Download Design Benefits - Fieldbus Foundation

Design Benefits
The Future is
Digital
Arasu Thanigai
Pepperl+Fuchs
On Behalf of FF Marketing Society
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The Future is Digital
Design Benefits from
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Applying Foundation Fieldbus
Bus structure and Wiring
Loop Integrity
Going digital
available verification tools
Majority vendor support
Flexible hazardous area realization
Eliminating Marshalling
The Future is Digital .
User Benefits - Life Cycle Savings
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Cost saving in plant life cycle
Design
Installation
Operation
FAT,SAT
Renewal
Maintenance
OPEX Savings
CAPEX Savings
Saving of Cable & Cabinet
Small # of instruments (control in
field)
HPT / HPT-IS / FISCO / iC
Engineering
FAT/SAT
Smaller System Footprint
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Expand operator’s aspect
Down-Time reduction by diagnosis
Asset management
Improvement of maintenance work
–Remote maintenance work, Automatic
maintenance work
–Application of diagnostics
Small # of instruments to be checked
software change in field instruments
download
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The Future is Digital .
Fieldbus Project Costs
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Estimated Project Savings
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Materials/Field Devices: Marginal Increase
Installation Labor: Significant reduction
Commissioning: Significant Reduction
Design time: Significantly reduced
Overall Capital Savings
– Savings will be realized if the project is
planned as a fieldbus project and the
information is shared with all levels of the
organization!
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The Future is Digital .
Conventional 4-20mA Design
-Multiple IS Barriers
-Multiple cables
Ethernet/TCP/IP
Work
station
Internet/Intranet
PC/VME
Management
Ethernet TCP/IP
Operations
Maintenance
Ex
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The Future is Digital .
Foundation Fieldbus Design
Benefits in wiring and infrastructure
-Common Power Supply
-Common Bus cable
Ethernet/TCP/IP
Work
station
Internet/Intranet
PC/VME
Management
Ethernet TCP/IP
Operations
Maintenance
H1
Common Bus
Fieldbus
FF Power
Supply
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The Future is Digital .
Fieldbus EX
Conventional wiring
2nd level
1st level
junction box
Multicore cables
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The Future is Digital .
Fieldbus system wiring
Fieldbus
power
supplies
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………….
80
80 Segments > 900 Instruments
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The Future is Digital .
Control system
Benefits in hardware
Less barriers, no marshalling,
less I/O cards, less wiring,
smaller control room
Conventional
Fieldbus
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The Future is Digital .
Benefits-wiring and termination savings
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marshalling cabinet
For 10 instruments
20 terminations
2 terminations
FF Power
Supply
marshalling cabinet
20 terminations
distributor
20 terminations
11 terminations
5000 m cable
10
500m
The Future is Digital .
800m cable
Benefits by Concept
Foundation Fieldbus is realized by
 connecting many instruments on the same
segment
 allowing various hazardous area methods on the
same segment (e.g. Ex d and Ex i using Fieldbus
barriers)
 providing intelligent field instruments regardless
their function, whether temperature, ON/OFF
valves, flow, pressure, etc.
 using standardized device configuration methods
DD and EDDL
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The Future is Digital .
Benefits by Concept
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reduced cabling (wiring)
reduced infrastructure and components involved
eliminate the variety of isolators and converters
needed for DI/DO/AI/AO/RTD/etc
no marshalling required for grouping
DI/DO/AI/AO/RTD/etc
provide high levels of diagnostics, not just Lead
break /Short circuit
Get rid of manufacturer-dependent configuration
tools
The Future is Digital .
Benefits by Higher Integrity
Foundation Fieldbus combines all components of
the control loop (e.g. AI, PID, AO) on the same
cable pair (segment)
Conventional: A “loop” is often considered the
arrangement of equipment between DCS and
field device (I/O card, isolator, field instrument,
cabling).
It is usually not the “logical” loop (e.g. AI, PID,
AO).
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The Future is Digital .
Design – Perception of single loop
integrity
HMI
DCS
CPU: Performs PID function
non
Ex
non
Ex
Ex
Ex
IS barrier
(Intrinsic safety)
for wiring into
hazardous area
4-20mA
4-20mA
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The Future is Digital .
Design - Single loop integrity on FF
HMI
DCS
Redundant H1 card
Redundant - IS
Device Coupler
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The Future is Digital .
Benefits by Bus structure
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Foundation Fieldbus enables single Loop
Integrity
– AI, PID and AO on the same cable
– Major components are redundant
• FF H1 card (host)
• Redundant FF power supply
– In conventional (particularly I.S.), more components
are involved, so more prone to failure
→ Fieldbus is less prone to failure
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The Future is Digital .
Benefits by Being Digital
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Digital communication increases signal
transmission accuracy
– Analogue loop: A/D (sensor to device) – D/A (device to
cable) – A/A (signal isolator / I.S. barrier) – A/D (DCS)
– D/A (DCS) – A/A (signal isolator / I.S. barrier) – A/D
(cable to device) - D/A (device to actuator)
– Fieldbus loop: A/D (sensor to device) - D/A (device to
actuator)
(Note that all transmission and DCS calculation is alldigital)
→ Higher accuracy by design
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The Future is Digital .
Benefits – Design Validation
Easy verification of segment power distribution using
software tools
 Effect of temperature
 Individual loop calculations (with individual voltage and
current parameters) are not required
 Spur calculations negligible (spur voltage drop is < 0.1V)
 Segment loading factors
• Proper segment design for various zones of applications
 Documentation
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The Future is Digital .
Many Vendor support – Power Supply
Single
High Power IS
FISCO - IS
Redundant,
Multi-segment
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The Future is Digital .
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Many vendor support – Device couplers
Zone1
Fieldbus barriers
Ex me [ia]
Zone 1/0
IS
Zone 1
Ex me
Zone 2
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The Future is Digital .
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Validation Benefits at Hazardous area
applications design
Fieldbus signal:
 Ex parameters standardized
– FISCO: 17.5V, 380mA, 5.32W (IEC 60079-27)
– Entity: 24V, 250mA, 1.2W (FF-816)
Verification of intrinsic safety
 Eliminated using FISCO
– I.S. achieved by following the design rules
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Simplified for Entity using High Power Trunk
(Fieldbus barrier / HPT-IS)
– Point-to-point connection (spur)
– Max. 120m spur length allows to calculate worst case
cable parameters, reducing the verification to a simple
comparison
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The Future is Digital .
Engineering Benefits - Flexible Hazardous
area design
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Design criteria covered by IEC61158-2
Further supported by AG 181 ( rev 3.1)
Project applications vary based on
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Length of the trunk and spur cable
Number of devices to be connected
Level of redundancy required
Amount of diagnostics information required
All these applications requirements are met by
designing the fieldbus with the appropriate
hazardous area concepts
The Future is Digital .
User Benefit : Design guidelines
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The Future is Digital .
User Benefit : Choices of IS Approach at
Hazardous locations
Refer AG 181-3.1
-Limited Power
-High Power
High power ( Exe + IS )
High Power IS
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The Future is Digital .
User Benefit : Choices of IS Approach at
Hazardous locations
Example IIC Gas Group application
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The Future is Digital .
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The Future is Digital .
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The Future is Digital .
Design Benefits – Flexibility in IS design
Limited Power – ENTITY / FISCO Power
FISCO IIC FF
Power Supply
IS Spurs
V = 12.4V
~11V
- -
I = 120mA
Zone 1
IS Verification
Eliminated
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The Future is Digital .
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The Future is Digital .
Design Benefits – Flexibility in IS design
High Power Trunk – Exe + IS
Fieldbus barrier
Ex e
Ex ia
(FISCO + Entity)
HPT Power
supply
~11V
IS Spurs
V = 30V
I = 500mA
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IS Verification
Eliminated / Simplified
The Future is Digital .
Zone 1
Design Benefits – Flexibility in IS design
High Power Trunk - IS
HPT –IS Power supply protected by
DART
DART Segment Protectors
V = 22.4V
IS Spurs
I = 360mA
~11V
Zone 1
--------
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The Future is Digital .
IS Verification
Simplified
Design Benefits – Flexibility in Bringing the
same HPT to different hazardous areas
Device Couplers
Fieldbus
barrier
Ex e
Ex ic
19..32V
Zone 2
Ex d
Ex ia
230VAC
Zone 1
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The Future is Digital .
Zone 1
Benefits by selecting relevant Hazardous
area approach
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Flexibility to handle changes and additions late in the
project
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Selecting the cost effective solution
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Reducing the hardware
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Future expansion
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Additional features
The Future is Digital .
Benefits by Eliminating Marshalling
Fieldbus is designed with “spares” provisions (spare spurs,
spare trunks)
 Signals do not need to be grouped by type
(AI/AO/DI/DO/RTD/…), and can simply be connected to
any segment
 Change a on/off valve to electric actuator to control
valve late in the project without changing I/O cards,
drawings, wiring, etc
 Adding further non-control related signals (e.g. for
monitoring) does not require infrastructure
 Adding signals does not require change of cabinet
drawings
 Fewer intermediate wire connections in the panel
simplifies drawings
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The Future is Digital .
Summary
The main benefits in the design phase are:
 Faster and easier to design
 Reduced time in validation
 Higher accuracy (digital data throughout)
 Reduced components
 Less prone to failures
 Multivendor Support
 Greater flexibility while selecting hazardous area
concepts based on the project needs
 Diagnostics are integrated and reduces design
and commissioning time
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The Future is Digital .