murali krishnan engineering methodology emerson
TRANSCRIPT
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Fieldbus Foundation India Marketing Committee
Fieldbus Engineering Methodology
Murali Krishnan TEmerson Process Management,
Asia Pacific
Fieldbus FoundationParadigm Change in Instrumentation Technology
Date : 26th of September, 2008 (Friday)Time : from 09:00 am to 06:00 pm.Venue : Automation 2008 Conference Hall.
: Conference Hall, Bombay Exhibition Centre (NSE),
Goregaon (East), Mumbai INDIA
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Designing Fieldbus Segments Segment Design Considerations
Constraint Checks
Communications Processing
Components Selection
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Segment Design Considerations Instrument Functionality
Instrument Location
Process Control Requirements
Availability Requirements
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Instrument Functionality
Pick the right instrument for the application
Find out which function blocks are availablewith an instrument
Most common function blocks are AI, AO, PID,
DI, DO
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Transmitter
PID with Auto Tuning
Output Splitter (OS) Control Selector (SEL)
Arithmetic
Integrator Signal Characterizer
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Multi Input Temperature Transmitters
Classic & HART I/O
H1
AS-i
DeviceNet/Profibus
8 RTD/ TCInputs
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Discrete I/Os Transmitter
Classic & HART I/O
H1
AS-i
DeviceNet/Profibus
8 DI / 8 DO& logic
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Process Control Requirements
How are the measurements being used?
Monitor only or used in PID control? Required update time?
Input processing, such as P-T compensation?
Output processing, such as split-range?
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Process Control Requirements The measurement device and control element of a
PID loop mustbe on the same segment forControl-in-field (CIF)
The PID Function Block can be located in thetransmitter (CIF), valve (CIF), or control can bein the controller (CIC)
Where to locate the PID block(s) depends on the
complexity of the control strategy
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Availability Requirements
Redundancy requirements
Equipment segregation Distribution of critical loops
Component redundancy
- Fieldbus Power supplies/Power Conditioners- H1 card
- LAS (Back up LAS in a field device)
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Designing For Process Modularity
Hot Oil Return
D-38004
D-38003
D-36003
D-36004
Condensate Stripper
Raw Methanol Stripper
Fuel Gas Header
Weir
TT101A LT101
FT501
100%
100%
TT101B
PT401
LT101
Segment 2
PIDAI AO
Segment 1
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Process Safety Levels (Client Driven)Level 1 ValvesFailure of this valve will result in a total system trip, causing a shutdown of the entire unit, or otherunavoidable losses in excess of $100M. Level 1 valves and their associated measurement shallreside on H1 segments with no other devices. The ISD shall show the criticality rating and shallprominently display that no additional devices shall be loaded on this segment.Level 2 ValvesFailure of a level 2 valve will result in an emergency situation, where prompt operator action wouldbe required to "save" the unit from immanent total shutdown. The material and energy capacity ofassociated vessels, geographic location, and elevation/accessibility of such valves should beconsidered. Failure of a level 2 valve will result in a total system trip, causing a shutdown of the entireunit, or other unavoidable losses in excess of $100M. However, the level 2 valve's process dynamics
allow time for quick recovery from the failure, either by quickly fixing a fault or by taking manualcontrol. Level 2 valves and their associated measurement shall reside on H1 segments with no otherlevel 1 or 2 valves. The ISD shall show the criticality rating.Level 3 ValvesFailure of this valve will not result in any short-term risk of total unit shutdown. Level 3 valves can go totheir fail position without requiring any immediate operator action. Level 3 valves can reside on cards
or segments with other level 3 valves, or on a segment with a level 2 valve. Consideration should begiven to the impact of common mode failures among level 3 and level 2 & 3 valves on the samesegment.
EXAMPLE ONLY VARIES WITH CUSTOMER
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Assigning Fieldbus Devices to a Segment
Maximum 16 devices per segment
Recommended loading- Total of 12 devices per segment
- Total of 4 control loops per segment
Devices should be placed on segmentsbased on location, control function, andreliability requirements
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Constraint Checks
Distance Limits
Spur Length Power Consumption
Voltage Drop
Communications Processing
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Spur Length
Terminator Terminator
Trunk
Spur
T T
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2008 FFIMC - Automation 2008-Mumbai
Topology
Trunk
To H1
Card
Combination Topology
JBSpur
JunctionBox
Most Common
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Fieldbus Network Components (non-IS)
PCPS
T1 +S1 +S2 + S21 +S22 +S23 .+ Sn
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Voltage Drop26 ma
11 ma
15 ma
17 ma
Total = 69 ma
Fieldbus
PowerSupply19 V
3000 feet
#18 AWG, 6.4 /1000ft
Voltage = 19 - [ (3000 x 6.4/1000 x 69/1000) x 2 ]
Voltage = 19 - 2.65Voltage = 16.35
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Segment Power Considerations
JunctionBox
Fieldbus
PowerSupply
Non-IS Application (Safe)
Intrinsic Safety Models
Entity (IS) FISCO (Zone 1) FNICO (Non incendive)
Field Barriers
?
?
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2008 FFIMC - Automation 2008-Mumbai
Single
Power Conditioner
(Examples)
Redundant,Multi-segment
FISCO, FNICO
Redundant,Multi-segment
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2008 FFIMC - Automation 2008-Mumbai
Wiring Blocks
(Examples)
Zone 2Ex nL
Zone 1Ex me
Zone 1/0
Ex ia
Fieldbus BarriersEx me [ia]
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Fieldbus Design Tools (Examples)
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Fieldbus Segment Design Tool Report
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Link Active Scheduler runs segment Link Active Scheduler (LAS) is the data
Traffic Cop of the segment- Controls all access to the segment- Keeps track of who is on the segment- Runs Macro Cycle-
Time Clock for segment
LAS can be in any device on segment thathas the capability- All host have LAS- Many devices have LAS
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Communications Processing
The LAS allocates both scheduled (for closedloop control) and unscheduled (Set point,monitoring loops, alarms) time on the bus
Macrocycle time depends on block executionspeed, number of blocks, communicationsbetween blocks, etc.
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2008 Fieldbus Foundation
Scheduling
Time
Scheduled CyclicCommunication
UnscheduledCommunication
AI
PID
AO
Scheduled Function
Block Execution
FUNCTION BLOCK SCHEDULING
LAS ScheduleMacrocycle
LAS ScheduleMacrocycle
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
PIDIN
OUT
BKCAL_INFIELDVUE
AO
BKCAL_OUT
CAS_IN
AIOUT
Valve
Transmitter
Function Blocks in FOUNDATION fieldbus
Solutions
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2008 Fieldbus Foundation
ControlControlin the Fieldin the Field--An ExampleAn Example
AIN
Flow Transmiter
OUT
Valve
AOUT
PID
BKCAL_OUT
CAS_IN
BKCAL_INOUT
IN
AIN-PID-AOUT Loop
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Communications Processing
AI PID AO
20ms 30ms 30ms 25ms
This sample loop on a segment results
in a minimum 105 ms macrocycle time.
AI PID AO
20ms 30ms 30ms 25ms
> 105 ms
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Communications Processing
Adding a second loop on the segmentresults in a longer macro-cycle time, but nottwice as long (30ms compelled data time).
AI PID AO
20ms
30ms
30ms
25ms
AI PID AO
AI PID AO
20ms
30ms
30ms
25ms
AI PID AO
> 135 ms
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2008 Fieldbus Foundation
Advantages of Control in the Field
FOUNDATIONTM fieldbus allows for control in the field!
Deterministic Control
Single loop integrity available
Faster Speed of response
Free up controller to handle advanced applications(embedded APC)
Devices with more function blocks offer moreflexibility for Control in the Field
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Instrument data Sheets for Ff devicesInstrument data Sheets for Ff devices
Working voltage (9-32 volts) Maximum current draw from bus Function block requirements Block execution speeds Standard/Advanced Diagnostics requirements Interoperability tested (ITK4.0 FF base standard)
Polarity sensitivity Capacity for instantiable function blocks LAS capability Device revision
Channel number and description Any local indicator required
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Fieldbus View MacrocycleGraphs the macrocycle for a given segment
Quickly evaluate Fieldbus segmentcommunications
Quickly evaluate Fieldbus segmentcommunications
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Segment Design Drawing
May be used in place of loop drawings
Will show general topology of segment Can be used for documentation of design
constraints
- Segment & spur length- Voltage drop and current draw
- Loop execution requirements
- Process Criticality Level
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Sample Segment Drawing
Typical Instrument Segment DiagramMTL/REL Red. Power Cond.
March 23, 2004
None
Sudhir Jain
DATE:
SCALE:
DRAWINGNO:
DESIGN: DRAWN:
CHECKED:
APPROVAL:
JOB: REV:
CADFILE:
CUST.
APPR.
PROJ.
ENG.CHK:BY:REVISIONS
ISSUED FOR CUSTOMER APPROVAL
DATE:REV:
A
Emerson Consider It Solv ed
ISSUED FOR CONSTRUCTION0
0
Located @ xxxx
H1InterfaceFieldbusModule
Controller: 01Card: 03Port: 01
DeltaV Cabinet: DV-01
BKWH
H1Terminal
Block
ToShieldBusBar
onDeltaVCarrier
Field
BK
WH
FJB-101
(Note: Typic al wire tagging
for all f ield devices.)
JunctionBox
Reference Drawings
CabinetWiringDetails
P&ID
84-
5+
76-
1 2
Cable #
Multipair cable or Single pair
XXXX Meters
BK
WH
BK
WH
BK
WH
BK
WH
BK
WH
BK
WH
BK
WH
BK
WH
Fieldbus
XX M
Fieldbus
XX M
Fieldbus
XX M
Fieldbus
XX M
Fieldbus
XX MBK
WH
BK
WH
Single Pair
141-PV-101
BK
WH
Note:
This is a one piece block (Megablock) that has internal
jumpering, (i.e. no hard-wired jumpers required). Hard-
wired jumpers are required when y ou tie two blocks
together.
This block can be ordered with internal spurguards which
limits the spur current to 60 mA during a short c ircuit
condition.
The connectors are pluggable therefore com missioning
and maintenance are simplified.
3+
FPS/01-0301
Port
Card
Controller
BK
WH
BK
WH
T+-S
BK
WH
BK
WH
BK
WH
BK
WH
BK
WH
Relcom/MTLRedundant
PowerConditioner
EmersonProcessManagement
Fieldbus
XX M
Fieldbus
XX M
Fieldbus
XX M
Fieldbus
XX M
Fieldbus
XX M
Fieldbus
XX M
Fieldbus
XX M
Cut&Tape
(Typ.forall)
BK
WH
BK
WH
BK
WH
BK
WH
BK
WH
BK
WH
BK
WH
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2008 Fieldbus Foundation
2008 FFIMC - Automation 2008-Mumbai
Fieldbus Design Tools and DocumentsThe following is a summary ofcommon tools/documents used inFieldbus Design and Implementation:
Fieldbus Design Methodology (FDS) :A document that spells out factors totake into consideration during thedesign process.
Segment Design Tool : In the form of
drag and drop to check segment design Vendor-specifc documents for
Procedures, Application Notes andDesign Review
Foundation Fieldbus Installation Guide.
Fieldbus Pre-commissioning Procedure. Fieldbus Troubleshooting Guide
Fieldbus Troubleshooting GuideFieldbus Troubleshooting GuideFieldbus Troubleshooting Guide
DeltaV Foundation Fieldbus Installation Guide.DeltaV Foundation Fieldbus Installation Guide.
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2008 FFIMC - Automation 2008-Mumbai
Designing Fieldbus Segments - Summary
1. Select the proper instrumentation
2. Group according to location & controlfunction
3. Lay out fieldbus segment
4. Check segment length & spur length5. Check current draw & voltage drop
6. Check communications loading
7. Choose wiring methods
8. Choose components