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Training program on Basics of Fieldbus Technology and FOUNDATION Fieldbus Engineering for Process Automation,

18th and 19th January 2013 at Hotel Regaalis, Bangalore

FOUNDATION Fieldbus Engineering for Process Automation

By

Sachin RasaneI&C Consultant & Trainer

OGIC, Pune

[email protected] +91 94223 59938

ISA Bangalore Section

mailto:[email protected]

Basics of Modern Industrial Automation©

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FOUNDATION Fieldbus Engineeringfor Process Automation

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Academic- Instrumentation and Industrial Electronics Engineering- VES Engineering College, Mumbai- Year 1988

Worked in:- Domain – Oil and Gas Upstream (Onshore Projects)- EPC – Jacob’s, Worley Parsons, Kvaerner- Engineering Consultants – Comprimo, Granherne- System Vendors – Emerson, Honeywell- OEM - GE- Contractors – Al-Hassan, Mannai Engineering- End Users – PDO-Shell, Occidental, Chevron, ADCO, ARAMCO, PKKR, MRPL, HPCL etc.

Currently working with:- OGIC– Oil and Gas Instrumentation Club (Conducting Trainings and Workshops for Graduate / Junior

Engineers and Providing Corporate Training). Initiative to reduce Industry-Academia Gap.

Association:- Member of IEC- Sr. Member of ISA- Formed OGIC (Oil and Gas Instrumentation Club) for Global Instrumentation Community


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AgendaApplying Foundation Fieldbus in Project offers several benefits compare to Conventional Instrumentation. Fieldbus installation can be relatively quick andeconomical if we understand the Technology, Engineering and Design phase.

Fieldbus Engineering Team & Responsibilities Journey to FONDATION Fieldbus Why Fieldbus? It’s Benefits to End User!! Project Phases Vendor Responsibilities Process Types Fieldbus Selection Fieldbus Design for Process application Installation/Commissioning Operation and Maintenance

This Presentation will highlight some key points from EPC/End Usersperspective for successful implementation of Fieldbus Project.


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Fieldbus Team and Responsibilities Fieldbus Development Team Vendors EPC/Consultant End User

Many engineering firms believe that there are no great differences between 4-20 mA analog and Fieldbus installations. Without an engineering partner with Fieldbus skills, the cost of project will be greater & Project will be mess!!

End UserFieldbusVendors

Fieldbus DevelopmentTeam

EPC / Consultant


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Fieldbus Team and Responsibilities

Fieldbus Development Team

EPC / Consultants End UserFieldbus Vendors

1. Tender2. Evaluation3. EPC/Vendor

selection4. Procurement5. Design and

Engineering Co-ordination

6. Construction7. Installation8. Commissioning9. Operation and

Maintenance

1. Tender 2. Proposal3. Evaluation / Proc.4. Field Instrument

Design5. ICSS –

DCS/ESD/F&G Design

6. HAZOP/SIL7. Procurement8. Project

Co-ordination9. Construction SoW

& Assist.10. As-Built11. Maintenance

1. R&D2. Product Design3. S & M / Proposal4. Fieldbus Instr.

Selection5. DCS/ESD/F&G6. Hardware Design7. Software Design8. Networking Design9. FAT/SAT10. Install. & Comm.11. As-Built12. AMC

1. Develop Fieldbus Standards

2. Define Fieldbus Guidelines for Vendors / Consultants / End Users

3. Feedback from End Users / EPC / Consultants /Vendors

4. Continuous Improvement

They all are I&C Engineers / Experts but the Roles and responsibilities are different according to the Business need of the company they represent !!


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Fieldbus Team Qualification Qualified Engineering Partners Project Phase Awareness Process and Equipment Knowledge Product and Application Knowledge (Fieldbus & Field Instruments) Fieldbus & Network Knowledge (Control System) Familiar with Enquiry & Design Docs (P&ID, Instrument Index, Data

Sheets, Specs, Layouts …etc.)

End UserFieldbusVendors

Fieldbus DevelopmentTeam

EPC / Consultan

t


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The Journey to Foundation Fieldbus….The Process Automation technology developed in each decade was complimentto next one…!!

Lets have a look at the historical overview and the development trends ofI&C technology, process environments and instrumentation, and the tasksof end users in different decades.

50’s – Electro-mechanics / Pneumatic / Hydraulic Systems 60’s – Combination of Pneumatic & Stand alone Controllers 70’s – Integrated Circuits and PLC’s 80’s – DCS with Smart devices / CAD 90’s – Foundation Fieldbus

All above Technologies played crucial role in development of Fieldbus …!!


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I&C – Technology Trend50’s – Electro-mechanics / Pneumatic / Hydraulic Systems In the 1950s, development trends focused on electro-mechanics, Bringing field instruments closer to the process, and reading and monitoring

process data near the process level. Pneumatic analogue

instruments were introduced and also various measurement devices for pressure, temperature and flow spread in the industry. Feedback control was applied in hydraulic controls.


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I&C – Technology Trend60’s – Combination of Pneumatic & Stand alone Controllers In the 1960s technical development took place particularly in the fields of

electronics. Pneumatic and electric instrumentation systems relying on analog signals

spread into factories. Instrumentation

structures were standardized, and centralized control room solutions were implemented. Electronics was first used in the devices for automation data logging and processing and process control.


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Digital and microprocessor technologies were applied in electronic devices and control stations. Graphic design curves were introduced for Process trends.

I&C – Technology Trend70’s – Integrated Circuits and PLC’s Trends of the 1970s were integrated circuits and programmable logic

controllers (PLC). The development of analog systems reached its peak, distributed digital systems (DDS) gained ground, and control rooms became increasingly complex.

The centralized control systems incorporated measurement, communication and information handling.


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Intelligent Field devices were supplied by specialized vendors. End Users paid more attention to the selection and specification of devices. CAD & Spreadsheet was introduced for Design and planning. Development of International / Local Company Standards.

I&C – Technology Trend80’s – DCS with Smart Devices / CAD In the 1980s microprocessor technology was the peak area of development. This

was the start of the era of video cameras, integrated systems and cabling was replaced by data buses using coaxial or optical cables. Process supervision was centralized, the operations hierarchically distributed. Management systems were characterized by control room operation, process stations, and distributed control functions.


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I&C – Technology Trend80’s – International Standards Development


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The purchase price of a device is marginal compared to the total cost during its lifespan. This emphasizes the importance of Safety, reliability and maintenance..

I&C – Technology Trend90’s – Foundation Fieldbus The integration of electronic components and microcomputers into process

management has continued to grow, and intelligence has been distributed to field technology devices. Field instrument and fieldbus development projects have been initiated, changed, and merged together. Fieldbus and Highway Addressable Remote Transducer (HART) devices are used for the measurement of temperature, pressure, DP and level.


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I&C – Technology Trend90’s – Foundation Fieldbus

Transmitter Control Valve

Fieldbus Segment

50’s & 60’s Contribution to Fieldbus Concept- Control in the Field

70s & 80’s Contribution to Fieldbus Concept- • Function Blocks in the Field• 4-20mA – Two wire system to Digital


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What is Fieldbus???

A digital, bi-directional communication link among intelligent field devices and Automation systems, allowing control in the field or Automation System.


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Fieldbus Concept

Fieldbus is a local area network (LAN) for process control. The two wires are a shielded twisted pair similar to the usual 4‐20 mA wiring used for conventional devices. Because devices share the wires, the devices can send data to each other without a DCS controller (host).

Fieldbus data transmissions have more information than just a single variable about temperature, pressure, or valve position. From the data shared between the devices, the devices can be configured to control the process. The host then only supervises the operation. This is called “Control in‐the‐field”.


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Fieldbus Components

H1 Interface Card Bulk DC Power Supply Fieldbus Power Supply Fieldbus Cable – Trunk and Spur Device Coupler with Junction Box Terminators Fieldbus Instruments

A Fieldbus segment’s wiring carries power to devices and signals between devices. The Fieldbus Segment typically consist of following Components;


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Fieldbus Components

H1 Interface Card and Fieldbus Power SupplyA DCS with an H1 interface is usually located in the control room. Its function is to oversee the operation of the control system, made up of the devices connected on the Fieldbus segment.

A DC bus voltage (nominally 24V but can be from 9‐32VDC) is supplied to the devices on the segment by a Fieldbus Power Supply. The Fieldbus Power Supply is needed to separate the bulk DC power supply from the Fieldbus wiring so that the signals are not absorbed by the bulk DC power supply. The Fieldbus Power Supply is normally installed near the control room but could also be located in the field or in a marshalling panel.


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Fieldbus Components

Fieldbus Power Supply

Fieldbus is required to be isolated from ground (to improve noise immunity). A DC power supply’s job is to regulate the output voltage (say at 24VDC). A Power Conditioner allows power to flow to the Fieldbus, but blocks the digital communication signal from flowing to the Isolator or DC power supply. It’s like a one way valve. A current limiter is provided in the Fieldbus Power Supply to prevent damage from a short‐circuit or over‐load condition.

Fieldbus Power Supplies with the Foundation™ Fieldbus checkmark should be used for Foundation™ Fieldbus as per specification FF‐831.


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Fieldbus Components

Fieldbus Cables - Trunk and SpurFieldbus uses shielded, twisted‐pair cable. A twisted‐pair is used, rather than a pair of parallel wires, to reduce introduction of external noise onto the wires. A shield over the twisted‐pair further reduces noise. The twisted‐pair wires, the shield, and their covering jacket are called a cable.

For reliable Fieldbus segment operation, use cable with the Foundation™ Fieldbus Checkmark, which demonstrates compliance with the FF‐844 standard (also known as Type A Fieldbus cable).


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Fieldbus Components

Device CouplersDevice Couplers are the industry‐standard method of wiring devices to a Fieldbus segment. Device Couplers provide short circuit protection that prevents the entire segment from failing if one device or Spur cable is shorted.

Two different types of Device Couplers are available

Non‐isolated Device Couplers are used in the majority of Fieldbus installations where isolation is not required. These installations are typically classified Division 2, Zone 2, or non‐hazardous.

Isolated Device Couplers are used where Isolation may be required for Division 1 or Zone 1, 0 hazardous area installations.

The pluggable screw terminal type Fieldbus Device Couplers make wiringeasier and more reliable. Only Device Couplers with the Foundation™ FieldbusFF‐846 checkmark should be used.


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Fieldbus Components

Device CouplersConnection Diagram Actual Connection


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Fieldbus Components

TerminatorsTwo Terminators are required at each end of the Trunk cable on each Fieldbus segment. Generally, one Terminator is at the control room end of the cable and the other Terminator is in the junction box in the field.

The Terminator can be a separate part, or it may be part of a Device Coupler or a Fieldbus Power Supply. The Terminator should be clearly marked so that it can be identified in an installed system.

A Fieldbus segment without two Terminators will not have the properly‐shaped signals. A segment with only one Terminator may appear to function properly, but will have distorted signals with increased amplitude.

A segment with three or more Terminators will have decreased signal amplitude, and devices may lose the ability to communicate with one another. An extra Terminator will typically cause a 300 mV drop in signal level and a missing Terminator will cause a similar increase.


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Fieldbus Components

Fieldbus Instruments - Field Bus SignalDevices on a Fieldbus segment transmit digital signals to each other over the same wires that power the devices. Each transmission on the segment is received by all devices. Only one device called as Link Master (LM) device on an H1 fieldbus determines which device may transmit next.

A DC bus voltage (nominally 24V but can be from 9‐32VDC) is supplied to the devices on the segment by the Fieldbus Power Supply. A Fieldbus device draws a constant amount of current when not transmitting. To transmit information, the device varies the amount of current it draws from the segment to create a signal “riding” on the 24VDC. Digital data is sent on the Fieldbus at a rate of 31.25 Kbits/second.


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Fieldbus Components

Fieldbus Instruments – Process Impulse Hook UpClose-coupled Hook Ups for mounting Fieldbus pressure instrumentation can Significantly enhanced measurement accuracy and deliver enormous advantages;

Eliminate impulse lines and connections

Simpler installation Reduced maintenance Reducing potential leak paths, Process is cleaner as well as safer, Making an environmentally

friendly choice.


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Why Fieldbus?Construction and Installation Benefits for EPC / End User

Many devices connected to single pair wire. Less wire, cables, fewer barriers, fewer panels Reduced control equipment, cards, power supplies. Powerful software configuration. Drag & Drop Technology. Plug & Play. Control in The Field. Less Control Room Equipment. Less Space Requirement.Reduced Installation cost….!


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Why Fieldbus?Operation Benefits for End User

Digital Communication. High resolution, Distortion free characteristics. MORE RELIABLE DATA FOR CONTROL. Control Residing in the Field Devices. Less chance of performance degradation. BETTER LOOP PERFORMANCE BETTER CONTROL. Easy Accessibility Increase monitoring, optimization, management. MORE EFFECIENT OPERATION.


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Why Fieldbus?Maintenance Benefits for End User

Self Test & Communication Capabilities Reduce downtime, Increased plant safety Self diagnostics will notify when a problem occurs MAINTENANCE CREW WILL HAVE ADVANCED INFO ON PROBLEMS Remote Maintenance Interchangeability Configuration, Calibration and Reporting from any office with NT computer REDUCED MAINTENANCE TIME REDUCE INVENTORY


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Why Fieldbus?Design and Engineering Advantage No need of JB ICTD, Marshalling ICTD, Control System ICTD, Loop Diagram

per Tag. They all are replaced with Fieldbus Segment Diagram.- Saving huge nos. of Deliverables and Activities.

Cable Schedule Design becomes easy. No need of Various types of Cables, Cables Nos., Various types Glands and accessories – Saving Huge nos. of man-hours on Bulk MTO preparation.

Saves Technical Evaluation of Bulk MTO Saves Procurement Time for Bulk Material

Fieldbus Design and Engineering activity is complex compare to Conventional 4-20 mA Design and take almost same manhours.

CTR


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Fieldbus – Business OverviewWhy it takes time to adopt Technology in India? System & Instrumentation Manufacturers (Vendors) EPC Companies / Consultancies End Users

In current industrial scenario, the pressure is overwhelming to perform, produce,deliver faster, better and cheaper. Fieldbus is perfect solution…!!The main hurdles in promoting Fieldbus are;

Competitive business Low Cost expectation

Vendors should take Lead and Organize Events to promote Technology!End Users should be Vendor Neutral and provide equal opportunities forall Vendors to create Healthy Competition!


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Fieldbus – Business Lifecycle

The Fieldbus Foundation strongly recommends having a knowledgeable and experienced engineering partner on how to execute Fieldbus project. .!

Fieldbus Business

OEM

EngineeringConsultant

Process &Power

EPC Contractor

Manufacturing Companies

Field InstrumentsSystem Vendors

Integrators

End Users

Promoters


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Fieldbus - Projects Types under EPC Contract and SoWProcess Types Continues Process - O&G, Chemical, Petro-Chemical, Water, Power etc. Batch Process – Pharma, Food & Beverages, Nylon & Tyrecord etc.

EPC Project Types and SoW Greenfield – Totally New plant – Low Risk and low Complex Brownfield – Expansion / Demo Mod Scope – Medium / Installed Base Pref. Revamping and Upgradation – Online replacement – High & Complex

Nearly over 20,000 FOUNDATION fieldbus systems installed around the world. Revamping and Upgradation Projects are in Boom!!Example – ONGC – BPA and BPB Turnaround project!!!


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Typical Project LifecycleIts very important to understand Project Lifecycle to promote latest

Technologies like Fieldbus for Process Industries,

Phase IFeasibility Phase

Phase IIConcept Phase

(Pre-FEED)

Phase IIIFEED Phase

The objective is to

demonstrate both technical and economic

viability.

The objective would be to

select the best option(s) and

further define to reduce risk and improve project cost estimate

accuracy.

A robust FEED will deliver the estimate for

final sanction together with

the documentation

for the next contracting

phases.

Phase IVDetail

Design

The FEED output will

enable procurement

activity to commence prior

to main EPC contract award.

Right time to consider Fieldbus


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Fieldbus Selection Criteria's1. Geographical Location / Local Approval and Vendor Support2. Process type – Batch OR Continuous / Hydrocarbon OR Water OR Other…3. Process Operation and Safety… i.e. Hydrocarbon OR Water OR Other…4. Process and Ambient Conditions5. Instrument Locations6. System Integration requirement7. End User Approval (O&M requirements and Training)8. I&C - Budget

Operation & Maintenance

Middle Management

TopManagement

EPC / Consultant(Design / Evaluation /

Order / Project Co-ordination)

Fieldbus Vendor(Training / Proposal / MAC-MIC Projects /

AMC)

End User


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Fieldbus with Hybrid Network - Selection StrategyWhite Paper on ONGC O&G Upstream Revamping Project by Mr. Raut

1. In some process the types of parameters to be monitored are of wide variety.2. In some cases fluids are not consistent in nature. 3. For some typical applications where special type of instruments have been

necessary and the manufacturers are yet to develop models with FF interface.4. In some cases (Revamping Projects) existing electronic devices are already in

existence and in operation, the signals have been interfaced either HART protocol or through RTU and MODBUS link with HOST system.

5. All digital inputs like – Rotating Equipment / Valve Status, Level Switch , Pressure Switch , Flow switch etc have been first interfaced with Digital I/O module and then to HOST controller through Profibus interface.

6. It is essential to select right types of devices to ensure reliable , consistent and trouble free operation

The Host system has been designed to support a hybrid network to accommodatedevices with 4-20 ma signal , HART signal , Profibus DP and FF signal , most ofthe filed devices ( around 90 % ) are with FF interface .


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Fieldbus with Hybrid Network SelectionSerial

no Parameters &application Instrument device Type of device

01 Well head pressure /temperature Pressure /Temperature transmitters with Radio telemetry

Radio transmitters powered with solar cell.

02 Flowing status of wells /flow rate Clamp on Ultrasonic flow meters FF / MODBUS device

03 Gas flow to dispatch header / gas flow from individual gas wells

Orifice meters (senior orifice fittings) with multiple sensors

FF device

04 Tank level indicators Guided wave Radar type level indicators

MODBUS

05 Line temperature of oil & gas line Strip type RTD device with filed transmitter

FF type

06 Water injection header flow rate Orifice meter /DP transmitters FF type

07 Gas lift header pressure Pressure transmitter FF type 08 Gas lift finger flow rate DP transmitter with P&T

compensation FF type

09 Test gas flow rate Senior orifice meter FF type 10 Effluent water dispatch meter Magnetic flow meter FF type 11 Mass flow meter for stabilized oil Coriolis meter MODBUS


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Fieldbus Detail Design under EPC Projects

I&C Detail Design Activities and Deliverables divided into Three Categories

Fieldbus Instruments Deliverables

Construction SoW and Deliverables

Control System Design

(DCS/ESD/F&G)

• P&ID’s – Instr. Inputs• Instrument Index• Field Instrument

Spec.• Calculation Sheet• Instrument Data

Sheet• Hook Ups• MTO• etc.

• SoW• Layouts• Cable Schedule• Hook Ups• Bulk MTO• JB & System Drawings• etc.

• SoW• ICSS System Specification• System Architecture• I/O List• Segment Diagrams• C&E Diagram• P&ID’s• Graphic Specification• System Drawings• etc.


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Fieldbus Enquiry from End User / EPCFieldbus Enquiry Package should have minimum following Information;

1. Scope of Work2. PFD’s (check Revision Status)3. P&ID’s (Check Revision Status)4. Process Operating Philosophy5. ICSS Specification / System Architecture / Utilities6. Field Instrument Specification7. Instrument Data Sheets8. I/O List and Alarm & Trip setting List9. Fieldbus Instrument Location Layouts10. Instrument Cable Routing Layouts11. Hazardous Area Classification Layout12. Control Room Layout13. Approved Vendor List


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Vendor – Typical I&C Activity Flow Chart

• FEED• Conceptual Design

• Tender

• Proposal• Detail Design• Enquiry Spec

• Order

• DCS / Safety• System Design

• H/W – S/W Design

Installation, erection, Calibration and

Commissioning of field Instruments and DCS/Safety/F&G System by EPC /

Instrument Contractor with System Vendor

• Installation• Erection

• Calibration• Commissioning

Detail Engineering Design for Field Instrumentation, Hardware and

Software, Networking, SCADA etc. by System

Vendor

Engineering documents are made For Technical and Commercial Offer

to win project and further (after getting an

Order) Detail Engineering Design

activity by EC or EPC and System Vendor.

Engineering documents are made For Technical

and Commercial Analysis

/ study purpose for Tender Enquiry. This

activity is mainly done by EC for End User or directly by End User.


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Fieldbus Proposal & Engineering - Important Tips for Vendors Vendor Engineering Team shall have thorough Knowledge of client / Local and

International Codes and Standards. Vendor shall know EPC Activities and able to read Deliverables like P&ID,

Process Philosophy, C&E, Layouts (Instrument/Piping/Mechanical) and Hazardous Area classification etc. to discuss project scope on same level.

Vendor – S&M team shall have Process Application and Multi-discipline Engineering knowledge (Only knowing Fieldbus and its Product Technical Specification is not enough to WIN and execute projects).

Vendor shall understand Project Phase, Project SoW and Client’s Techno-Commercial requirements before they submit their Proposal (that helps to WIN confidence level of Client’s Project/Instrument/ProcurementTeam)

Vendor shall approach with detail Fieldbus Implementation plan, its benefits, and after sales Support.

Vendor shall produce examples of detail Project Pay back period using Fieldbus with compare to Conventional System and produce Case Studies of critical process Application.


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Fieldbus Proposal from VendorVendor – S&M shall include minimum following Deliverables in Proposal

after Bid – No Bid decision

Fieldbus Technical Proposal Content1. Introduction2. Project Scope and about Proposal3. Details BoM in given format with Item code-Model / Description / Quantity4. System Architecture / Segment Design Procedure with sample layout5. List of Deliverables (Panel & Segment Drgs, Data sheets, Calculations etc.)6. List of Activities (Meeting, Site Visits, Configuration/FAT/SAT Support etc)7. ToC (Table of Compliance)8. Deviation List9. Assumption List10. Notes or Remarks if any11. Project Team Chart and Project Schedule12. EQC Criteria's (Case Study, Data Sheets, proof of Similar project experience)13. Fieldbus Instrument / Control System / Components - Product Manuals


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Fieldbus Design & Engineering Flow Chart

Design Strategy Levels

Facility & PlantLevel Activities

System Level Activities

Equipment Level Activities

Prepare Master DDRAnd Activity List

Prepare Project Schedule & Start

Activities

Deliverable Design and Quality Check

Client Approval and Release for “AFC”


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Fieldbus Design & Engineering Flow Chart

Design Strategy Levels

Facility & PlantLevel Activities

System Level Activities

Equipment Level Activities

Refer PFD, Study Process and Sub-Process, respective P&ID’s, It’s connectivity, Main Headers, Plant Interlocks (ESD / PSD) and main Controls,Highlight signals by different colors, Compare I/O List

Refer P&ID’s and Equipment List, study Process Operation, Check Interlocks (ESD / PSD) and Controls, Check Equipment & Boundary Limits Highlight signals by different colors, Compare I/O List

Check Overall System Requirement (ICSS). Check DCS interface with ESD / F&G and Third Party, Design System Architecture as per End Users requirement.


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Fieldbus Design Activities Design Activities by Vendor “Engineering Team” for MAC / MIC Contract

1. Study total Project SoW and Proposal submitted by S&M Team2. Understand entire Process and Purpose3. Site Visit / Collect data and prepare site Visit Report4. Carry out As-Built if necessary (exp. QP Offshore Project)5. Check Design Deliverables recd. From Client and revision6. Collect Company Specifications applicable for the project7. Understand Local/Company Codes and Standards8. Make List of Activities and Deliverables9. Prepare TQ list in the beginning and highlight missing part if any10. Confirm Scope and clarify responsibilities of other parties (OEM Interface /

Contractor Interface / Skid boundary limits).11. List points to discuss during KoM and highlight extra activities to be done

which is not defined originally in SoW. Clarify & get Client Approval12. Start Design and Engineering and get it approved from Client


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Fieldbus Design – Reference Drawings for Vendors1. Scope of Work2. PFD’s3. P&ID’s4. Process Operating Philosophy5. ICSS Specification / System Architecture6. Field Instrument Specification7. Graphic Specification / Alarm Priority Specification8. Instrument Data Sheets9. Equipment List10. I/O List and Alarm & Trip setting List / C&E Diagram11. Fieldbus Instrument Location Layouts12. Instrument Cable Routing Layouts13. Hazardous Area Classification Layout14. Control Room Layout15. Approved Vendor List


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Fieldbus Instruments Design Preparation

PT001

PICA001

I/P

PCV

FF

PCV-001

PT001

PZA001

HHH

ESDV-001

Fieldbus Loop SIS Loop

Refer Abbreviation and Symbol List of End User. Not from any other Project.

P&ID Mark up Mark up FF-DCS, SIL-ESD Instruments using different color Markers. Identify Digital signals to DCS using different color Markers. Update Instrument Index with Type of Instrument


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Fieldbus Instrument Design & SelectionFieldbus Instrument Selection and Data Sheet Preparation

Refer End User’s Field Instrument Spec. for Process and Utility, Process Connection, Instrument Application, Type, Selection, Installation etc.

Refer Instrument Index and identify type of field Instruments (Transmitters, Control Valves, Switches, MOV’s, ESDV’s etc.)

Identify Fieldbus Approved Devices and 4-20mA, HART for some typical applications where special type of instruments have been necessary and the manufacturers are yet to develop models with FF interface.

Check Process Data (from Process Dept.) Body and Wetted Part MoC Power Supply / Signal Type IP Rating / Hazardous Area Class / NACE if required Process Hook Up Electrical Hook Up Installation Material Select Field Instrument Model No.

• Instrument Data Sheet

• Area Class & IP• Hook Up


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Fieldbus Segment Design

03PT021

03PIRCA

021

Area/Sub-Area Code

Instrument Tag Function in System (Pressure, Indication, Recording, Control and Alarm)

Instrument Sequential Tag No.

Instrument Type (Pressure Transmitter, FT, LT, TT, AT, QT)

Area/Sub-Area Code

To 03-PCV-021(Pressure Control Valve)

PCV

Instrument Sequential Tag. No.

I/P

H

L

FC

FF


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Fieldbus Segment Design1. Check and Mark Main Process and Sub Process areas on the P&ID2. Refer Instrument location layout and check Control Room distance from

each Sub Area.3. Refer Hazardous Area Classification Layout and identify Hazardous and

Non-Hazardous Areas and its classification OR refer Instrument Data Sheets

4. Check and Club Instruments Segment on Instrument Location Layout. Verify Process Operation Requirement.

5. Initially club 12 Open loops and max. 4 closed loops per segment 6. Identify Fieldbus JB strategic location and Mark it on Instrument Layout7. Check Spur and Trunk Routing to-fro JB 8. Refer Piping Isometric / Mechanical Layouts to check spur length9. Refer PDMS Layouts (if available) for elevations and nozzle orientation to

measure vertical spur length10. Check and discuss Fieldbus cable routing with Electrical and follow

Company Design guidelines


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Fieldbus Segment Design1. Check and discuss Field Cable routing with Civil for excavation, road /

Pipeline crossovers, Cable Tray routing and supports2. Ensure the total Segment length (Trunk + Spur) should not cross

1900mtrs. for type A cable3. Prepare Segment Diagram with Instrument tag no. / spur no. / Fieldbus JB

no. / Trunk no. and give tag nos. to all components as per company Tagging Philosophy.

4. Prepare ICTD for each Segment - Fieldbus JB with Polarity, Terminal nos., wire color code, spur nos., trunk nos. and Components nos.

5. After Self and Discipline check, issue it for AFC 6. Vendor has to refer Segment diagrams with AFC Revision for Fieldbus

Configuration and Verify lengths and Node Voltage is within acceptable limits. In case of deviation, Vendor to mark addition or deletion of fieldbus Instrument on Segment Diagram and Consultant has to re-Design and issue Segment Diagram for AFC with next Revision. This activity to be done jointly by Vendor and Consultant or End User.


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Fieldbus Segment Design - Reliability ConsiderationsSince Fieldbus uses shared wiring, reliability precautions need to be taken for

segments used in critical applications.

The shared wiring and the Fieldbus Power Supply are critical resources, because all the devices share the same cable and power supply. If these fail, then the whole segment is inoperative. The main Fieldbus reliability issues are:

Spur short circuits – New Instr. & Spur Install / Instr. Service / Waterlogged Trunk failures Power failures Surges Segment monitoring


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Fieldbus Segment Design - Reliability Considerations

Spur short circuits Reasons:

• New Instrument Installation• New Spur Installation and connection• Instrument Maintenance• Instrument get Waterlogged

Design Consideration:Use Device Coupler with built in Current between the Trunk and the Spur cable. The current limiter only allows a given amount of current to be used by each device. If a Spur is shorted, the current will be limited within a few microseconds. Only the shorted device is affected; the rest of the devices continue to operate.


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Trunk Cable failures :• Trunk get cut during excavation• Can get damaged due to Overheat• If bend above bending radius• Accidentally due to sharp object during

construction

Design Consideration:The Trunk cable needs to be protected in a conduit or a sturdy cable tray with proper supports. This activity to be done in co-ordination with Civil for main Cable Racks and for cable routing along with the Main pipe racks. Also Keep sufficient distance from Electrical cables trays to avoid Electromagnetic interference.


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Fieldbus Segment Design - Reliability ConsiderationsPower Supply failures :If Fieldbus segment power fails, the entire Fieldbus segment is taken down and control is lost.

MTTF of the components of a Redundant Fieldbus Power Supply.

The Availability for a Fieldbus segment due to the redundant FPS system can be 99.9999989% or even higher. This means that a Fieldbus system could be down due to redundant power supply failures on average for 0.3 seconds/year.

Design Consideration:The Power Supply failure issue can be solved by using Redundant Power Supply with Alarm signal to be connected to DCS to notify the Operator.


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Fieldbus Segment Design - Reliability ConsiderationsLightning Surges:

There is no protection against a direct lightning strike. The energy involved is too great. The struck device simply disintegrates. Lightning strikes also have effects at great distances from the strike point.

Since many Fieldbus devices share the same cable, a lightning surge can adversely affect all of them by breaking down the electrical isolation of Fieldbus devices.

Design Consideration:For further information on Surge Protection, always refer technical data available from manufacturers of Surge Protection equipment for Fieldbus. Note that it is important that the Surge Protection devices are specifically designed for Fieldbus..


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Segment reliability can be improve by continuously monitoring the segment to get early warning of potential issues. Diagnostic products are available to monitor:

DC voltage Device signal levels Noise levels Shorts to the shield Communication health

This information can be tracked by the asset management system for trend analysis. With this information, it is possible to reduce the number of unexpected failures.

Segment Reliability - Design Consideration:


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Fieldbus Design for Hazardous AreasFieldbus Design and Installation in Hazardous areas involves detail study of company policy, Process Safety and an analysis of the benefits and costs of each option. Special installation and design practices may need to be followed for the hazardous area.

Exp. Gas Compressor Hazardous Class. in• Open Area Installation• In Building

Design Reference Drawings: Company Design Standards Hazardous Area Classification Layout Hazardous Area Classification Chart Instrument Location Layout (Scale Drg) Instrument Data Sheet and P&ID’s


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Fieldbus Design for Hazardous Area – Zone 2Zone 2, a non‐Arcing method of protection means that the wiring and electrical apparatus do not generate sparks or hot surfaces that could cause an ignition under normal operating conditions. In this case, the wiring must be adequately protected to prevent open, shorts, and grounding. Can not work ONLINE (when Power is ON). Required HOT permit to ensure no hazardous gases are present.Zone 2, “High Energy Trunk” method is used when the Trunk carries an incendive level of power and must be protected as in the non‐Arcing case, but the Spurs are energy limited by the Device Coupler to limit energy on spure and Fieldbus device. Due to High Trunk energy it is common to use Redundant PS for high reliability.Due to the high power on the Trunk, the number of devices and length of the segment are not limited being in the hazardous area. Can work ON Line without HOT permit.


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Fieldbus Design for Hazardous Area – Zone 2Zone 2, Fieldbus Power Supply certified as FISCO device (Fieldbus Intrinsically Safe COncept). Its output is limited in energy such that a short, open, or grounding of the wiring will not cause an ignition in the presence of hazardous gases. So, in this case, the entire segment is energy limited. This has the advantage of being able to live work the entire system. The disadvantage is that, because of the limited energy, the cable length will be shorter than the previous methods discussed, and the number of Fieldbus devices on the segment will be less.


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Fieldbus Design for Hazardous Area – Zone 0 / 1Increased Safety method is a non‐Arcing technique for Zone 1. Since gases are more likely to be present in Zone 1 than in Zone 2, the requirements on the equipment certified and installed under Increased Safety are higher to reduce the Probability of an ignition. If the Zone 1 certification requirements are met, the Fieldbus segment is installed as if it were non‐hazardous.

High Energy Trunk for Zone 1 has an incendive‐level trunk which is installed using Increased Safety techniques. The segment contains an Isolated Device Coupler, as Fieldbus Barrier, in the field to separate the Trunk from the Spurs (Galvanic Isolation). The Spurs are then Intrinsically Safe (entity or FISCO).

The Trunk cable, however, cannot be live worked, and requires HOT permit before any work is done. The Fieldbus devices and the Spur cables may be worked without permit (subject to Company Safety Policy).


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Fieldbus Design for Hazardous Area – Zone 0 / 1Using FISCO (Fieldbus Intrinsically Safe COncept) method both the Trunk and Spurs are protected by a FISCO Fieldbus Power Supply that limits the energy to meet the Zone 1 requirements. the advantage is that the entire segment (beyond the FISCO supply) may be live worked. A Redundant FISCO Supply is available to improve system availability.


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Fieldbus Installation Check List1. Strictly follow Company Installation Guidelines, if not available follow Fieldbus

Foundation Guidelines.2. Check inside the field device against sour, corrosion, water, etc. before

Installation also check Instrument Tag plate for Range and model no. against Data Sheet. Check firmware has any bug or malfunction during callibration.

3. Use “Company’s” Process Hook Up Standard – Project Drawing for Process Connection against each Tag no. carefully.

4. Check Direct / remote Installation on 2” pipe.5. Use Type A Fieldbus cable. Check Fieldbus Checkmark. Use proper gland.

Check termination, Ferrules with Polarity, Shield.6. Refer Segment Drawing and check all Fieldbus devices, Spures, Trunks, JB,

Fieldbus Components with Tag nos.7. Check Fieldbus Trunk and Spure cable route. Keep distance from Electrical

cables as per Company Standard.8. Check Function Blocks sheet for each loop; Once device is correctly

configured information must be stable and consistent to process current; check online parameters and also quality (good, bad) directly at FB´s.


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Fieldbus Installation Check List1. Strictly follow Company Installation Guidelines, if not available follow Fieldbus

Foundation Guidelines.2. Check inside the field device against sour, corrosion, water, etc. before

Installation also check Instrument Tag plate for Range and model no. against Data Sheet. Check firmware has any bug or malfunction during callibration.

3. Use “Company’s” Process Hook Up Standard – Project Drawing for Process Connection against each Tag no. carefully.

4. Check Direct / remote Installation on 2” pipe.5. Use Type A Fieldbus cable. Check Fieldbus Checkmark. Use proper gland.

Check termination, Ferrules with Polarity, Shield.6. Refer Segment Drawing and check all Fieldbus devices, Spures, Trunks, JB,

Fieldbus Components with Tag nos.7. Check Fieldbus Trunk and Spure cable route. Keep distance from Electrical

cables as per Company Standard.8. Check Function Blocks sheet for each loop; Once device is correctly

configured information must be stable and consistent to process current; check online parameters and also quality (good, bad) directly at FB´s.


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Fieldbus Standards – Let’s make it Better….!!!


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“FOUNDATION™ Fieldbus Engineering for Process Automation” by Sachin Rasane

fieldbus presentation

Documents