Foundation Fieldbus Implementation. EPCM Perspective. Rajiv Gupta. 28 November

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1 Foundation Fieldbus Implementation EPCM Perspective Rajiv Gupta 28 November

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

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

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

CABLES SEGMENT DESIGN FIELDBUS JUNCTION BOX PACKAGE PHILOSOPHY INTEGRATED ASSET

4 FIELDBUS in Instrumentation Design Basis 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 28 November

protection for Fieldbus: IS (Entity), FISCO, FNICO (or FISCO ic), High-powered

5 WHERE TO USE FIELDBUS 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. antisurge 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 28 November

) Fieldbus devices shall not be used in special loops e.g. antisurge control etc.

6 Showing FIELDBUS in P&ID s A different line style/solid bubble is used for the connection between fieldbus devices 28 November

7 Showing FIELDBUS in P&ID s ISA includes depiction of FF which is expected to be adapted universally 28 November

8 FIELDBUS FIELD DEVICES 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 28 November

Certification code for hazardous area protection Function blocks requirement Function blocks

9 HOST SYSTEM 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 28 November

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

10 FFPS (POWER SUPPLY for FF) 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 28 November

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.

11 FFPS (POWER SUPPLY for FF) 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 28 November

with common Bulk Power Supply feeder Failure or faults in any of the redundant FFPS shall be

12 FIELDBUS CABLES Cable type A as per IEC 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 28 November

Recommended colour: For intrinsically safe (entity) and FISCO application: Orange with blue longitudinal stripes.

13 SEGMENT DESIGN 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. 28 November

), FFPS Specifications Cable specifications (particularly loop resistance in case of FISCO/ FINCO / High powered trunk applications).

14 PROCESS CONSIDERATIONS 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 28 November

Devices used for same functions in same location/ equipment on

15 JUNCTION BOXES 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 28 November

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

16 PACKAGE PHILOSOPHY 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. 28 November

Package vendor/ contractor shall furnish the number of segments and provide all internal hardware for the

17 EIL experience in FF engineering 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 28 November

trunk, higher distance of field devices. EIL has implemented Control in Field 12 spur FFJB to have identical design and optimum size of FFJB.

18 EIL experience in FF engineering 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. 28 November

Few spare segment cables laid to accommodate additions during commissioning Integrated Asset Management System for advanced

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

data/web download and actual supply Mismatches between FF and Non FF during loop modifications, HAZOP.

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

diameter of trunk cables results in ease of construction, faster construction and more space in duct/trays/mct s, also adds

21 THANKS 28 November

R4D0-FB-IA* FieldBarrier. Features. Assembly. Function. Connection IN + - S OUT ... ... Spur 2. Spur 1. Zone 1. Zone 0

R4D0-FB-IA* FieldBarrier. Features. Assembly. Function. Connection IN + - S OUT ... ... Spur 2. Spur 1. Zone 1. Zone 0 FieldBarrier Features Assembly 8... 12 outputs Ex ia IIC, FISCO and Entity Advanced fault isolation and diagnostics at the spur FieldBarrier in Zone 1/Div. 2 Instruments in Zone 0...1/Div. 1 For FOUNDATION