & Improved Operation


Marshalling: to group AI / AO / DI / DO / etc




Long wires, standard length

Allows pre-fabrication of wire

(ferrules, mounting)

Conventional signals (4-20mA,

RTD, thermocouple, 0-

5V/10V/24V) slow, hardware

filtered, length less important



Field Conventional wiring

Quality (material) Safety

Location / access

Weight/size,

10



Fieldbus versus conventional



Control room DCS wiring EXAMPLES

Fieldbus

Conventional




Installations do not haveto look messy. They

can be very nice, too.

Fieldbus

Conventional



Control room DCS wiring EXAMPLESFieldbus Conventional




Fieldbus Fieldbus



Control room DCS wiring

Important:

do not use individual wires to

wire cabinet. Use fieldbus cable

and shield properly.

Why?

Higher signal

frequency protect

them against

disturbances.

Individual wires will

cause crosstalk from

one wire to another

communication faults

can occur.?



Fieldbus CableRecommended:

Type A cable: Shielded twisted pair

Other cable is possible, but there are limitations in termsof achievable cable distance and electromagneticcompatibility (EMC).

Fieldbus is a digital high speed (31kBit/s)communication, a current modulated signalsuperimposed on the DC power.



Fieldbus Cable

Shielded pair

principle

Foil

shield

Foil plus

braided

shield

SWA

SWA

Multi-pair

Multi-pair (multi-trunk)

Pl t thi



Please not this way

Images obscured

Brand is irrelevant.



Control room DCS wiring


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Fieldbus system Field wiring

? Parallel wiring

(terminals)

special wiring

blocks

(daisy chaining)


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Fieldbus system Field junction boxes

Principle of wiring distribution in junction box:all devices are in parallel

Source: FF AG 140 Rev. 1


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Please not this way


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2424 Successful Implementation & Improved Operation24


Use dedicatedwiring blocks

with built-in

electronic

short circuit

protection.

LEDs: - built-in s/c protection


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Good Wiring Practices

Test segment wiring before connecting components Avoid damaging the wire when removing insulation Ground the cable shield only at one point (at the control

room end) Insulate the ungrounded end of the cable shield (at the

instrument) Ground armor on both sides (potential equalization) Use crimp ferrules

Ferrule diameter must fit wire Crimp tool must fit ferrule

Ferrule must fit terminals Maintain polarity and associated color codes throughoutthe segment


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Good Wiring Practices

Lessons learned:

Torque screwdriver Wire end ferrules

Right (!) wire strippers

Fieldbus tester

Harms

wire strands

Choose

right size


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Fieldbus Design Tools(Examples)


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Project Procedure

Best practice: Bench test

Functional tests and interoperability test

FAT

SAT


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Installation Guidelines

Cable Tests

Experience has shown that new cable irregularities areso infrequent that it is more efficient to check cableafter installation

Cable Installation Verify that cable is properly installed, bypassing impact

from wiring components Segment Checkout

Check of proper wiring of wiring components Device installation

Check of proper device installation Loop checkout

Functional test


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Installation tools

Portable fieldbus diagnostic test equipment(Handhelds)

Measures relevant fieldbus

parameters Establish baseline

after commissioning


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Handheld diagnostic tools

Handheld

Diagnostic

ToolDevice 1 Device 3Device 2

T

Device Coupler

& Terminator

(non-IS) Spurs

FFPS

T

FF Power Supply

& Conditioner

&Terminator

24VDC

Host

Computer

H1 Interface

Connect at respective location to obtain accurate measurement.


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Handheld diagnostic tools

Handheld

Diagnostic

Tool

FFPS

T

FF Power Supply

& Conditioner

&Terminator

24VDC

Host

Computer

H1 Interface

Fieldbus

barrier

Device 1 Device 3Device 2

Fieldbus barrier

& Terminator

Intrinsically

Safe Spurs

T

Fieldbus

barrier

To measure at fieldbus barrier/IS segments, Handheld needs to be Ex i approved.

Important since the galvanic isolation of fieldbus barrier impacts on measurement.


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Earthing/Grounding

Grounding in the control room One point grounding only

Continuous shield from control room to the field

Shield not connected at the field instrument

Connect cable armor at both ends (potential

equalization)


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Earthing/Grounding


T

Wiring Block

& TerminatorFFPS

T

FF Power Supply

& Conditioner

&Terminator

24VDC

Host

Computer

H1 Interface


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Fieldbus

barrier


Fieldbus barrier

& Terminator

Intrinsically

Safe Spurs

T

Fieldbus

barrier

Earthing/Grounding

FFPS

T

FF Power Supply

& Conditioner

&Terminator

24VDC

Host

Computer

H1 Interface


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Local field junction box for 4

instruments. Rust prevented

proper grounding, so that

separate ground connection

was required


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Field Fieldbus wiring

Green: fieldbus

Red: Power (Motors, etc)

For easy maintenance


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Troubleshooting


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Daisy chaining not recommended


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Troubleshooting

Electrical welding can generate significant surges


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Bend radius too tight, Upward facing gland risks water ingress

Two cables into one gland

prevents sealing of gland

Water ingress caused corrosion of wire and terminals


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Water ingress caused corrosion of wire and terminals


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Cable jacket stripped back too far

Troubleshooting

Wires coming out of ferrules


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Wires coming out of ferrules


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Troubleshooting

Earth stud not connected internal

surge protectors not working


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Troubleshooting

Ground not connected


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Troubleshooting

Poor cable (shield) quality


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Troubleshooting

Grounding concept failure-prone


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Troubleshooting

Water marks, fungus inside junction box


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Troubleshooting

Wire squeezed by enclosure lid water ingress

http://forums.fieldbus.org/showthread.php?t=1298


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Conclusion

Fieldbus is robust if the installation is adjusted to

the requirements of a digital communication line

Do not simply copy 4-20 methods

Use fieldbus smartly (e.g. eliminate marshalling)

Good wiring practices are more important thanon 4-20 due to bus structure

Train your installers on fieldbus practices


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Installation Issues and Solutions

Andreas AgostinIndustrial Network Sales Specialist Asia Pacific

MTL Instruments Singapore, part of Cooper Crouse-Hinds

22.02.2012 Kuala Lumpur

[email protected]

Ph: +65 97585161

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2 Installation - Issues and Solutions