Design Benefits. Teo Puay Yong Pepperl+Fuchs. On Behalf of FF Marketing Society. The Future is Digital. 1 The Future is Digital

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1 Design Benefits The Future is Digital Teo Puay Yong Pepperl+Fuchs On Behalf of FF Marketing Society 1 The Future is Digital

2 Design Benefits from Applying Foundation Fieldbus Bus structure and Wiring Loop Integrity Going digital available verification tools Majority vendor support Flexible hazardous area realization Eliminating Marshalling 2 The Future is Digital.

3 User Benefits - Life Cycle Savings Cost saving in plant life cycle Operation Design Installation FAT,SAT Renewal Maintenance CAPEX Savings OPEX Savings Saving of Cable & Cabinet Small # of instruments (control in field) HPT / HPT-IS / FISCO / ic Engineering FAT/SAT Smaller System Footprint 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 3 The Future is Digital.

4 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.

5 Conventional 4-20mA Design -Multiple IS Barriers -Multiple cables Ethernet/TCP/IP Management Work station Internet/Intranet PC/VME Ethernet TCP/IP Operations Maintenance Ex 5 The Future is Digital.

6 Foundation Fieldbus Design Benefits in wiring and infrastructure -Common Power Supply -Common Bus cable Ethernet/TCP/IP Management Work station Internet/Intranet PC/VME Ethernet TCP/IP H1 Operations Maintenance Common Bus Fieldbus Fieldbus EX FF Power Supply 6 The Future is Digital.

7 Conventional wiring 2 nd level 1 st level junction box Multicore cables 7 The Future is Digital.

8 Fieldbus system wiring Fieldbus power supplies Control system Segments > 900 Instruments 8 The Future is Digital.

9 Benefits in hardware Fieldbus Less barriers, no marshalling, less I/O cards, less wiring, smaller control room Conventional 9 The Future is Digital.

Supply marshalling cabinet 20 terminations distributor 20

10 Benefits-wiring and termination savings For 10 instruments marshalling cabinet 20 terminations 2 terminations FF Power Supply marshalling cabinet 20 terminations distributor 20 terminations 11 terminations 5000 m cable 500m 800m cable 10 The Future is Digital.

11 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.

12 Benefits by Concept 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 12 The Future is Digital.

13 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.

14 Design Perception of single loop integrity HMI CPU: Performs PID function DCS non Ex non Ex IS barrier (Intrinsic safety) for wiring into hazardous area Ex Ex 4-20mA 4-20mA 14 The Future is Digital.

15 Design - Single loop integrity on FF HMI DCS Redundant H1 card Redundant - IS Device Coupler 15 The Future is Digital.

16 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.

17 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.

parameters) are not required Spur calculations negligible (spur voltage drop is < 0.

18 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.

19 Many Vendor support Power Supply Single High Power IS FISCO - IS Redundant, Multi-segment 19 The Future is Digital. 19

20 Many vendor support Device couplers Zone1 Fieldbus barriers Ex me [ia] Zone 1/0 IS Zone 2 20 The Future is Digital. Zone 1 Ex me 20

21 Validation Benefits at Hazardous area applications design Fieldbus signal: Ex parameters standardized FISCO: 17.5V, 380mA, 5.32W (IEC ) 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.

22 Engineering Benefits - Flexible Hazardous area design Design criteria covered by IEC Further supported by AG 181 ( rev 3.1) Project applications vary based on 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 22 The Future is Digital.

23 Segment Overview Power Supplies Surge Protec. Device Coupler Device Couplers FieldbusBarrier Terminator Surge Protect. Field Devices Field Devices Field Devices Fieldbus Process Interfaces Field Devices 23 The Future is Digital.

24 Physical Layer IEC Physical Layer standard 31.25kbit/s transmission rate Up to 32 devices per segment - depends on several factors Limited to 16 by host Limited by Power(current) Limited to less by distance Limited to less by process cycle time Shielded twisted pair recommended can use existing field wiring 2-core-cable carries power and signal (like HART) Up to 1900m (total) with best cable up to 9.5km with repeaters Limited by Power (voltage) Up to 120m spur length Manchester II coding used to transmit data Data transmission approximately by a ± 9mA modulation signal Minimum working voltage 9 Volts ( Range is 9-32V) and current consumption 10-30mA per device 24 The Future is Digital.

Physical Layer Point-to-point ( = 1 device only)

practice Daisy chain Device connection Can be

25 Physical Layer Point-to-point ( = 1 device only) - not cost efficient Line (bus with spurs) Line - high maintenance Daisy chain - prone to failures Chickenfoot (tree) - Highest reliability, best practice Daisy chain Device connection Can be intrinsically safe Chickenfoot 25 The Future is Digital. 25

26 Fieldbus Cable Instrumentation Cables Electrical power cable with poor noise immunity Fieldbus Foundation Cable Type and Description Type A: Multi or single-twisted-pair, individually shielded Type B: Multi-twisted-pair, with an overall shield Type C: Multi-twisted-pair, without a shield Type D: Multi-core, without twisted pairs with an overall shield Max Length 1900 m (6232 ft.) 1200 m (3936 ft.) 400 m (1312 ft.) 200 m (656 ft.) 26 The Future is Digital. 26

27 Fieldbus Cable Example: Type A cable: Shielded twisted pair Recommended Type A does not specify the diameter; You can get type A cable in AWG 22, AWG 18, AWG 16, etc Type A is also available as multicore: as long as individual pairs are twisted and shielded, it is type A 27 The Future is Digital.

28 User Benefit : Design guidelines 28 The Future is Digital.

29 29 The Future is Digital.

30 User Benefit : Choices of Approach at Hazardous locations Zone2 -Limited Power -High Power Refer AG High power ( Exe + IS ) High Power IS 30 The Future is Digital.

31 Typical Zone Certifications Safe area, Zone2 Existing standards -Ex na ( Non arcing) / Ex nl ( energy Limiting) -FNICO ( Non-Incendive) -Ex nl and FNICO changed to Ex ic ( similar to IS) -Zone1 -Ex d ( Explosion Proof) -FISCO -High Power Trunk (FieldBarrier, DART) 31 The Future is Digital.

32 Application - Zone2 - ExnA / ExnL Ex na 230V, 500mA Ex nl Zone V 230VAC V 230VAC 32 The Future is Digital.

33 Application - Zone2 - Exic Ex na 23V, 500mA Ex ic I O V U O U O Zone2 230VAC V FISCO / ENTITY 230VAC 33 The Future is Digital. Spur. Intrinsically safe Ex ic, Exia Non-incendive Ex nl

34 Application Area - Zone 1 (EEx d) Fieldbus Power Hub Segment Protector Ex me Ex e V 230VAC V Instruments Ex d Zone 1 34 The Future is Digital.

35 User Benefit : Choices of IS Approach at Hazardous locations Zone1 - IS -Limited Power -High Power Refer AG High power ( Exe + IS ) High Power IS 35 The Future is Digital.

36 User Benefit : Choices of IS Approach at Hazardous locations Example IIC Gas Group application 36 The Future is Digital.

37 37 The Future is Digital.

38 Design Benefits Flexibility in IS design Limited Power ENTITY / FISCO Power FISCO IIC FF Power Supply IS Spurs V = 12.4V I = 120mA ~11V - - Zone 1 38 The Future is Digital. IS Verification Eliminated

39 39 The Future is Digital.

40 Design Benefits Flexibility in IS design High Power Trunk Exe + IS Fieldbus barrier Ex e HPT Power supply V = 30V I = 500mA ~11V 40 The Future is Digital. Ex ia (FISCO + Entity) IS Verification Eliminated / Simplified Zone 1 IS Spurs

41 Design Benefits Flexibility in IS design High Power Trunk - IS HPT IS Power supply protected by DART DART Segment Protectors V = 22.4V I = 360mA ~11V Zone IS Spurs 41 The Future is Digital. IS Verification Simplified

42 Design Benefits Flexibility in Bringing the same HPT to different hazardous areas Device Couplers Fieldbus barrier Ex e V Zone 2 Ex ic Ex d Ex ia 230VAC Zone 1 Zone 1 42 The Future is Digital.

43 Benefits by selecting relevant Hazardous area approach Flexibility to handle changes and additions late in the project Selecting the cost effective solution Reducing the hardware Future expansion Additional features 43 The Future is Digital.

44 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 44 The Future is Digital.

45 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 45 The Future is Digital.

Introduction to Fieldbus Foundation Physical Layer

Introduction to Fieldbus Foundation Physical Layer Fazi Hashim MTL Muhammad Syafiq bin Hamid KLAESB Product Sales /Application Engineer Email: muhammad.syafiq@klaesb.com Fieldbus What is fieldbus Benefits