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Design Benefits The Future is Digital Arasu Thanigai Pepperl+Fuchs On Behalf of FF Marketing Society 1 The Future is Digital Design Benefits from 2 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 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 3 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 The Future is Digital . Fieldbus Project Costs Estimated Project Savings – – – – – 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! 4 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 5 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 6 The Future is Digital . Fieldbus EX Conventional wiring 2nd level 1st level junction box Multicore cables 7 The Future is Digital . Fieldbus system wiring Fieldbus power supplies 1 …………. 80 80 Segments > 900 Instruments 8 The Future is Digital . Control system Benefits in hardware Less barriers, no marshalling, less I/O cards, less wiring, smaller control room Conventional Fieldbus 9 The Future is Digital . Benefits-wiring and termination savings 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 11 The Future is Digital . Benefits by Concept 12 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). 13 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 14 The Future is Digital . Design - Single loop integrity on FF HMI DCS Redundant H1 card Redundant - IS Device Coupler 15 The Future is Digital . Benefits by Bus structure 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 16 The Future is Digital . Benefits by Being Digital 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 17 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 18 The Future is Digital . Many Vendor support – Power Supply Single High Power IS FISCO - IS Redundant, Multi-segment 19 The Future is Digital . 19 Many vendor support – Device couplers Zone1 Fieldbus barriers Ex me [ia] Zone 1/0 IS Zone 1 Ex me Zone 2 20 The Future is Digital . 20 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 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 21 The Future is Digital . Engineering Benefits - Flexible Hazardous area design Design criteria covered by IEC61158-2 Further supported by AG 181 ( rev 3.1) Project applications vary based on – – – – 22 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 23 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 24 The Future is Digital . User Benefit : Choices of IS Approach at Hazardous locations Example IIC Gas Group application 25 The Future is Digital . 26 The Future is Digital . 27 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 28 The Future is Digital . 29 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 30 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 -------- 31 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 32 The Future is Digital . Zone 1 Benefits by selecting relevant Hazardous area approach 33 Flexibility to handle changes and additions late in the project Selecting the cost effective solution Reducing the hardware Future expansion 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 34 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 35 The Future is Digital .