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KEYWORDS
Fieldbus, Fieldbus Control System, Fieldbus instruments, Segment Drawing, Fieldbus configuration, Fieldbus specification, Fieldbus engineering, Fieldbus troubleshooting, Fieldbus Commissioning.
ABSTRACT
The growing industry acceptance and lifecycle benefits of Fieldbus technology have made its consideration mandatory when planning a new or upgraded control system installation. However, there are important issues, such as troubleshooting, design optimization, and end user acceptance, which need to be addressed and resolved during the project cycle, for the benefits of the technology to be fully realized. This paper makes key engineering recommendations, and offers guidance for an efficient and safe implementation, of an H1 Foundation Fieldbus System, based on experience from a recent application on a natural gas processing plant.
INTRODUCTION
Foundation Fieldbus technology is designed to provide a digital, twoway, multi-drop communication link between field devices such as sensors, transmitters, actuators, and controllers, and various operator, engineering, and maintenance interfaces. The existing literature contains many technical papers on Foundation Fieldbus technology, with most of them emphasizing particular benefits and successful case studies. However, the application reality is that the technology is still in a state of evolution. Many experienced engineers now find themselves taking incremental steps, trying to understand and master this new digital technology. The intent of this paper is to contribute in this process by sharing our Copyright 2004 by ISAThe Instrumentation, Systems and Automation Society. Presented at the 14th Annual Joint ISA POWID/EPRI Controls and Instrumentation Conference, 47th Annual Power Industries (POWID) Conference; www.isa.org
experiences with other engineers who may be facing the practical application challenges of a Fieldbus system implementation.
Loop check Device configuration download 5. Maintenance Shop Fieldbus System and Tools Cost of hardware , software, and auxiliary equipment devices. Fieldbus tools such as handheld devices and Fluke 1,2,3.
6. Spare Parts Stocking costs for Foundation Fieldbus instruments and non-Foundation Fieldbus instruments Management, tracking , and software upgrade of Foundation Fieldbus instruments. The most significant savings can be achieved only if the end user is able to establish an effective maintenance and asset management program. When evaluating overall costs, manufacturers specialist fees and training costs should be included for the asset management program implementation. Other benefits, such as interoperability, greater system functionality, plug and play, common look and feel, are not typically converted into cost savings, but should also be considered when evaluating the need for the technology. Unfortunately Foundation Fieldbus benefits are not necessarily extended to the design-engineering phase since the engineers prime concern is to perform well, on schedule, and within budget. Developing a new design philosophy will add risks to the job. Implementation of Foundation Fieldbus technology will require training of the engineering team. The engineer should evaluate the resources available, such as tools, standards, availability of skilled people, project schedule and budget before recommending implementation of Foundation Fieldbus. The technology should be implemented only when the proper resources are available or when mandate by the end user. The end user should be aware that asset management implementation is usually not included in the engineering scope of work, and if required, the engineering scope of work should specifically include this effort. Any doubts about the technology should be addressed up-front. An informed end-user will guarantee a successful implementation. If the end-user has no specific plans to take advantage of the Foundation Fieldbus capabilities, such as through asset management, it may not be possible to achieve significant savings or successfully realize the benefits of the technology. In this case the project may be better served with a conventional analog system. Copyright 2004 by ISAThe Instrumentation, Systems and Automation Society. Presented at the 14th Annual Joint ISA POWID/EPRI Controls and Instrumentation Conference, 47th Annual Power Industries (POWID) Conference; www.isa.org
CONTROL ARCHITECTURE
Foundation Fieldbus architecture specifies two types of network segments HSE and H1 links. HSE is in the early stages. HSE interfaces take full advantage of the low cost and ready availability of commercial off the shelf Ethernet technology and runs at 100 Mbits/ or higher. Segment configuration execution speed should be carefully estimated during Fieldbus segment design and configuration. The number of data transmissions over the bus will be reduced to a minimum if excessive number of control function blocks is implemented on the field devices. Spare capacity should be adequate to meet unforeseen changes and future needs. The control system supplier should play a critical role in the Control Architecture design and should be involved at the very earliest moment of the design. The E&C engineer should keep in mind that the vendors priorities may not match his/her own, and that in the end the control architecture is the engineers responsibility. The vendor should agree with the engineers architecture, or propose an alternative. The engineer should not hesitate in requiring the vendor to guarantee the system performance as long as the vendor had the opportunity to participate in the design.
Copyright 2004 by ISAThe Instrumentation, Systems and Automation Society. Presented at the 14th Annual Joint ISA POWID/EPRI Controls and Instrumentation Conference, 47th Annual Power Industries (POWID) Conference; www.isa.org
1. Does the control system use open scaleable system architecture that can deploy commercial software standards such as OPC (OLE for Process Controls) and ODBC (Open Database Connectivity)? 2. Does the Control System use Open Network protocol? The engineer should be aware that an open network protocol must have all the layer defined by an open standard and that a Ethernet protocol is only related to the first two layers of any protocol, therefore it can be also proprietary.(1) 3. How easy and cost effective can the system migrate existing or third party control products? Does the vendor offer a migration plan for future updates?(1) 4. Does the system support Fieldbus bridges on both H1 and HSE? Foundation Fieldbus bridges define how the devices in different ports can communicate to guarantee full plant integration. Some systems will have the communication inside their proprietary CPU, no guaranteeing the FF (1) schedule, the control performance and the openness of the system. 5. Is there any license policy to run function blocks in the process control station?(1) 6. Can it support redundant Fieldbus interface modules connected to the same Fieldbus H1 port? (1) Are they treated redundantly? . 7. Is there any known issue in the system? If yes how would they affect the control system performance? 8. Does the system accept both Fixed Fieldbus function blocks and instantiable Fieldbus Foundation Function blocks? (Fixed Foundation Fieldbus is defined where the block is always present, in fixed quantities, running all the time. Devices with instantiable blocks have a library of block types that can be executed inside of the device).(1) 9. Can any power supply be used in the system or only special brands? What are the minimum requirements? 10. What kind of Fieldbus barriers for IS applications does the system use? How many devices can be connected to each safety barrier? Do we need to use a repeater connected to the safety barrier or is it already embedded in the barrier? 11. How many devices can be connected per Fieldbus segment? How many devices can be connected in one Fieldbus interface module? 12. How many back-up masters can be configured in one segment? Is there any restriction? 13. Does the system accept any Fieldbus approved device with no restriction? Does the system have a list with approved devices to guarantee a smooth integration? 14. If a listed device presents problems would the manufacturer offer support? 15. Does the system take full advantage of the Fieldbus technology? Or it is more like an old DCS with Fieldbus communication?(1) 16. Can the manufacturer supply any reference from existing users? 17. How the vendor handles future upgrade revisions? The Control System must be kept current to assure it will work with new Foundation Fieldbus instruments revisions and the current revision level has to be backwards compatible with older Foundation Fieldbus Instruments. Copyright 2004 by ISAThe Instrumentation, Systems and Automation Society. Presented at the 14th Annual Joint ISA POWID/EPRI Controls and Instrumentation Conference, 47th Annual Power Industries (POWID) Conference; www.isa.org
14. Does the device have an automated software wizard to allow easy setup and calibration from the host system? 15. Can the device be field calibrated? If yes, how? 16. How does the vendor handle firmware updates? Is the vendors presence required to update the software? 17. Does its guarantee include interoperability with other Foundation Fieldbus approved devices? 18. Does the instrument operation and installation manual include Fieldbus configuration and start up sections? 19. Does the device have any reset capabilities? If yes, how it is done? 20. Can the instrument be bought pre-configured? Fieldbus instruments should be sized and specified in basically the same way as conventional instruments, but some additional features are required. As a minimum , Foundation Fieldbus instruments shall have the following features: 1. 2. 3. 4. Foundation Fieldbus Certification Function blocks shall be downloadable into the devices by the end user. User shall be able to download upgraded revision into the devices Instrument shall be capable of performing continuous diagnostics , including self-tests function and to provide specific diagnostic information to the host system. 5. Fieldbus instruments shall have automated software wizards to allow easy set-up and calibration.
Copyright 2004 by ISAThe Instrumentation, Systems and Automation Society. Presented at the 14th Annual Joint ISA POWID/EPRI Controls and Instrumentation Conference, 47th Annual Power Industries (POWID) Conference; www.isa.org
FIG.2 (2)- TREE TOPOLOGY Following are some recommendations for segment design: 1. The segment design should be defined at a later stage in the project after the control strategy is defined, the P&IDs consolidated, and the instruments selected and located. 2. When designing the topology the engineer should also consider the construction schedule. Wiring of new devices can disturb the segment and cause countless frustrations during commissioning. 3. We recommend that at least one instrument on the segment has to have Backup Link Active Scheduler (LAS) capability. The instrument used as LAS backup should have a monitoring function only. The LAS backup should be identified on the segment drawing. 4. Redundant process measurements shall be on separate H1 segments. 5. Limit the number of devices per segment as follows: (5) For segments with only monitoring instruments, limit segment to 12 devices. Segments should not contain more than (4) control valves or damper actuators. For loops requiring 1 or 0.5 second execution time, limit segment to 8 devices For loops requiring 0.25 second execution time limit segment to 3 devices with a maximum of one final control element 6. The segment designer should follow closely the vendor wiring recommendations. Special attention should be given to installation limitations, such as spur length, number of instruments per barrier and segment, power draw, number of VCRs, grounding, shielding, and polarity. 7. All function blocks shall reside on the same segment if the PID function is implemented on the field device 8. Access the need for individual short circuit protector for each segment. Access risk area and I/O group segregation. Copyright 2004 by ISAThe Instrumentation, Systems and Automation Society. Presented at the 14th Annual Joint ISA POWID/EPRI Controls and Instrumentation Conference, 47th Annual Power Industries (POWID) Conference; www.isa.org
11. Limit periodic writes to Static or Non-Volatile Parameters Fieldbus devices have a non-volatile memory write limit which can stop its operation after the limit is reached. (3) 12. Before starting the configuration, make sure that all the known issues for the devices were considered. 13. Use valid units and XD_Scale. Engineers shall be aware that each Fieldbus instrument only supports certain engineering units. 14. Make sure that the device description files and capability file are available for each instrument revision. 15. Test graphic faceplates during FAT. Some Fieldbus instruments may require a different faceplate. 16. The control strategy should be implemented such that a PID output of 100 % always means that the valve is open, independently of the actuator being air to open or air to close. 17. Execution speed, advanced diagnostics, failure mode, and operator access should be considered when locating where the PID block resides. 18. When all function blocks of a PID loop cannot reside on the same segment, the PID control shall reside in the host system. 19. When the PID function resides on the field device, it should be located in the final control element
FE 001
IA
FY 001
FF FCV 001
FIG. 2 FIELDBUS LOOP ON P&ID DRAWING Copyright 2004 by ISAThe Instrumentation, Systems and Automation Society. Presented at the 14th Annual Joint ISA POWID/EPRI Controls and Instrumentation Conference, 47th Annual Power Industries (POWID) Conference; www.isa.org
2. Datasheets Instrument datasheets should include the classical information but also the information required by the Fieldbus device specification. Our recommendation is to maintain the traditional ISA type datasheet and to add a second page with the following Fieldbus requirements: LAS capable ( Yes/ No) Minimum Operating Voltage Quiescent Current Draw (mA) Polarity Sensitivity ( Yes /No) DD Revision Level Channel Numbers and description Function blocks available Number of VCR parameters 3. Logic Drawings the self-documenting features of the control system should replace this document. Try to use the self-documentation feature as much as possible. 4. I/O List - If possible the engineer should import the project I/O List or the Instrument Index to the control system database. Working on a common database will reduce the chances of mistake during design. 5. Location Drawings are required (three dimensional location is preferred). This document shall be as accurate as possible and must be available as early in the project as possible, since it is necessary to the design of Instrument Segment Diagrams. 6. Instrument Segment Diagram (ISD) Loop Drawings - When a loop is contained on a H1 segment loop drawings should be replaced by segment drawings. When loops are on multiple segments or contained conventional I/Os a traditional loop drawing is required in addition to ISD drawings. If loop drawings are mandated, segment drawings should be also issued. If only individual loop diagrams are used technicians could be misled into believing that disconnecting would only affect the single loop. Figure 3 shows a segment drawing using a chicken foot topology. Additional information such as trunk and branch length, current draws and device configuration could be added. Soft data and configuration data are not shown on the ISD diagram.
Copyright 2004 by ISAThe Instrumentation, Systems and Automation Society. Presented at the 14th Annual Joint ISA POWID/EPRI Controls and Instrumentation Conference, 47th Annual Power Industries (POWID) Conference; www.isa.org
CONTROLLER: FRONT01
DWG. 700XXX
SG-01-03-02A
TS-1 POWER ERROR PORT 1 PORT 2 12 + 11 10 SH + + SH 9 8 7 OR BL
(OR)
+ SH TRUNK +
4 SH + -
(BL)
FY813A-FB2
24VDC
(BL)
(OR)
FIT810-FB1 (OR) FIT810-FB2 (BL) FIT811A-FB1 (OR) FIT811A-FB2 (BL) FIT812A-FB1 (OR) FT812A-FB2 (BL)
(OR)
SG-03-02A
SH 1 + SH 2 + SH 3 + SH TRUNK -
5 SH + 6 SH + 7 SH +
24VDC TS-5 F5 F6
(OR) (BL)
LY811A-FB1 LY812A-FB2
(OR)
LY812A-FB1
(+)
(+)
(-)
(-)
(-)
C5 C7
(BL) (OR)
8 SH +
+ SH TERMINATOR
GND GND
CH 1 DWG 703065
SPARE
1 2 3 4 5 6 7 8
(OR) (BL)
(BL)
FB + -
AC L1 N G
FB + -
AC L1 N G
FB + -
(OR) (BL)
NOTES 1. * INDICATES NEUTRAL CONDUCTOR TAPED WHITE. 2. ** INDICATES GROUND CONDUCTOR TAPED GREEN.
(OR) (BL)
FB + -
PROJECT XYZ
Copyright 2004 by ISAThe Instrumentation, Systems and Automation Society. Presented at the 14th Annual Joint ISA POWID/EPRI Controls and Instrumentation Conference, 47th Annual Power Industries (POWID) Conference; www.isa.org
operators will gain experience and graduate upwards from there. Training is also an important component for ultimate end user acceptance.
CONCLUSION
As one can see a successful Fieldbus implementation will require planning, standards, and training. Be prepared and reap the great benefits brought by the Fieldbus technology.
REFERENCES
Evaluating a Foundation Fieldbus System 20 Questions & Answers http:// www.smar.com Fieldbus Topologies http:// www.vcsum.org (3) http://plant web.emersonprocess.com (4) Fieldbuses for Process Control Engineering, Operation, and Maintenance by Jonas Berge (5) Aramco FF Specification http://iceweb.com.au
(1) (2)
Copyright 2004 by ISAThe Instrumentation, Systems and Automation Society. Presented at the 14th Annual Joint ISA POWID/EPRI Controls and Instrumentation Conference, 47th Annual Power Industries (POWID) Conference; www.isa.org