3 - Fieldbus Foundation

Transcription

Fieldbus Foundation – India End User Committee
Foundation Fieldbus Technology
Engineering Advantages
Mistry
y Harendra G.
Chief Engineer – Instrumentation
Tecnimont ICB Pvt. Ltd., Mumbai, India
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© 2009 Fieldbus Foundation
Projects phases

Feed Engineering Phase
Detail Engineering and Procurement Phase
Construction Phase
Commissioning phase
Operation phase
Maintenance phase
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Requirement from Technology

Maximum number of devices per segment
Maximum cable length
Minimum number of hardware
Minimize wiring and installation time
Minimize cable tray requirements
Minimize control room space
Interoperability
More self-diagnostics
self diagnostics information sho
should
ld be a
available
ailable
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Different systems
Generally rules followed in projects…..
Monitoring loop and Simple close loop FF type
Complex / Critical loop
loop, ESD system
system, BMS loops
loops, Rotary machine
protection system should be 4-20 mA (i.e. Non-FF) conventional type.
Oye…Two different system !!!!!!
How to get defined benefits from Technology?.....
….Will it be really economical?.......
..........What to do?......How to do?.....
……Where to go?...........
4-20 mA
FF
4-20 mA devices…………
…FF devices………field…
……DCS……..HART……
……xx….?????......
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Foundation Fieldbus Engineering

Hardware Engineering
Software Engineering
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Hardware engineering

Selection of Foundation Fieldbus type
Fieldbus topology
Hardware redundancy
Segment loading (design)
Segment hardware planning
Testing Kits / Maintenance tool / Calibration tool
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Foundation Fieldbus Types
General Purpose (Safe) Fieldbus
Energy
gy Limited Fieldbus
Intrinsically safe (Entity)
Intrinsically safe (FISCO)
Non-Incendive
Non Incendive (FNICO)
High Power Trunk (HPT) Fieldbus

HPT Fieldbus for Zone-1
HPT Fieldbus for Zone-2
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General Purpose (Safe) Fieldbus
Control system
FF power
supply
Redundant FF power supply
Trunk
Control Room
Field
Safe Area
TRUNK IN
TRUNK OUT
WIRING HUB
Ch-1
Ch-2
Ch-3
Ch-4
Ch-5
Ch-6
Ch-7
Ch-8
Spur
FF Fieldbus devices
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Energy limited Fieldbus - FISCO Concept
Control system
FISCO power
supply
Redundant FISCO power supply
Live workable
Ex i trunk
Zone 1 / Div 1
Hazardous Area
Control Room
Field
TRUNK IN
TRUNK OUT
WIRING HUB (FISCO)
Ch-1
Ch-2
Ch-3
Ch-4
Ch-5
Ch-6
Live-workable
Ex i spurs
FISCO Fieldbus devices
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Energy limited Fieldbus - FNICO Concept
Control system
FNICO power
supply
Redundant FNICO power supply
Live workable
Ex nL trunk
Zone 2 / Div 2
Hazardous Area
Control Room
Field
TRUNK IN
TRUNK OUT
WIRING HUB (FNICO)
Ch-1
Ch-2
Ch-3
Ch-4
Ch-5
Ch-6
Ch-7
Ch-8
Live-workable Ex nL
spurs
FNICO (Ex nL) or FISCO (Intrinsically Safe) Fieldbus devices
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High Power Trunk Fieldbus : Zone-1
Control system
Zone 1/ Div 2
Hazardous Area
FF power
supply
C t lR
Control
Room
Field
High energy
Ex e trunk
Fieldbus
Barrier-1
Zone 1/0
Division 1
Hazardous Area
Fieldbus
Barrier-2
Fieldbus
Barrier-3
Exe Junction box
Live-workable
Ex i spurs
FISCO or Entity fieldbus devices
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High Power Trunk Fieldbus : Zone-2
Control system
FF power
supply
High Energy
Ex nA trunk
Zone 2
Division 2
FIELD
TRUNK IN
TRUNK OUT
WIRING HUB Ex nA(L)
Ch-1
Ch-2
Ch-3
Ch-4
Ch-5
Ch-6
Ch-7
Ch-8
Live-workable Ex nL
spurs
Ex nL or Intrinsically Safe Fieldbus devices
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Hardware Redundancy

Redundant Power supply

Redundant Foundation fieldbus Power conditioner
Redundant system controller power supply
Redundant Bulk Power supplies
Power feeder to bulk power supply

Redundant system controllers
Redundant Foundation Fieldbus H1 card
Separate back plan for redundant hardware
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Segment Design
Constraints

Field bus for safe / Hazardous area
Voltage drop calculation
Current calculation
Spare capacity
Signal attenuation calculation
Segment execution time.
Segment criticality Rating
ITB specific requirements/ end user
requirements for control loop loading.
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Hardware planning

H1 card quantity
FF Power supply conditioner card quantity
FF Cable quantity
Number of FF junction box (Assembled)
FF termination block / FF Barriers Quantity
Surge protector quantity
Terminators quantity

Hardware for Online diagnostics

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Testing kits / Maintenance Tool / Calibration Tool
Fieldbus Diagnostics monitor
Fieldbus Power and signal Probe
Fieldbus Wiring Validator
Fieldbus monitor
Field Communicator
FF device Calibration Tool
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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
Multi-variable optimization
Advanced diagnostics configuration
Alarm and Alert configuration for better operation
•

I
Improve
quality
lit and
d productivity
d ti it
Redundant Link Active scheduler (LAS) configuration
Segment execution time configuration
All selected software shall be of latest revision
Asset management software configuration
•
•
•
•
•
•
Predictive maintenance
Reduce time to repair
Root cause identification and elimination
Avoid failure
Reduction in Inventory cost
Centralized maintenance
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Engineering Tips for Economical benefits

Maintenance / calibration tools or HHC, Valve signature software
should be common for FF and 4-20 mA HART based system
C
Common
h
hardware/software
d
/ ft
system
t
for
f FF and
d 4-20
4 20 mA
A IInstruments
t
t
Select instruments with FF check mark logo
Selected hardware should have Interoperability
Never start work without a comprehensive plan.
Avoid uneconomical decisions and changes in philosophy during
detail engineering
g
g
Atleast One Engineer to be trained at system vendor place for
commissioning activities.
Regular training to team and knowledge share
Develop procedures and knowledge base for future
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CASE STUDY
Example
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Case Study - Example

Analogue Input (AI) = 1000
Analogue Output (AO) = 100
Intrinsically safe system suitable for Zone-1 IIA/IIB T3
High Power trunk concept (with IS Field barriers) fieldbus system
Cable length between junction box and control room is 300 mtrs
Control loop I/O card, FF H1 card, Segment power supply module are
redundant
DCS Vendor engineering hrs same for FF or HART system
Branch cable and spur cable length not considered for comparison
All transmitters are normal DP flow / Pressure / Level / Temperature
transmitter.
transmitter
Asset management software shall be installed in DCS. No separate system.
Cost of MCT, cable gland not considered for cost comparison
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CAPEX : Material cost (Case Study Example)
Description
Unit
Rate $
Qty
4-20mA
HART $
Foundation
Fieldbus $
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)
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M h lli and
Marshalling
d I/O card
d Cabinet
C bi t (HART)
14
2083
4
2083
8349
1100
65
71500
Junction Box (HART)
138
828
FF Junction
J
ti Box
B
with
ith 3 I.S.
I S Barrier
B i (Pre-wired)
(P
i d)
138
2708
Cable (12 Pr x 0.5mm²) - HART
41250 m
10
Cable (2 Pr x 1.5mm²) - FF
41250 m
3
117266
1
1801
1801
System Cabinet (FF)
Field device (FF additional cost)
HHC (FF addional cost)
Ph i l llayer ttesting
Physical
ti ttools
l
Saving
with FF
81120
29655
+ 17 %
113850
372396
411568
1 sett
736
Total
962254
798310
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CAPEX : Installation cost (Case Study Example)
Description
Termination : 4-20 mA Signal wires (HART)
Unit
Rate $
Qty
23100
6
7425
6
14
677.96
4
977.96
Cable pulling – 12 pair – Home run - HART
41250
3.67
Cable pulling – 2 Pair – Trunk - FF
41250
2.85
Main cable tray – 600 mm – HART (with Material)
300
34.20
Main cable tray – 300 mm – FF (with Material)
300
27.72
Termination : FF signal wires (FF)
Cabinet Installation - HART
Cabinet Installation - FF
Total
4-20mA
HART $
Foundation
Fieldbus $
Saving
with FF
138600
44550
9650
2717
+ 42 %
151388
117563
35117
28548
334755
193378
Control room size reduction is approx. 12 Sq. meter
Assumptions :
Branch cable tray quantity and size same for FF and HART tags
tags.
FF/HART junction box installation cost is same.
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CAPEX : Commissioning cost
Description
Days
Per Day
Rate $
HART System Loop checking and commissioing
3 Technician @ 15 loops in 10 hrs
74
300
FF System Loop checking and commissioing
1 Technician + 1 engineer @ 10 segment in 10 hrs
14
1100
Total
4-20mA
HART $
Foundation
Fieldbus $
Saving
with FF
22200
15400
22200
+ 31 %
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.
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Q
Questions
ti
?
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