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: o Multiple devices on the same pair of wires o Multiple I/O per device on the same pair of wires o Innovative multi-channel devices o ~100 I/O signals per fieldbus H1 card o Virtual Marshalling™ for easy I/O signal changes  Do more: o Simplified loop check o Tighter control o Instrument diagnostic alarm management o Intelligent discrete devices o 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 o Learn more to get more out fieldbus  FF has evolved over the years o 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 NE107 IIoT Control-in-the-Field Loop Check Intelligent on-off devices

FF Design Better and simpler

Fieldbus Design the Easy Way  Count devices, not I/O signals  One worst case ‘Typical’ power calculation o Voltage drop  One worst case ‘Typical’ loading calculation o Scan time

FOUNDATION Fieldbus for IIoT - Build on the Fieldbus You’ve Got  Add instruments for equipment condition and performance monitoring o On premise or IIoT  Fieldbuses usually not fully populated  Add sensors for condition monitoring and energy management Control System Condition Monitoring System & Energy Management System etc. Process Control & Monitoring Condition Monitoring & Energy Management etc.

FF Configuration Engineer to avoid alarm flooding

Same as for Avoid Alarm Flooding: HART Instrument Diagnostic Alarm Management  If the instrument diagnostic alarm management system is not configured there will be a flood of nuisance alarms o System will not be used  ISA108 guidance being developed  Interim guide: o http://www.eddl.org/DeviceManagement/Pages/DeviceDiagnostics.as px  Specify a control system supporting diagnostics alarm management o Filtering based on criticality o Routing to the right person

Same as for HART Instrument Diagnostic Alarm Routing Instrument Tech Operator • Failure • Failure • Maintenance Required • Function Check • Out of Specification Nuisance Alarms Devices

Same as for HART Instrument Diagnostics Alarm Rationalization  Categorize severity of diagnostics: o NAMUR NE107  Identify criticality to the process for each device tag  Configure system and devices

Factory Acceptance Test (FAT) Test to make sure instrument diagnostics alarm management will work as intended

Same as for HART FAT Interoperability / Integration Test  Connect one of each device type  Open each device type in the IDM software o Verifies the DD file for each type and version of the device has been loaded o Verifies the device displays correctly  Download a device configuration o Verify the download is error free

FF Installation Wiring

Same as for Good Digital Communication Installation HART 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 Don’t spend too much  Ground device housing and junction boxes  Don’t coil signal cables and power cables together the first 3…  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

Same as for Other Good Installation Practices 4-20 mA  Do not pull cable with too much force  Make sure cable glands are tight  Seal unused conduit entries Don’t spend too much  Use correct size ferrule/fork and tool  Do not cram wires in device terminal compartment the first 3…  Do not over/under-tighten screws  Make sure covers are tight  Do not tighten cable-tie too much  Label wires  Observe polarity

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

Same as for HART Instrument Technician Culture Change  Review instrument diagnostic alarms o Instrument technicians must review the instrument diagnostic alarm summary and log every day  Spend time on devices which need attention  Check the software first o 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) o Rewrite work procedures to include IDM software  Inspection, replacement, calibration and other tasks

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

Same as for HART Monitor Network Health  Periodically check communication Packet Error Rate (PER) to detect deteriorating communication before alarms appear  Built-in control system communication diagnostics

System Management Keep systems up to date with new device types and versions

Same as for HART 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 o You don’t have to figure which you need now and which you don’t o You never know when new devices will be installed o 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 onto the system automatically as they become available

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