Emerson Early Design Considerations for Project … · Early Design Considerations improve ... •...

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© 2010 Fieldbus Foundation

Early Design Early Design

Considerations improve Considerations improve

Project SavingsProject Savings

Murali Krishnan T Murali Krishnan T

Emerson ProcessEmerson Process ManagementManagement

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Fieldbus Changes the Project Economics

CAPEX:Fieldbus

can reduce project costs

by 10%

• Control room space, and installation costs such as wiring cost

• Engineering & Construction costs

• Startup & commissioning costs

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Fieldbus Training is a MUSTFieldbus Training is a MUST

• Fieldbus is different from 4-20

mA

• New competencies required

• For all persons involved

• At every stage of the project

• Classroom and hands-on

• Real test tools and equipment

• Helps to improve Project

Schedule

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Fieldbus Training is a MUSTFieldbus Training is a MUST

• Customized to project hardware and procedures

• Design engineers• Design Considerations

• Fieldbus segment design software

• Installation team• Lay cable and terminate

• Segment Checkout

• Device commissioning Team• Check bus parameters

• Connect devices & commission

• Troubleshooting using tools

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3 Ways to Do Closed Loop Digital Control

• Control in Controller

(CIC)

� Traditional way

• Control in the Field (CIF)

� Single loop integrity when used in conjunction with backup LAS

� Less communication

� Devices must be on the same bus

• Operator can't see

the difference

• 80/20 Rule

Transmitter

Valve

AI PID AO

Valve

Transmitter

AI PID AO

Transmitter Valve

Controller

AI PID AO

CIF

Technical

White

Paper

Available

CIF

Technical

White

Paper

Available

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ARC White paper on CIF

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Schedule “Time Table”CIF

Scheduled (Cyclic)

� Real-time block links

– Closed loop process

variables

– Controller output

Unscheduled (Acyclic)

� Alarms and Events

� Maintenance, Diagnostic, &

� Configuration

� Open loop monitoring

Macrocycle 250 ms

UnscheduledCV1

TX1

CV2

TX2

CV3

TX3

Macrocycle 250 ms

UnscheduledPID

AI

AO

PID

AI

AO

PID

AI

AO

PID

AI

AO

PID

AI

AO

PID

AI

AO

AI

AIL

ink

Lin

k

Lin

k

Lin

k

Lin

k

Lin

k

Lin

k30 ms

Open loop

monitoring

devices

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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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Communications Processing

Adding a second loop on the segment results in a longer macro-cycle time, but not twice 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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AutoTune

Analog Input

Analog Input

Transmitter

LCD

Diagnostics

DCS/Host

AI Application

Resource

Sensor Transducer

PID

Value/Functionality of FF sensors is up to the manufacturer

Value/Functionality of FF sensors is up to the Value/Functionality of FF sensors is up to the

manufacturermanufacturer

Integrator

SignalCharacterizer

ArithmeticMore Function

Blocks Now -

CIF

Output Splitter

Control Selector

Input Selector

Multiplexed

Analog Input

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Assigning Fieldbus Devices to a Segment

Maximum 16 devices per segment

Recommended loading (one second

macrocycle)

� Total of 12 devices per segment

� Total of 3 control valves per segment

Devices should be placed on segments based

on location, control function and

reliability requirements

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Device Current ConsumptionDevice Current Consumption

� Average less than 17 mA� The lower the better

Manufacturer Description mA

Fisher Valve Positioner 18

Rosemount Pressure transmitter 17.5

Rosemount Temperature

transmitter

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Rosemount Vortex flow meter 18.5

Rosemount Analytical pH analyzer 22

Micro Motion Coriolis mass flow

meter

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Rosemount Analytical Oxygen analyzer 18

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Complete Range of Fieldbus DevicesComplete Range of Fieldbus DevicesPressure Pressure Machinery Health Electric On/Off Electric Modulating On/Off Pneumatic

Positioner

On/Off Pneumatic Coriolis Flow DP Flow Temperature Temperature Remote Indicator DI/DO

Multi Temperature Magnetic Flow Vortex Flow Amperometric pH Conductivity Amperometric

pH Conductivity O2 Yoko PressureRadar Level

Honeywell

Temperature

Radar Level

Hand Held

Valve Monitor

Pressure

O2 & Combustion Valve Manifold E&H Flow

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New Types of Ff devices to reduce CostsNew Types of Ff devices to reduce Costs

High Density Temperature Transmitter

Machinery Health Transmitter

8 DI and 4 DOWithout

fieldbus you

cannot benefit

from new

innovations

2 Channel Temperature Transmitter

8 Point Remote Indicator

Temperature Multiplexer

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Simplify Complex Device WiringSimplify Complex Device Wiring�Conventional

– One device, twelve wires– Electric actuator (MOV)

• Open, stop, close, ESD,

overload...

– Valve positioner• Setpoint, feedback, limit

switches...

– On/Off actuator• Setpoint, limit switches...

– Mass flow transmitter• Mass, volume, density,

temperature...

�Fieldbus– One cable, twelve devices– Many DI/DO cards

eliminated

Conventional:

Multiple pairs

Per device

Bus:

Single pair

Many devices

AUMA ROTARK

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Instrument Functionality Instrument Functionality -- OnOn--Off valvesOff valves

Uses Single DO

Block

2-Wire device for power to both

Sensor Communication Module

and (2) Low power piezo pilots,

digital readback, alarms and

diagnostics

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Installation : Checkout fieldbus wiring

Systematic Approach

� Don’t rush

Follow procedures

� Grounding Checks

� Proper voltages

� Terminators Functioning

� Verify Results

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Resistance & Capacitance Verification

Conductor-to-conductor & conductor-to-shield

resistance checks

Conductor-to-ground/earth & shield-to-

ground/earth resistance checks

Cable capacitance checks

Test Expected Result

(+) to (-) conductor > 50 kohm

(+) to shield > 20 Mohm

(-) to shield > 20 Mohm

Shield to ground < 100 ohm

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Fieldbus Tester Tools: Relcom FBT6

Monitors:

� Voltage

� Peak noise

� Average noise

� Wiring

– Shield not shorted to signal

� Retransmits

– Communication errors

� Add/Drop

– Devices added/removed

� LAS signal

– Control system interface card

� Lowest signal

� Device count

Indicates OK/Bad for each test

Store 8 test results and upload to Excel

FBT6

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Fieldbus Tester Tools: Relcom FBT5

Validates wiring

� Injects signal

� Do not use in hazardous areas

� Automatically powers off after a few minutes

– To conserve battery

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Advanced Diagnostics

FieldConnex Advanced Diagnostic ModuleFieldConnex Advanced Diagnostic Module

– A single tool for commissioning, monitoring, and troubleshooting

– Versions to suit your every need

� Stationary ADM– Monitors four segments

– Integrated in Power Hub– Stand-alone motherboard

� Mobile ADM– Single segment monitoring– For any power supply

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MTL F809F onMTL F809F on--line monitoringline monitoring

� Monitors parameters on

8 fieldbus segments

� Reports parameters over FOUNDATION fieldbusTM H1

– Module is a Fieldbus device

� Diagnostic software– Integrated into Host

F809F

F800 system

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F809F measured parametersF809F measured parameters� Segment voltage� Signal voltage

– All devices– Address of device having lowest voltage

� Average and peak noise– Low frequency band– FF signalling band– High frequency band

� Fieldbus to shield short circuits– + to shield– - to shield

� Device retransmissions� Number of devices recognised on bus

� Address of LAS

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Summary

• Training from the start & at all stages

• Use of Control In the Field

• Maximize number of devices per segment

• Make use of the Ff products that will reduce

the number of devices, segments, wiring

• Use of Power Conditioners with Advanced

Diagnostics module for installation check

• Document Project Savings at the end of the

Project and share it with others

• Ff Technology for small to medium size

plants too.

Date post:	07-Aug-2018
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Emerson Early Design Considerations for Project … · Early Design Considerations improve ... •...

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