05-fieldbus foundation project execution-jigish jepal · fieldbus project execution methodology...

Automation 2011

Name : Jigish JepalJob Title : Executive ManagerCompany : Yokogawa India Limited

© 2011 Fieldbus Foundation

FFIC : Automation 2011 ‐Mumbai

Presentation Points

Key Points in Fieldbus Project

Typical early (before ~2004) FF project execution and lesson Learned

Present day (after 2004) FF project execution

Fieldbus project execution methodology

Fieldbus project execution procedure ‐ example

Fieldbus project support tools

Fieldbus segment design guideline and segment check tools

Engineering tools

Factory Acceptance Test procedure

Site Acceptance Test procedure



Key Points in Fieldbus Project (1/2)

Understanding of Difference of FF System from Conventional System

・Technology・Design & Engineering・Design & Engineering ・FAT / SAT Methodology ・Installation ・Commissioning ・Device Functions

Establishment of FF Project Execution Methodology

・Project Handling Procedure

・Design and Engineering Procedureg g g・Design Documentation・Design Information Exchange Scheme



Key Points in Fieldbus Project (2/2)

Common Understanding of FF System among Users/EPC/Licensers andVendorVendor

Assignment of Experienced Engineers in Project Team

Confirmation of Device Interoperability and Availability of AuxConfirmation of Device Interoperability and Availability of Aux. Equipments; Power Supply /Exi Barrier/Terminator etc.



Typical early (before ~2004) FF project execution and lesson Learned

Conventional I/O Basis

Feed Phase Engineering Phase Site Activity Phase

Feed Generation & Debug SATDetailed Design Commissioning

Spec. FreezeKOM

FATBasic Design

Shipping

Feed Phase

SAT &

FF Basis

Engineering Phase Site Activity Phase

FF Knowledge Device InteroperabilityExperienced Engineers Resource

Feed

Spec. FreezeKOM

FATBasic Design Generation & DebugDetailed Design SAT &

Commissioning

Shipping Risk at Site

PJT Execution Procedure

Design Documents

Device& Aux.Equipment Selection

Segment DesignDevice Grouping PID Allocation

Device Interoperability

FAT/SAT Procedure

Service & Maintenance Tool

p g

© 2011 Fieldbus FoundationFFIC : Automation 2011 ‐Mumbai

‐ Device Grouping, PID Allocation‐Macrocycle, Cable Length :Trunk & Spur

Problems observed in earlier stage of Project

Present day (after 2004) FF Project Execution

Feed Phase

FF Basis


Feed

Spec. FreezeKOM

FATBasic Design

Generation & DebugDetailed Design SAT & Commissioning

ShippingRisk at Site

Feed

Feed Phase

FATBasic Design

Generation & DebugDetailed Design SAT & Commissioning


Spec. FreezeKOM Shipping

•Fieldbus Tutorial

Design and Engineering Tools & ProcedureBenefits to Customer•Fieldbus Tutorial

•FF Technology Introduction•FF Project Execution Guide•FF Segment Design Guideline•Functional Design Specification•Segment Check Tool

•System Engineering Guide• Better Engineering Tool

•FAT Procedure•SAT Procedure

•Minimize Human Errors•Prevent Re‐works•Shorten PJT Schedule



•Device&Aux.Equip. Selection Guide

Fieldbus Project Execution Methodology

Project KOM Main frame of FF project execution procedure is same as conventional I/O

FF t d i i Basic Design

Hardware Design

system. FF segment design in basic design phase is a key element in the FF project execution.

Each work item needs somechanges and additions toimplement FF technology

Software Design

Needs to set up

implement FF technology.

System Staging& Internal Test

FAT

Needs to set up•FF system project coordination procedure

•Design information exchange schemeFAT methodology is FAT

Delivery

exchange scheme gydifferent from theconventional I/O system.



Fieldbus Project Execution Procedure : Example (1/3)

MilestoneDeliverables by Customer Deliverables by System Vendor

Kick Off1) Project Execution Plan2) PJT Organization

1) PJT Schedule2) PJT Organization Kick Off ) g

3) PJT Schedule4) QA/QC Plan5) Technical & Commercial Proposal 6) Bill Off Materials (BOM)

2) PJT Organization3) Inquiry Specification4) FF Design requirements

Basic System design ‐ FF Segment Design Philosophy

FF System Design Specification‐ FF Segment Design Specification

1) Instrument Index

H/W Design Specification1) DCS System Configuration 2) DCS H/W E i t S

2) I/O Point List3) Loop Drawing

2) DCS H/W Equipment Spec3) Equipment Dimension4) Power Supply/Grounding5) Subsystem/Aux.Equipment

Hardware Design Design Requirements for;1) Console&Aux. Cabinet 2) Subsystem 3) Aux.Equipment



A


MilestoneDeliverables by EPC Contractor Deliverables by DCS Vendor

FF Design Information1) D i Li & T

A

1) H/W Design Specification& Drawig

2) BOM f H d

1) Device List & Type2) FB Assignment3 Device Grouping4) Expected Cable Length5) Cable Specification

2) BOM of Hardware3) I/O Card Assignment4)Typical Loop Configuration

FF Segment Detail Design

1) Complex Loop Schematics) i f l & Material Order & Manufacturing

S/W Design Specification1) Control Functions 2) MMI F ti

2) Narrative of Complex Loop&FB3) Sequence& Interlock Logic4) Graphic Sketch5) Subsystem Communication Spec

Software Design 2) MMI Functions3) Alarm Function4) Access/Security Functions5) Graphic/Logging 6) Subsystem Interface



B


MilestoneDeliverables by EPC Contractor Deliverables by DCS Vendor

)

B

1) Communication Point List

1) JB Schedule for Marshalling Rack2) Wiring Details3) Installation Details

1) Loop Drawings 1) Communication Point List2) Graphic Display Data3) Logging Formats4) Group Display Assignment5) Trend Assignment

2) Ｔｅｒｍｉｎａｌ Assignment ofMarshalling Rack

S/W Generation

System Staging

l

FAT

Internal Test

FAT Procedure



Delivery

Fieldbus Project Support Tools (1/2)

FeedPhase

Engineering Phase

Site ActivityPhase

Project Execution Phase

Support Tools Category

General Specification of FF

FF Tutorial

FF Technology Introduction

General Information

General Information

General Information

X

X

XFF Technology Introduction

FF Segment Design Guideline

FF PJT Execution Guideline

System Engineering Procedure

General Information

Design Guideline

Procedure & Manual

Design Guideline

X

X

X

X

X

X

X

X

Segment Check Tool

Engineering Tool

Device&Equip. Selection Guide

Design Tool

Engineering Tool

Design Guideline

X

X

X

X

X

FAT Guideline

SAT Guideline

Start‐up & Service Manual

Training Manual

Design Guideline

Design Guideline

Procedure & Manual

Manual

X

X

X

X

X

X

X



Training Manual

Quotation Guideline

Manual

Quotation Guideline

X

X

Fieldbus Project Support Tools (2/2)



SAT Guideline

General Specification FF in DCS

FF Tutorial

FF Technology Introduction

Plant/ Process

I & C System AFE FDS SAT Commissioning OperationInstallation

SAT Guideline

Start‐Up & Service ManualFF Segment Design Guideline



Segment Check ToolProcess Design

System Design

AFE FDS SAT Commissioning OperationInstallation

Site Activity Phase


FAT Guideline

SAT Guideline

Training Manual

Quotation/ClarificationsFeed Phase

FATH/W Design & Manufacturing

Gen./Debug

Detailed Design

g

Quotation Guideline

Basic Design


S/W Design/ Configuration




SWIFT Plus Engineering Tool

i & i S l i G id



Engineering PhaseDevice&Equip. Selection Guide

FAT Guideline

SAT Guideline

Fieldbus Segment Design Guideline

Table of Contents

1. General1.1 FF Segment Design Methodology

2. Basic Segment Design2.1 Hazardous Area Classification

4. Segment Execution Time4.1 Macrocycle Time4.2 Scheduling

2.2 Redundancy 2.3 Segment Loading 2.4 Spare Philosophy

3. Wiring Design

5. Control Assignment

6. Application Specific Design 6.1 Control Valve Fail State6 2 ESD Valve Status Equalization3. Wiring Design

3.1 Topology3.2 Cable Length3.3 Cable Type 3 4 Power Consumption

6.2 ESD Valve Status Equalization6.3 Risk Assessment For Control

Loops7. Documentation

3.4 Power Consumption3.5 Minimum Operating Voltage

7.1 Segment Drawing7.2 Loop Configuration Drawing



Fieldbus Segment Check Tools



Typical Engg. Tool

INtools RDB CustomerDB

MS‐Excel Engg.

Source Documents

Instrument Index Module

MS Excel/ Access

ggDB

Export (INtools)

Cross link

Source ocumentsP&IDControlNarrativesetc.

Meeting Typical FAT Text DB

Auto generationEngg. Tool

Meeting

Typicalloops

Typical FAT Text DB

Typical Loops

oopsmarking on P&ID

w/generic tag numbers

DCS DBDCS DB w/target tag numbers

Builder (DCS)

Export (DCS)



Factory Acceptance Test Procedure

Device List Verification

DD File And Capabilities File Verification

Fieldbus Application Verification

: Connection of Function Blocks

H1 Communication Scheduling Chart Verification

Connection Test with Actual Field Device ( by Using Representative Model)( y g p )

Segment Functional Test for Selected Segment

with Actual Field Devices



Site Acceptance Test Procedure

Confirm Physical Connection of the Field Devices

Download Configuration Data to Field DevicesDownload Configuration Data to Field Devices

Loop Connection Check

Verify Voltage at Device Terminals

Observe and Check Signal WaveObserve and Check Signal Wave

Verify Loop Operation ( LAS Redundancy Check etc.)

Adjust Loop Parameters

Arrangement of Proper Site Organization for Site Activities

Note

(SAT & Commissioning) Prepare Tools for Troubleshooting at FAT/ SAT (Bus Monitor, Volt Meter and Oscilloscope)



Thank You

Fieldbus FoundationIndia Committee

21st September, 2011



www.fieldbus.org