Fieldbus Foundation – India End User Committee

Foundation Fieldbus TechnologyFoundation Fieldbus Technology Engineering Advantages

Mistry Harendra G.yChief Engineer – InstrumentationTecnimont ICB Pvt. Ltd., Mumbai, India

1© 2009 Fieldbus Foundation

Projects phases

Feed Engineering PhaseDetail Engineering and Procurement PhaseConstruction PhaseCommissioning phaseOperation phaseOperation phaseMaintenance phase

2© 2009 Fieldbus Foundation

Requirement from Technology

Maximum number of devices per segmentMaximum cable lengthMinimum number of hardwareMinimize wiring and installation timeMinimize cable tray requirementsMinimize cable tray requirementsMinimize control room spaceInteroperabilityMore self diagnostics information sho ld be a ailableMore self-diagnostics information should be available

3© 2009 Fieldbus Foundation

Different systems

Generally rules followed in projects…..Monitoring loop and Simple close loop FF typeComplex / Critical loop ESD system BMS loops Rotary machineComplex / Critical loop, ESD system, BMS loops, Rotary machine protection system should be 4-20 mA (i.e. Non-FF) conventional type.

FFFF4-20 mAOye…Two different system !!!!!!How to get defined benefits from Technology?.....….Will it be really economical?.................What to do?......How to do?.....

4-20 mA devices……………FF devices………field………DCS……..HART…………xx….?????......

……Where to go?...........

4© 2009 Fieldbus Foundation

Foundation Fieldbus Engineering

Hardware EngineeringSoftware EngineeringSoftware Engineering

5© 2009 Fieldbus Foundation

Hardware engineering

Selection of Foundation Fieldbus typeFieldbus topologyHardware redundancy Segment loading (design)Segment hardware planningSegment hardware planningTesting Kits / Maintenance tool / Calibration tool

6© 2009 Fieldbus Foundation

Foundation Fieldbus Types

General Purpose (Safe) FieldbusEnergy Limited Fieldbusgy

Intrinsically safe (Entity)Intrinsically safe (FISCO) Non Incendive (FNICO)Non-Incendive (FNICO)

High Power Trunk (HPT) FieldbusHPT Fieldbus for Zone-1 HPT Fieldbus for Zone-2

7© 2009 Fieldbus Foundation

General Purpose (Safe) FieldbusControl system

Redundant FF power supplyFF power supply

FieldSafe Area

Trunk

Control RoomFieldSafe Area

TRUNK IN TRUNK OUT

WIRING HUB

Spur

Ch-1 Ch-2 Ch-3 Ch-4 Ch-5 Ch-6 Ch-7 Ch-8

8© 2009 Fieldbus Foundation

FF Fieldbus devices

Energy limited Fieldbus - FISCO ConceptControl system

Redundant FISCO power supplyFISCO power supply

FieldZone 1 / Div 1

Live workable Ex i trunk

Control RoomFieldZone 1 / Div 1

Hazardous AreaTRUNK IN TRUNK OUT

WIRING HUB (FISCO)

Live-workable Ex i spurs

Ch-1 Ch-2 Ch-3 Ch-4 Ch-5 Ch-6

9© 2009 Fieldbus Foundation

FISCO Fieldbus devices

Energy limited Fieldbus - FNICO ConceptControl system

Redundant FNICO power supplyFNICO power supply

FieldZone 2 / Div 2

Live workable Ex nL trunk

Control RoomFieldZone 2 / Div 2

Hazardous AreaTRUNK IN TRUNK OUT

WIRING HUB (FNICO)

Live-workable Ex nL spurs

Ch-1 Ch-2 Ch-3 Ch-4 Ch-5 Ch-6 Ch-7 Ch-8

10© 2009 Fieldbus Foundation

FNICO (Ex nL) or FISCO (Intrinsically Safe) Fieldbus devices

High Power Trunk Fieldbus : Zone-1

Control system

C t l R

Redundant FF power supply FF power supply

High energy Ex e trunk

FieldControl Room

Zone 1/ Div 2 Hazardous Area

FieldbusBarrier-1

FieldbusBarrier-2

Fieldbus Barrier-3

Exe Junction box

FISCO or Entity fieldbus devices

Zone 1/0Division 1Hazardous Area

Live-workable Ex i spurs

11© 2009 Fieldbus Foundation

FISCO or Entity fieldbus devices

High Power Trunk Fieldbus : Zone-2Control system

Redundant FF power supplyFF power supply

FIELDZone 2

High Energy Ex nA trunk

FIELDZone 2Division 2

TRUNK IN TRUNK OUT

WIRING HUB Ex nA(L)

Live-workable Ex nL spurs

Ch-1 Ch-2 Ch-3 Ch-4 Ch-5 Ch-6 Ch-7 Ch-8

12© 2009 Fieldbus Foundation

Ex nL or Intrinsically Safe Fieldbus devices

Hardware Redundancy

Redundant Power supplyRedundant Foundation fieldbus Power conditionerRedundant system controller power supplyRedundant system controller power supplyRedundant Bulk Power suppliesPower feeder to bulk power supply

Redundant system controllersRedundant system controllersRedundant Foundation Fieldbus H1 cardSeparate back plan for redundant hardware

13© 2009 Fieldbus Foundation

Segment DesignConstraints

Field bus for safe / Hazardous areaVoltage drop calculationCurrent calculationSpare capacitySignal attenuation calculationSegment execution time.Segment criticality Rating ITB specific requirements/ end user requirements for control loop loading.

14© 2009 Fieldbus Foundation

Hardware planning

H1 card quantity FF Power supply conditioner card quantityFF Cable quantityFF Cable quantityNumber of FF junction box (Assembled)FF termination block / FF Barriers QuantitySurge protector quantitySurge protector quantityTerminators quantity

Hardware for Online diagnostics

15© 2009 Fieldbus Foundation

Testing kits / Maintenance Tool / Calibration ToolFieldbus Diagnostics monitor Fieldbus Wiring Validator Field Communicator

16© 2009 Fieldbus Foundation

Fieldbus Power and signal Probe Fieldbus monitor FF device Calibration Tool

Software Engineering (configuration)

Function block (AI,AO,PID etc) execution in field devices• Use the power/capability of the instruments• Increase the single loop integrity• Reduce host system controller loading• Reduce host system controller loading• Multi-variable optimization

Advanced diagnostics configurationAlarm and Alert configuration for better operation

I lit d d ti it• Improve quality and productivityRedundant Link Active scheduler (LAS) configurationSegment execution time configurationAll selected software shall be of latest revisionAll selected software shall be of latest revision Asset management software configuration

• Predictive maintenance• Reduce time to repair• Root cause identification and eliminationRoot cause identification and elimination• Avoid failure • Reduction in Inventory cost• Centralized maintenance

17© 2009 Fieldbus Foundation

Engineering Tips for Economical benefits

Maintenance / calibration tools or HHC, Valve signature software should be common for FF and 4-20 mA HART based systemC h d / ft t f FF d 4 20 A I t tCommon hardware/software system for FF and 4-20 mA InstrumentsSelect instruments with FF check mark logo Selected hardware should have InteroperabilityNever start work without a comprehensive plan.Avoid uneconomical decisions and changes in philosophy during detail engineeringg gAtleast One Engineer to be trained at system vendor place for commissioning activities.Regular training to team and knowledge shareRegular training to team and knowledge shareDevelop procedures and knowledge base for future

18© 2009 Fieldbus Foundation

CASE STUDYCASE STUDYExample

19© 2009 Fieldbus Foundation

Case Study - ExampleAnalogue Input (AI) = 1000Analogue Output (AO) = 100Intrinsically safe system suitable for Zone-1 IIA/IIB T3High Power trunk concept (with IS Field barriers) fieldbus systemCable length between junction box and control room is 300 mtrsControl loop I/O card, FF H1 card, Segment power supply module are redundantDCS Vendor engineering hrs same for FF or HART system Branch cable and spur cable length not considered for comparisonAll transmitters are normal DP flow / Pressure / Level / Temperature transmittertransmitter. Asset management software shall be installed in DCS. No separate system.Cost of MCT, cable gland not considered for cost comparison

20© 2009 Fieldbus Foundation

CAPEX : Material cost (Case Study Example)

Description Qty Unit Rate $

4-20mA HART $

Foundation Fieldbus $

Saving with FF

AI card (16 channels) HART 68 1543 104179

AI/AO card (8+8 channels) HART 30 1543 46302

FTA card (16 channels) HART 83 318 26231

AI/AO Card Nest (Card Rack) HART 15 6250 92969

IS Barrier (AI/AO) HART 1320 104 137500

%

FF H1 Card (4 segment) 69 1151 79126

FF H1 Card Nest (Card Rack) 11 6250 66016

FF Power supply board (Power supply module, Physical layer diagnostic module, software) 34 81120

M h lli d I/O d C bi t (HART) 14 2083 29655 + 17 %Marshalling and I/O card Cabinet (HART) 14 2083 29655

System Cabinet (FF) 4 2083 8349

Field device (FF additional cost) 1100 65 71500

Junction Box (HART) 138 828 113850

FF J ti B ith 3 I S B i (P i d) 138 2708 372396FF Junction Box with 3 I.S. Barrier (Pre-wired) 138 2708 372396

Cable (12 Pr x 0.5mm²) - HART 41250 m 10 411568

Cable (2 Pr x 1.5mm²) - FF 41250 m 3 117266

HHC (FF addional cost) 1 1801 1801

Ph i l l t ti t l 1 t 736

21© 2009 Fieldbus Foundation

Physical layer testing tools 1 set 736

Total 962254 798310

CAPEX : Installation cost (Case Study Example)

Description Qty Unit Rate $

4-20mA HART $

Foundation Fieldbus $

Saving with FF

Termination : 4-20 mA Signal wires (HART) 23100 6 138600

+ 42 %

Termination : FF signal wires (FF) 7425 6 44550

Cabinet Installation - HART 14 677.96 9650

Cabinet Installation - FF 4 977.96 2717

Cable pulling – 12 pair – Home run - HART 41250 3.67 151388 42 %Cable pulling – 2 Pair – Trunk - FF 41250 2.85 117563

Main cable tray – 600 mm – HART (with Material) 300 34.20 35117

Main cable tray – 300 mm – FF (with Material) 300 27.72 28548

Total 334755 193378

Control room size reduction is approx. 12 Sq. meter

Assumptions :Branch cable tray quantity and size same for FF and HART tagsBranch cable tray quantity and size same for FF and HART tags.FF/HART junction box installation cost is same.

22© 2009 Fieldbus Foundation

CAPEX : Commissioning cost

Description Days Per Day Rate $

4-20mA HART $

Foundation Fieldbus $

Saving with FF

HART System Loop checking and commissioingHART System Loop checking and commissioing3 Technician @ 15 loops in 10 hrs 74 300 22200

+ 31 %FF System Loop checking and commissioing1 Technician + 1 engineer @ 10 segment in 10 hrs 14 1100

15400

Total 22200 15400

Assumptions :Calibration cost for FF or HART device is same.Continuity and Meger check for cable not considered for comparison, because of not much difference.

23© 2009 Fieldbus Foundation

Q ti ?Questions ?

24© 2009 Fieldbus Foundation