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Foundation Fieldbus

at GNFC

End User Perspective

By: GNFC TDI-II, Dahej

Represented by

C. H. Parmar & H. K. Jinwala

�FF Architecture @ TDI-II

�FF installation @TDI-II

�Design Criteria for TDI-II

� Implementation @ TDI-II

�Installation & commissioning Problems

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List of contents

FF ARCHITETURE @ TDI-II

ServerHSE

H1 CARD

FF POWER SUPPLY

FF JBCHICKEN FOOT

TOPOLOGY

FF DEVICES

CONTROLLER

H1 TRUNK

SPUR

FF Installation @ TDI-II

�Host System : Honeywell Experion PKS

�Total IO Count of DCS-ESD : 8500 Nos.

�H1 Card Used : 101 Nos. (Redundant)

�FF Trunk/JBs Used : 372 Nos.

�Total FF Devices Installed : 2850 Nos.

�Total Close loop: 570 Nos.

�Total Close Loop on FF : 495 Nos.

�Control in Host Close Loops : 315 Nos.

�Control in Field Close Loops : 180 Nos.

�Control in Host Open Loops : 800

�Control in Field Open Loops : 11504

86 % Close loops on FF

FF Control Functions

Control in Host

PID

AO

AI

control functions all reside in central

controllers.

Control in Field

AOAI

control and I/O functions to be distributed

to field instruments.

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PID

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PID CONTROL FROM HOST

SYSTEM

Control In Host

Controller

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Block Diagram: Control In Field with Close loop

Field Bus

Module

Segment

PID Block in Fieldbus

Module

Segment Details

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Field Bus

Module

Redundant Field Bus

Module

BLAS Enable

Device

Communication Details

� Max. two (2) control elements (i.e. Control valves) Per Segment.

�Max eight (8) devices having final control elements per Segment.

�Max . ten (10) monitoring devices per Segment.

�Each segment shall have an enable backup Link Active Scheduler (LAS) in field device .

�The master and primary backup Link Active Scheduler (LAS) shall be reside in the redundant H1 interface card .

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Design Criteria @ TDI-II

�Critical / Complex close Loops and interlock IOs have been configured as Control on Host .

�Non critical Close loops / Open loops have been configured as control in field .

� Each Segment of FIM has been protected by Surge Protector .

�Longest Segment Length : 900 mtr.

�spur cable length : 120 mtr.

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Design Criteria @ TDI-II

Design Criteria @ TDI-II

� NEST Loading

� Segment wise configuration of each H1 interface module .

� Segregation of critical tags are configured in single FIM for control on Host.

� Segregation of Non- critical tags are configured in single FIM for control in Field.

� Segment Validation Calculations using segment calculator.

� Advantages :

� Minimise the Controller Module Count

� DCS Controller load reduces.11

FF: Control in Field with Open loop

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Control In Field

with Open Loops

FF: Control In Field with Close loop

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Control In

Field with

Closed Loop

FF: Control in HOST

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Control In

Host

Variety of Parameters withFF Device

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FF HARDWARE IMPLEMENTATION @ TDI-II

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Barrier with 6 spur each capacity

Heat shrinkable sleeve for

shield isolation

JB side Terminator

0.8 mm2 Grade A

Spure cable

1.5 mm2 Grade A

Trunk cable

Hazardous area FF Junction Box its Components

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FF Termination at DCS Marshalling Side

Looping of Overall shield at

Marshalling side.

Wiring of DCS at Marshaling

end

Wiring of Field (Segment

cable) at Marshaling end.

Heat shrinkable sleeve

for shield isolation

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Termination count of Class A: Single-point Shielding.

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Instrument

Signal Earth

Typical arrangement of FF Components at Honeywell make DCS

Redundant FIM

Modules

Redundant Fieldbus

Power Supply

-> Supporting to Total 4

FIMs (2 Redundant)

Advanced Diagnostic

Module For Each

Redundant Power Supply

4 Nos. of Segments ( 4

JBs or 48 nos. of Field

Devices) for 1 Redundant

FIM

COMMISSIONING PROBLEMS

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Device Description (DD) Files – It is set of protocol to talk between HOST and device and generally provided by Field device supplier.

� Non-Availability of (DD) Files.� For 2-3% of the cases DD files could not found easily.� System specific DD files.

� Nos. of revisions in DD file .

� Upgraded field device is not working with the earlier lower version of DD file.

� Configurable Ranges beyond Device Design Limit.� Field devices should not be configurable beyond its

design limit. Which creates confusion.� Non availability of basic variable units in Field Device

Library itself even though device was approved for ITK (Interoperability Test Kit) 4.1.

Commissioning Problems: DD Files

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� Non-availability of Device Type Manager (DTM) file� With this file Asset management Server (AMS) can

have all the remote maintenance access of device.

� Generating system alarm as Configuration error without any detailed description.� Some of the field devices randomly generating

system error even though same make and model with same configuration.

� There is no specific guideline to identify the exact problem of configuration error.

� No specific guideline to configure Fieldbus Diagnostic module and its feature.

� Electronic Hardware Failure – FIM (H1 Cards)

� Electronic pH transmitters Failures – Complete segment affected.

Commissioning Problems

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Un-desirable phenomena

PT1

Ad: 21

PV1

Ad: 26

Hazardous Area Safe Area (Test Bench)

Problem

with Field

Device

Commissioning Problems

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Un-desirable phenomena

PV1

Ad: 26

Hazardous Area Safe Area (Test Bench)

Commissioning Problems

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PT1

Ad: 258

Device Address

will get change

automatically

Commissioning Problems

DCS snap of old device detected as New one

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Detected as Un-commissioned

device even though same tag no.

and device address

� Device not detecting if it is Pre-configured with device address beyond (by Field device Supplier) un specified range.

Commissioning Problems

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CONNECTING NEW FF

DEVICES WITH DEVICE

ADDRESS 258.

HSE

FF POWER

SUPPLY

CONTROLLER

H1 CARD as

MASTER LAS

Commissioning Problems

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HSE

FF POWER

SUPPLY

CONTROLLERSolution:

In this case FIM has to be bypass to make HHT (Fieldbus communicator -475) as master and through HHT only we can change the desired device address.

POWER OFF

THE BOTH FIM

CONNET THE HHT – 475,

WHICH WILL ACT AS

SEGMENT MASTER LAS.

General Guidelines

�Field Devices should be supplied as Pre configured with Tag no. and Device address from Vendor Works.

�All Variety of DD Files has to be checked during System FAT.

�Reserve 20% Spare in all aspects which will help in future maintenance.

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Thank You

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Questions

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Troubleshooting

1) List of Symptoms: � Gather all the information.

2) Collect the data:� Voltage� Signal level� Noise� Retransmits� Shield shorts

3) Look up likely causes:

4) Inspect the Physical layer for the problem:� Connectors not securely plugged in or Loose wires.� Damaged cables or wires or both.� Cable shield grounded at more than one location or not Grounded.� Cable bend radius too small. 32

Online Diagnostic tools:

On-lineDiagnostic Module

Power Supply System

Controller I/O

Fieldbus

Alarm

HOST control System

Instrument Management Software(including field bus diagnostics)

Software TroubleshootingAdvanced Diag. Module

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Customer Requirements

�Lower installation cost

Multiple instruments on a single pair of wiresFaster commissioning - loop checkMulti-variable transmitters

�Operational improvementsMore real time information “about” the processMeasurement validation - quality - safetyTighter control by distribution of control functionsMechanism for continuous innovation

�Lower maintenance costRemote access - unified toolsAdvanced process and device diagnosticsIntegrated plant asset management functions

� Fieldbus is open and interoperable– Supports interchangeability

– Supports various bus topologies

– Supports control and automation functions

� Supported by multiple vendors– Broad range of equipment

� Standard control system interfaces

� Bi-directional communications– More information transmitted - alarm

reporting

– Improved performance and availability

– Improved maintenance - on-line diagnostics

� Standard support equipment– Ease of configuration - single tool

– Faster commissioning

Hybrid Instruments or Intelligent Instruments with Custom Interfaces

Analyser

Proprietary or Custom Interface

PLC

I/O

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FOUNDATIONTM Fieldbus : Overview

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FOUNDATION Fieldbus Topology

What does FOUNDATION Fieldbus do?

USER LAYER

PHYSICAL LAYER

H1“STACK”

SENSOR

Fieldbus wire

USER LAYER

PHYSICAL LAYER

H1“STACK”

ACTUATOR

Moves data from

here to there

Controls, alarms

Ensures secure

communication

Connects to the

wires here

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USER LAYER

PHYSICAL LAYER

H1“STACK”

H1 Communication Task� Establishes basic communication

services between Fieldbus devices

� Encoding and decoding of User Layer messages

� Supports scheduled messaging for time critical communication (Publisher/Subscriber)

� Supports unscheduled messaging for request/response communication (Client/Server)

� Supports unscheduled messaging for Event Notification (multicast)

� Publishes the “time” on the bus

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FF Structure

USER LAYER

PHYSICAL LAYER

H1“STACK”

User Layer� Provides the interface with the process

� Consistent definition of data for integrated and seamless distribution of functions in field devices from different manufacturers

� scheduling of function blocks

� Standard Function Blocks

� Off-line “system” configuration by host system

� Host system to operate the device without the need for custom programming

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FF Structure

FF Structure

� The Resource Block

Describes the characteristics of a device

Contains manufacturer information

� The Transducer Block

Physical I/O interface with the actual sensor or actuator

Performs A/D conversions, square root extraction, linearization etc

Transmits/receives information to/from Function Blocks

The Transducer Block is the window to the process - diagnostics

� Function Blocks

Similar to the function blocks in today’s DCS and PLC systems

Mandatory is at least one Function Block depending on the type of device

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Why FF over HART ?

�Integration of the digital protocol with 4–20 mA

Control Host

�Compatibility with Existing Control Wires

�Compatibility with Existing Knowledge Base and Work

Practices

�Multivariable Capability

�Control in the Field

�Alarms and Alerts

�Control and Calculation Capability

�Advance & Online Diagnostics

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Why FF over HART ?

Traditional 4-20 mA wiring,one IS barrier, one pair

for each device

4-20 mA

ISISIS IS

One IS barrier, one pairfor many devices

ISFieldbus

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Segment Calculation

� One of the Major Fieldbus designing tool

� Segment Calculator allows users to intuitively check

operational parameters to validate fieldbus segment

architecture.

� It provides a rapid “Go/No-Go” indication of the electrical

characteristics of the fieldbus network. All the relevant

parameters of the fieldbus segment are easily configurable,

including field device currents, cable lengths, cable cross-section

and number of fieldbus spurs. Power supply and host control

system types are easily selectable from pull-down menus, or can

be user-defined.

� Sample File : How to do Calculation ? 43

Pending points:

FF structure architecture

FIM failure prob.

pH cnductivity

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