How to Get More From FOUNDATION fieldbus Beyond wiring savings By - - PowerPoint PPT Presentation

How to Get More From FOUNDATION fieldbus

Beyond wiring savings By Alex To - TURCK BANNER Singapore

Topics Covered

 Background  Training  Design  Procurement  Integration  Configuration  Factory Acceptance Test (FAT)  Installation  Commissioning  Change Work Practices  Network Maintenance  System Management

Design Procurement Integration Configuration FAT Installation Commissioning Operation

Background

Do more

You Can Do More

 Plants are achieving wiring, I/O card, and marshalling savings:

• Multiple devices on the same pair of wires
• Multiple I/O per device on the same pair of wires
• Innovative multi-channel devices
• ~100 I/O signals per fieldbus H1 card
• Virtual Marshalling™ for easy I/O signal changes

 Do more:

• Simplified loop check
• Tighter control
• Instrument diagnostic alarm management
• Intelligent discrete devices
• Add instruments for equipment condition and performance

monitoring; on premise or IIoT

Fieldbus Training

Competency is a critical success factor

FF Training Helps

 FF capabilities still not fully utilized

• Learn more to get more out fieldbus

 FF has evolved over the years

• Learn more to do fieldbus the easier way

 Use consultants, EPC contractors, and subcontractors trained on FF  Train plant I&C personnel on FF to ensure continuity  Get trained on FF

Loop Check Control-in-the-Field NE107 Intelligent on-off devices IIoT

FF Design

Better and simpler

Fieldbus Design the Easy Way

 Count devices, not I/O signals  One worst case ‘Typical’ power calculation

• Voltage drop

 One worst case ‘Typical’ loading calculation

• Scan time

FOUNDATION Fieldbus for IIoT

• Build on the Fieldbus You’ve Got

 Add instruments for equipment condition and performance monitoring

• On premise or IIoT

 Fieldbuses usually not fully populated  Add sensors for condition monitoring and energy management

Process Control & Monitoring Condition Monitoring & Energy Management etc. Control System Condition Monitoring System & Energy Management System etc.

FF Configuration

Engineer to avoid alarm flooding

Avoid Alarm Flooding: Instrument Diagnostic Alarm Management

 If the instrument diagnostic alarm management system is not configured there will be a flood of nuisance alarms

• System will not be used

 ISA108 guidance being developed  Interim guide:

• http://www.eddl.org/DeviceManagement/Pages/DeviceDiagnostics.as

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 Specify a control system supporting diagnostics alarm management

• Filtering based on criticality
• Routing to the right person

Same as for HART

Instrument Diagnostic Alarm Routing

Operator Instrument Tech

• Failure
• Function Check
• Failure
• Maintenance Required
• Out of Specification

Devices Nuisance Alarms Same as for HART

Instrument Diagnostics Alarm Rationalization

 Categorize severity of diagnostics:

• NAMUR NE107

 Identify criticality to the process for each device tag  Configure system and devices

Same as for HART

Factory Acceptance Test (FAT)

Test to make sure instrument diagnostics alarm management will work as intended

FAT Interoperability / Integration Test

 Connect one of each device type  Open each device type in the IDM software

• Verifies the DD file for each type and version of the

device has been loaded

• Verifies the device displays correctly

 Download a device configuration

• Verify the download is error free

Same as for HART

FF Installation

Wiring

Good Digital Communication Installation Practices

 Don’t ground shield at device, insulate shield  Maintain shield through junction boxes  Route signal cables in separate tray from power cables  Don’t loop cable too tight  Ground device housing and junction boxes  Don’t coil signal cables and power cables together  Don’t damage shield and conductor insulation  Don’t strip off more jacket than necessary  Ground overall shield for multi-pair cable  Ground the cable armor

Don’t spend too much the first 3… Same as for HART

Other Good Installation Practices

 Do not pull cable with too much force  Make sure cable glands are tight  Seal unused conduit entries  Use correct size ferrule/fork and tool  Do not cram wires in device terminal compartment  Do not over/under-tighten screws  Make sure covers are tight  Do not tighten cable-tie too much  Label wires  Observe polarity

Don’t spend too much the first 3… Same as for 4-20 mA

FF Commissioning

Digital loop check

5-Point Loop Check is Not Required on Fieldbus Projects

 No 4-20 mA ranging  No 4-20 mA signal distortion  No traditional five-point loop tests  Instead a simple plausibility check

DIGITAL

• No range mismatch
• Not limited
• No biased
• No non-linearity
• No current calibration

mismatch

Change Work Practices

Getting into the habit of using the IDM software as part of the daily routine

Instrument Technician Culture Change

 Review instrument diagnostic alarms

• Instrument technicians must review the instrument

diagnostic alarm summary and log every day

• Spend time on devices which need attention

 Check the software first

• When operations say a device is not working,

instrument technicians must check the software first, before going to the field to take a look

• Avoid unnecessary field visits

 Rewriting Standard Operating Procedures (SOPs)

• Rewrite work procedures to include IDM software
• Inspection, replacement, calibration and other tasks

Same as for HART

Network Maintenance

Maintain installation in good condition to ensure the communication continues to work error free

Monitor Network Health

 Periodically check communication Packet Error Rate (PER) to detect deteriorating communication before alarms appear  Built-in control system communication diagnostics

Same as for HART

System Management

Keep systems up to date with new device types and versions

Keep System Up to Date

 Load the DD files for new device types and versions on the control system and IDM software

Same as for HART

DD File Management

 DD files are easy to download from the Internet  Load DD files for all devices, even if they are currently not in use

• You don’t have to figure which you need now and

which you don’t

• You never know when new devices will be installed
• The system is ready for all kinds of devices

 Some systems have DD wizard that automatically distributes the DD to all computers in the system  Some hosts offer update services which loads DD files

• nto the system automatically as they become available

Same as for HART

Conclusion

Get More from Fieldbus

 Simplified loop check  Tighter control  Instrument diagnostic alarm management  Intelligent discrete devices  Add instruments for equipment condition and performance monitoring; on premise or IIoT