FOUNDATION FIELDBUS PHILOSOPHY
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AJ.I.END.UENTS
DOCUMENT CATEGORY
PRPD
•
CKD
APPROVAL
APPD
AI'PD
D
REVIEW
DATE
0
TRANSMJIT AL NO.
DATE
B
15050901-KP·T· 001005
13-Aug· 15
DEPARTMENT
NAME
SIGNATUREITR.NO
DATE
TITLE
INFO
KOC APPROVAL PREVIOUS REVI SION
HODC REVIEW/APPROVAL(IF APPLICABLE)
APPROVAL CODE
15050901
I
EF/1852
CONTRACTOR DOC . No. :
A
FOUNDATION FIELDBUS PHILOSOPHY
Project: LOWER FARS HEAVY OIL DEVELOPMENT PROGRAM PHASE · 1 (60MBOPD) CONTRACT NO : COMPANY PROJECT NO: SCALE:
15050901-000·00·IC·PHL·0002
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SHEET
1 of 41
K.O.C. DOC. No. :
SHEET
1.0 INTRODUCTION ............................................................................................................................4
2.0 SCOPE ............................................................................................................................................4
3.0 DEFINITIONS & ABBREVIATIONS ................................................................................................4 3.1 DEFINITIONS .......................................................................................................................... 4 3.2 ABBREVIATIONS .............................................................................. ~ ..................................... 5
4.0 REFERENCE DOCUMENTS ..................................................................................................................lO 4.1 KOC DOCUMENTS ................................................................................................................ 10 4.2 PROJECT SPECIFICATIONS .................................................................................................... 11 4.3 APPLICABLE INTERNATIONAL CODES & STANDARDS ........................................................... l l 4.4 ORDER OF PRECEDENCE ...................................................................................................... 15
5.0 ENVIRONMENTAL CONDITIONS ..............................................................................................15
6.0 FOUNDATIONTM FIELDBUS OVERVIEW ...................................................................................lG
7.0 FOUNDATION™ FIELDBUS: PROJECT IMPLEMENTATION .................................................... 18 7.1 STRATEGY ............................................................................................................................. 18 7.2 DESIGN BASIS ....................................................................................................................... 18 7.3 DESIGN PROCESS .................................................................................................................. 18 7.41NSTALLATION & COMMISSIONING ...................................................................................... 19
8.0 FOUNDATIONTM FIELDBUS: DESIGN GUIDELINES ................................................................... 20 8.1 APPLICATION ........................................................................................................................ 20 8.2 SEGMENT DESIGN CONSIDERATIONS ................................................................................... 20 8.3 CONFIGURATION GUIDELINES .............................................................................................. 21 8.4 BULK POWER SUPPLIES ........-................................................................................................ 23 8.5 SCHEDULING ......................................................................................................................... 23 8.6 LINK ACTIVE SCHEDULER (LAS) ............................................................................................. 23 8.7 DESIGN DOCUMENTATION ................................................................................................... 23 8.8 FIELDBUS DEVICE REQUIREMENTS ....................................................................................... 24 8.9 HOST REQUIREMENTS ......................................................................................................................29 8.10 FAT ..................................................................................................................................... 30
8.11 REDUNDANCY ••.......•............•....•......................................................................................... 31 8.12 FF PSU REQUIREMENTS ......•.•.....••......................•.......•.•••..•••.•...............•....•••......•.............. 31 8.13 TOPOLOGY •.....•. •..•.•••• ••••.•.•.••••••••..••..•.•.•...... •.•.•• •.•...•.•••.••••••.•.•. •.•..•••••.....•..•....•.•...•.•...•...•• 31 8.14 HAZARDOUS AREA INSTALLATION OPTIONS .......................................•• ............................. 32 8.15 DESIGN CRITERIA .....••• .......•.•..•.•••...•••.•.•.••...•.•.•.•.•.•••.•.••..........•.........•...............................• 33
9.0. INSTALLATION, TESTING AND CALIBRATION ............•.......................•...................................39
10.0 APPENDIX 1:- FIELDBUS SEGMENT DIAGRAM WITH FIELDBUS BARRIER .....................•.. 40
11.0 APPENDIX 2:- FIELDBUS SEGMENT DIAGRAM WITH DEVICE COUPLER .....................•...... 41
1.0
INTRODUCTION
Kuwait Oil Company (K.S.C), hereafter called COMPANY, have awarded the consortium of Petrofac
International
Ltd.
(Petrofac)
and
Consolidated
Contractors
Group
S.A.L(Offshore)(CCC) thereafter called CONTRACTOR, the Works comprising all things to be done and services to be provided by CONTRACTOR including but not limited to the engineering
design,
procurement
of Material,
expediting,
shipping,
placement
of
Subcontracts, project management, construction, inspection , testing, pre-commissioning, training of COMPANY personnel, commissioning, operation and maintenance during the ramping up of production to 60 MBOPD until turnover,
performance testing and all other
works to complete the "Lower Fars Heavy Oil Development Program Phase-1 (60 MBOPD)" on a Lump sum Turnkey (LSTK) basis, to provide COMPANY with complete, proven and operable facilities.
Phase-1 facilities comprises of two well blocks which shall be designed to process a nominal 60,000 BOPD of heavy oil. The field shall be developed using thermal recovery process which shall employ Cyclic Steam Stimulation (CSS) followed by Steam Flood (SF).
The broad scope involves development of Production Support Complex (PSC), Central Processing facility (CPF), Well Blocks 02 and 03, Infield Satellite Station (ISS), Trunk and Steam Lines, Pipelines for Export Oil, Fuel Gas, Make Up and Disposal Water, Sub Stations, New Storage Tanks along with Loading and Filling Manifolds and New Crude Oil Control Centre (COCC) and Pumps in South Tank Farm (STF).
2.0
SCOPE
The ·scope of this document relates to all FOUNDATION 1M Fieldbus engineering, design, procurement, configuration, testing, installation and commissioning activities.
3.0
DEFINITIONS & ABBREVIATIONS
3.1
DEFINITIONS
For the purpose of this document, the words and expressions listed below shall have the meanings assigned to them as follows:
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DOC. TITLE:
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PROJECT
PAGE
LOWER FARS HEAWOll DEVELOPMEN T PROGRAM
Lower Fars Heavy Oil Development Program Phase-1 (60 MBOPD)
CONTRACT
15050901
KOC
Kuwait Oil Company
CONTRACTOR
Petrofac International Ltd and Consolidated Contractors Group S.A.L(Offshore)
VENDOR
SUPPLIER or MANUFACTURER
3.2 ABBREVIATIONS
Abbreviation
=
Definition
AMS
Asset Management System
API
American Petroleum Institute
ATEX
Atmosphere Explosive
BUS
A H1 Field bus cable between a host system and field devices connected to multiple segments, sometimes through the use of repeaters
CCR
Central Control Room Common File Format: a software file used by the host system to know
CFF
the devices detailed FOUNDATION 1),\ Fieldbus capabilities without requiring the actual device. This file format is used for Capabilities and Value files
Communications Stack
Coupler
A Communications Stack is device communications software which provides encoding and decoding of User Layer messages, deterministic control of message transmission, and message transfer A Coupler is a physical interface between a Trunk and Spur, or a Trunk and a device
CPF
Central Processing Facility
DC
Direct Current
DD
Device Descriptor; A DD provides an extended description of each
Petro~ac (OJ A ,::,:::o, "''""' '""oso:Hv
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LOWER FARSHEAVYOILDEVELOPMENT PROGRAM
l_co_ntrac~c::_:__~~-50_9~~------_f._OC:::-~-=---;-~0_5_0~~J_-0_0~~-00_-l0._~~00_ 02-_-:::_~---l6 of 41 -----~m_p_a:_;;_;~r;;:~~o~'-F_i-1_8_5_2-_ --t Definition
Abbreviation
object in the Virtual Field Device (VFD), and
includes information
needed for a control system or host system to understand the meaning of data in the VFD DDL
Device Description Language Ability to measure the maximum delay in delivery of a message
Deterministic
between any two nodes in a network. Any network protocol that depends on random delays to resolve mastership is non-deterministic
DLL
Data Link Layer: The DLL controls transmission of messages onto the Fieldbus, and manages access to the Fieldbus through the Link Active Scheduler (LAS). The DLL used by FOUNDATION™ Fieldbus is defined in IEC 61158 and ISA S50. It includes Publisher I Subscriber, Client I Server and Source I Sink service.
EMC
Electromagnetic compatibility
ESD
Emergency Shutdown
F&G
Fire and Gas
FAT
Factory Acceptance Test
FF
FOUNDATION™ Fieldbus
FFJB
FOUNDATION™ Fieldbus Junction box FOUNDATION™ Fieldbus Power Conditioner (provides impedance
FFPC
matching at Fieldbus signaling frequencies, the FFPC may be active or passive) FOUNDATION™ Fieldbus Power Supply Unit (specially designed to
FF PSU
incorporate power supplies and power conditioners, the later provide impedance matching at Fieldbus signaling frequencies . FF PSUs may incorporate segment diagnostic capability) A digital, two-way, multi-drop communication link among intelligent
Field bus
measurement and control devices. It serves as a Local Area Network (LAN) for advanced process control, remote input/output and high speed factory automation applications The Fieldbus Access Sublayer (FAS) maps the Fieldbus Message
FAS
Specification (FMS) onto the Data Link Layer (DLL)
Abbreviation
Definition
Function Blocks: Software blocks built into Fieldbus devices as FB
needed to achieve the desired control functionality. Standard FBs include AI, AO and PID control
FDS
FunctionalDe~gnSpedfication
FISCO
Fieldbus Intrinsically Safe Concept
FNICO
Fieldbus Non lncendive Concept
H1
FOUNDATION 1M Fieldbus network operating at 31.25 kbps
H1 Device
An H1 Field Device is a Fieldbus device connected directly to an H1 Fieldbus. Typical H1 Field Devices are valves and transmitters
HART HIST HMI
Highway Addressable Remote Transducer Host lnteroperability Support Test is a test performed to test host system conformance to the FOUNDATION]),\ Fieldbus specifications Human - Machine Interface Control system that has FOUNDATION]).\ Fieldbus capabilities to
Host System HPT
configure and operate FOUNDATION]),\ Fieldbus segments High Power Trunk High Speed Ethernet is the FOUNDATION]).\ Fieldbus backbone network
HSE
running at 100 Mbps
HVAC
Heating, Ventilation and Air-Conditioning
1/0
Input I Output
ICSS
Integrated Control and Safety System
IEC
International Electro technical Commission Interchangeability is the capability to substitute a device from one
Interchangeability
manufacturer with that of another manufacturer on a Fieldbus network without loss of functionality or degree of integration lnteroperability is the capability of a device from one Manufacturer to
lnteroperability
interact with that of another Manufacturer on a Fieldbus network without loss of functionality
IP
Ingress Protection
ISO
International Standards Organization
Definition
Abbreviation
lnteroperability Test Kit used by the Foundation to "tick mark" ITK
devices and confirm compliance with the relevant FOUNDATIONT>A Fieldbus standards. This is a pass/fail test. Only devices passing the full suite of tests receive the FOUNDATION 1M Fieldbus "tick mark"
JB
Junction Box
kbps
Kilobits per second
LAN
Local Area Network Link Active Scheduler: A LAS is a deterministic, centralized bus
LAS
scheduler that maintains a list of transmission times for all data buffers in all devices that need to be cyclically transmitted. Only one LM device on an H1 Fieldbus Link can function as that link's LAS A Link is the logical medium by which H1 Fieldbus devices are interconnected. It is composed of one or more physical segments
Link
interconnected by bus Repeaters or Couplers. All of the devices on a link share a common schedule which is administered by that link's current LAS
LCD
Liquid Crystal Display Link Master: Any physical device containing LAS functionality that can
LM
control communications on an H1 Fieldbus Link. There shall be at least one LM device on an H1 Link; one of those LM devices shall be elected to serve as LAS; typically the H1 card for that segment
LOT AM
List Of Technical Approved Materials The repetitious scheduling of the function block within all the devices
Macrocycle
on a segment. The LAS is responsible for scheduling of the segment macrocycle
MCC
Motor Control Centre
MOV
Motor Operated Valve
P&ID
Piping & Instrumentation Diagram
PCS
Process Control System
PECS
Packaged Equipment Control System
Physical Layer
The Physical Layer receives messages from the Communications Stack
Definition
Abbreviation
and converts the messages into physical signals on the Fieldbus transmission medium, and vice-versa PID
Proportional, Integral, Derivative
PLC
Programmable Logic Controller A Resource Block (RB) describes characteristics of the Fieldbus device
RB
such as the device name, manufacturer and serial number. There is only one RB in a device
Schedule
Schedules define when Function Blocks (FBs) execute and when data and status is published on the bus A section of a H1 Fieldbus that is terminated in its characteristic
Segment
impedance. Segments can be linked by Repeaters to form a longer H1 Fieldbus. Each Segment can include up to 32 physical devices (although the practical or project limit can be lower)
=
SPD
Surge Protection Device
SPI
SmartPlant Instrumentation
Spur
An H1 branch line final circuit connecting the field device to the Trunk A Transducer Block (TB) decouples Function Blocks (FBs) from the local 1/0 functions required to read sensors and command output
TB
hardware. TBs contain information such as calibration date and sensor type. There is usually one TB channel for each input or output of an FB Impedance-matching module located at or near each end of a
Terminator
transmission line. Terminators are used to minimize signal distortion and convert the current signal transmitted by one device to a voltage signal that can be received by all devices on the network
Topology
The segment structure: Tree ('Chicken Foot'), Spur, Combination of tree and Spur, etc. are examples A Trunk is the main communication highway between devices on an H1
Trunk
Fieldbus network. The Trunk acts as a source of main supply to Spurs on the network
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IPetrofac "''""'PHILOSOPHY j I--·------------·--------·---------·-·---··------l~ Contract No.: 15050901 DOC. No. : 15050901~000-00-IC·PHL-0002--·TREv~· ----
PAGE
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LOWEAFAR SHEAVYOIL DEVELOPMENT PROGRAM
10of41r---·Compa:;~;~~~~~~Q~F/185i-··------
Definition
Abbreviation UCP
Unit Control Panel
UPS
Uninterruptible Power Supply The User Application is based on "blocks," including Resource Blocks
User Application
(RBs), Function Blocks (FBs) and Transducer Blocks (TBs), which represent different types of application functions The User Layer provides scheduling of Function Blocks (FBs), as well as
User Layer
Device
Descriptors
(DDs)
which
allow
the
host
system
to
communicate with devices without the need for custom programming A Virtual Field Device (VFD) is used to remotely view local device data
VFD
described in the object dictionary. A typical device will have at least two VFDs
4.0
REFERENCE DOCUMENTS Except where a specific edition or revision is identified by date or revision I edition number, the edition in effect at the time of the contract shall govern.
4.1
KOC DOCUMENTS
Document No.
Rev
015-JH-1909
KOC-1-001 KOC-1-002
Rev 0
Equipment.
11 C8972-00-IC-SPC-0001
KOC
Rev 0
Control System Design
Std.
for
For
Packaged
Instrumentation
&
KOC Std . For Instrument Installation KOC Std. for Instrument Cables KOC
Std.
for
Hazardous
Area
Classification KOC Std. for Packing, Marking and
KOC-G-004 KOC-G-007
Instrumentation
Rev 0 6
Description
11 C8972-00-IC-SPC-1909
11 C8972-00-IC-SPC-0011,
KOC-1-011
KOC-G-002
Addendum/Criteria Doc No .
2
Documentation
4
-
KOC Standard for Basic Design Data
Petrofac l
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contract
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DOC. TITLE:
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LOWEAFAASHEAVYOILDEVELOPMENT PROGRAM 9
No.:_~.~~~-------- looc::__ti-:- ~~so9-o~:ooo~oo-I~-P~~oo2-§-:-;o-l 1 1 of41 ---z~~~~~~ ~m~ KOC Standard for Spare parts and KOC-G-009 Maintenance data KOC Standard for Plant Equipment Identification,
KOC-G-012
Nameplates
and
Pipeline Markers
4.2
PROJECT SPECIFICATIONS Document No.
Rev
11 C8972-00-IC-CRT-0001
1D
Description Instrumentation, Control and Telecommunication Design Criteria
4.3
15050901-000-00-IC-BOD-0002
B
Instrumentation Design Basis
15050901-71 0-00-IC-DAS-0033
A
Instrumentation Cables Datasheet
15050901-000-00-IC-PHL-0001
A
Instrument- Earthing Philosophy
11 C8972-00-IC-PHL-0002
2
Control System Design Philosophy
11 C8972-00-IC-PHL-0003
2
I&C SCADA Requirements
11 C8972- 10-IC-SPC-0001
2
Control System Specification
11 C8972-00-IC-SPC-01 06
1B
Telecommunication Specification
APPLICABLE INTERNATIONAL CODES & STANDARDS Document Number
Title
Revision
Atmospheres Explosibles (ATEX) Directive (94/9/EC)
Directive 99/92/EC
Electrical and Mechanical Equipment for use in
1st edition
Explosive Atmospheres (ATmospheres EXplosibles)
5th Jan 2000
Safety of Installation.
16th Dec 1999
International Society of Automation (ISA) ISA 5.1
Instrumentation Symbols and Identification
8th Sep 2009
ISA 5.2
Binary Logic Diagrams for Process Operators
1st Jan 1976
Document Number
Title
Revision (R 1992)
ISA 5.3
Graphic Symbols for Distributed Control/ Shared
1st Jan 1983
display Instrumentation, Logic and Computer Systems ISA 5.4
Instrument Loop Diagrams
1st Jan 1991
ISA 18.2
Management of Alarm Systems for the Process
23rd Jun 2009
Industries ISA TR50.02 Part 3 &
Fieldbus Standard for Use in Industrial Control
4
Systems Parts 3 & 4: Technical Report for Fieldbus
15th Apr 2000
Data Link Layer - Tutorial ISA 71.04
Environmental Conditions for Process Measurement &
16th Aug 2013
Control Systems: Airborne Contaminants American Petroleum Institute (API) API RP 551
Process Measurement Instrumentation
1st edition 1st May 1993
API RP 552
Transmission Systems
1st edition 1st Oct 1994
British Standards Institution BS EN 50288
Multi-element metallic cables used in analogue and
Various Parts
digital communication and control. Sectional specification for instrumentation and control cables. BS EN 60801
Electro Magnetic Compatibility for Industrial Process
Various Parts
Measurement and Control Equipment BS EN 60812
Analysis techniques for system reliability Procedure
30th Jun 2006
for failure mode and effects analysis (FMEA) BS EN 61158
Industrial Communication Networks Fieldbus
Various Parts
Specifications Engineering Equipment and Material Users Association (EEMUA) EEMUA PUB NO 189
A Guide to Fieldbus Applications to the Process Industry
1st Jan 1997
I DOC. TITLE:
Petrofac
...
.
ll j
FOUNDATION FIELDBUS PHILOSOPHY
oc._.__ No._ . _:_1_ 5_0_5_0~1~000-00:j(:-~-~ii:Oooi_ ____
Contract No. :._1_So_so_90 _ 1_ _ ___._o__
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JREV-:-;o--- 13
o f 41
i
LOWEAFAASHEA';;;;;;:-=0Pf.1ENT PROGRAM
r----~::~~~7~F /1 852
Title
Document Number
Revision
International Electrotechnical Committee (IEC) IEC 60079-0
IEC 60079-1
IEC 60079-2
IEC 60079 -7
IEC 60079-11
IEC 60079 -14
IEC 60079-15
IEC 60079-17
IEC 60079-18
IEC 60079-25
Electrical Apparatus for Explosive Gas Atmospheres ,
Edition 6.0
Part O:General Requirements
1st Jun 2011
Electrical Apparatus for Explosive Gas Atmospheres,
Edition 6.0
Part 1: Flameproof enclosures "d"
1st Apr 2007
Electrical Apparatus for Explosive Gas Atmospheres,
Edition 5.0
Part 2: Pressurized enclosures "p"
1st Feb 2007
Electrical Apparatus for Explosive Gas Atmospheres,
Edition 4 .0
Part ?:Increased Safety 'e'
1st Jut 2006
Electrical Apparatus for Explosive Gas Atmospheres,
Edition 6.0
Part 11: Intrinsic Safety "i"
1st Jun 2011
Explosive Atmospheres - Electrical Installations
Edition 5.0
Design, Selection and Erection.
1st Nov 2013
Explosive Atmospheres , Part 15 : Equipment
Edition 5.0
protection by type of protection "n"
1st Nov 2013
Explosive atmospheres - Part 17: Electrical
Edition 4.0
installations inspection and maintenance
1st Aug 2007
Electrical Apparatus for Explosive Gas Atmospheres,
Edition 3.0
Part 18: Encapsulation "m"
1st May 2009
Intrinsically Safe Electrical Systems
Edition 2.0 24 Feb 2010
IEC 60529
IEC 61000
Degrees of Protection Provided by Enclosures (IP
Edition 2.2
Code)
1st Aug 2013
Electro-magnetic Compatibility (EMC) - Generic
Various
Emissions Standard (Parts 1 to 6) IEC 61158-1
Fieldbus Standard for Use in Industrial Control
1st May 2014
Systems, Part 1: Introductory Guide. IEC 61158-2
Fieldbus Standard for Use in Industrial Control
Edition 5.0
Systems : Physical Layer Specification and Service
1st Jut 2010
Definition. IEC 61158-3-1 to 24
Fieldbus Standard for Use in Industrial Control
Various
. ·--
. I;~ Petrofac I
@ A
Contract _No. : 15050901
l
DOC. TITLE:
1 !FOUNDATION FIELoaus PHILosoPHY
1 II
-
r~·
-
~~-
J1 PAGE j00c:N';;:-·;-15o509ii!-~C-PH-l-0002_____JREV~-~~-=-~:~~:!~~~~F /1852
I
Document Number
LO\'/ER FAAS HEAVYOIL OEVELOPMENT PROGRAI.t
Title
Revision
Systems: Data Link Service Definition. IEC 61158-4-1 to 24
Fieldbus Standard for Use in Industrial Control
Various
Systems: Data Link Protocol Specification. IEC 61158-5-1 to 24
Fieldbus Standard for Use in Industrial Control
Various
Systems: Application Layer Service Definition. IEC 61158-6-1 to 24
Fieldbus Standard for Use in Industrial Control
Various
Systems: Application Layer Protocol Specification. Institute of Electrical and Electronic Engineers (IEEE) IEEE 802.3
Carrier Sense Multiple Access with Collision
28th Dec 2012
Detection (CSMA/CD) IEEE 802.4
Token-passing bus access method and physical layer specification
Fieldbus FOUNDATION 1M Technical Specifications AG-140
31.25 kbi ts Wiring and installation
AG-163
31.25 kbits Intrinsically Safe Systems
AG-181
System Engineering Guidelines
FF-103
Common File Format
FF-131
Standard Tables
FF-524
Device Descriptors File
FF-569
Host lnteroperability Support Test (HIST)
FF-581
Syst em architecture.
FF-586
Ethernet presence
FF-588
Field device access (FDA) agent
FF-801
Network Management
FF-816
31.25 kbi tls Physical Layer Profile/FISCO
FF-870
Fieldbus Message Specification
FF-880
System Management
Various Parts
Title
Document Number
Function Block Application Process Part 1
FF-890
Revision
-
(Architecture) Function Block Application Process Part 2
FF-891
-
(1 0 Standard FBs)
FF-892
Function Block Application Process Part 3 (Advance
-
FBs) FF-893
Function Block Application Process Part 4 (Multiple
-
1/0 FBs) Functi on Block Application Process Part 5 (Flexible
FF-894
-
FBs) FF-900
Device Description Language
-
FF-902
Transducer Block Application Process Part 1 (Basics)
-
FF-903
Transducer Block Application Process Part 2 (Details
-
for each Device Profile) FF-940
Communication Profile
-
4.4 ORDER OF PRECEDENCE
The supply of equipment, materials, services, and documentation shall be in accordance with the State of Kuwait and local rules and regulations and specific project requirements. In case of conflict on technical requirements, the following order of precedence shall apply: 1.
Specificati ons
2.
Data Sheets
3.
Drawings
In case of conflict or differences in requirements of the codes and standards, the most stringent of such codes and standards as defined by Contractor/Company shall apply.
5.0
ENVIRONMENTAL CONDITIONS
The site environmental conditions shall be in accordance with the requirements stated in Process Design Criteria Memorandum Phase I - CPF & ISS 15050901-000-PR-CRT-0001 & Process
Design Criteria Memorandum PHASE I - Export Oil Facility (EOF) 15050901-050-PR-CRT-0002 and KOC-G-007 Basic Design Data. ICSS equipment will be located in control and equipment rooms within enclosed buildings that have heating, ventilating and air conditioning (HVAC) systems to provide controlled temperature and humidity. Normal temperature is 24°C and humidity is 50%, ±10%. ICSS equipment shall continue to operate in HVAC upset conditions, when the temperature can fall to 5°C or rise to 50°C. Under these temperature excursions, the humidity can rise up to 90% (non-condensing).
6.0
FOUNDATION™ FIELDBUS: OVERVIEW FOUNDATION™ Fieldbus (FF) is based on an open architecture designed to be a process control network. It provides a communications protocol for control and Instrumentation systems in which each device has its own "intelligence" and communicates via an all-digital, serial, and two way communications system. All properties are measured, processed, communicated and controlled digitally; it enables digital closed loop control with signal fidelity. The gain in accuracy can be used to control closer to the operating point and improve process efficiency/throughput. FF is a deterministic; peer-to-peer protocol with individual devices communicating control information on a precise schedule without the need for a host to initiate communications; H1 bus communicates at 31 .25 kbps. The H1 FF network exhibits the following properties: • Master/slave network behaviour for acyclic communications (i.e. one device polls the others and the others merely respond) • Delegated token network behaviour for acyclic communications (i.e. devices serially granted time to broadcast at will) • Dedicated "scheduler" device for coordinating all segment communications • 8- bit address field (0 through 255 possible) • Maximum of 10 "live" devices on a segment (Refer to Section 8.3.1) HSE (High Speed Ethernet) bus communicates at 100 Mbps; it provides integration of high speed controllers, H1 subsystems, data servers and workstations; for details see Figure 1.
FOUNDATION™ Fieldbus is the only protocol with the built-in capability to distribute the control application across the network. H1 bus retains and improves upon the desirable features of the 4-20 mA analogue system such as: • A standardized physical interface to the field device. • Bus-powered devices on a single wire pair. • Intrinsic safety options In addition FOUNDATION™ Fieldbus enables a reduction in field cabling, marshalling cabinet footprint, hardware and installation costs, and faster facility start-up. However, the real value of FF technology is reduced operations and maintenance costs, increased plant performance and efficiency, and resistance to obsolescence. This is enabled by a digital architecture that uses the power of Smart field devices to deliver accurate control and an Asset Management System (AMS) to leverage the advanced diagnostic information to yield improvements in operating performance and process unit utilization . Figure 1:
Il l ( 1)
H l( 2) H1 (3) H 1(4 ) -
-- . . .
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- DOC. TITLE:
-
FOUNDATION FIELosus PHILosoPHY PAGE
·®·-
I I
~LOWER FAR S HEAVY OIL DEVELOPMENT PROGRAM
0oc:N~. : -15050~-~T-ooo-ci0:1c--P~~~oo2--=:_:::§:-:~=-~~~j=~~-~;~;~;'~~~~Fti85-2---
7.0
FOUNDATION™ FIELDBUS: PROJECT IMPLEMENTATION
7.1
STRATEGY FOUNDATION™ Fieldbus systems are a key part of Integrated Control and Safety Systems (ICSS) and a common approach applied across the LFHO Project is required to achieve: • Systematic, consistent and robust FOUNDATION™ Fieldbus (FF) system design • Common standard of control and monitoring of Process units. • Consistent methodology in design , application and architecture for FF systems
7.2 DESIGN BASIS This document provides the philosophy for implementation of FOUNDATION™ Fieldbus design for LFHO Project derived from KOC specifications and standards. 7. 3 DESIGN PROCESS To obtain the full benefits of FF technology, training and work practice changes are needed early in the project cycle. The design process should be front-end loaded where a comprehensive Fieldbus FDS is developed with the ICSS Vendor and due consideration is given to the changes when compared to traditional system implementation. The design includes: • The field devices and segments become an integral part of the PCS. This requires an integrated configuration, data management, and system architecture approach to field network design. • The system integration aspects of FF require the design activities to be performed earlier in the project lifecycle. • More complex functions are achieved in FF designs compared to traditional technologies. These complex functions offer considerable opportunities for operating cost-saving and improved commissioning and start-up. System, Field Device, and Segment Component testing processes are more complex than for simple analogue connections. • Standardization and modular design techniques shall be deployed. Typical configurations of hardware and software shall be thoroughly tested before high volume replication . • Systems, Field Devices, and Segment Components should all be subject to rigorous approval processes; these should include ITK registration, FF check mark and listed on the
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LOTAM for FF devices. Only ITK approved FOUNDATION™ FIELDBUS DD & CFF files shall be used. • Systems shall be rigorously tested; the FAT shall include representative tests that address the following:• Device integration : at least one of each of the FF device types shall be available at the staging facility. • Segment validation: Sample segments with the highest device load, communication load, and complex strategies shall be validated. All segments shall be verified at the H1 level and segment validation shall be done by ICSS Vendor. • Data reconciliation 7.4 INSTALLATION & COMMISSIONING
The inherent robustness of H1 segments is dependent upon the correct installation; specifically noise immunity is dependent upon the correct installation of terminators, cable screens and grounding systems. FF cable shield earthing and segregation shall have requirements similar to 4-20mA signals. Commissioning FOUNDATION™ Fieldbus technology requires a different approach than conventional analogue systems. With the right procedures and support, the FOUNDATION™ Fieldbus commissioning will be efficient and fast. The main areas to be addressed are: • Procedures: FF specific verification and loop check (segment) procedures are required . In addition , the installation should be verified prior to power-up and segment checkout. • Training: commissioning personnel should receive appropriate training. • Test equipment: FF specific test equipment should be provided. • Support: Vendor support should be provided to cover system management. • Records: The installed cable lengths should be recorded, and documentation are "as built". This will provide data required in the future to utilise spare capacity, and also baseline test records of all segments.
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FOUNDATION™ FIELDBUS: DESIGN GUIDELINES
8.1
APPLICATION
The use of 'Smart' field devices to facilitate remote maintenance and intervention shall be maximized. The PCS shall be based on FOUNDATION™ Fieldbus (FF) and wherever possible FF devices shall be used for control and monitoring. The PCS shall be supplied with an AMS to handle the diagnostic information and facilitate remote maintenance. AMS is considered as another sub-system that will be integrated with ICSS for collecting diagnostic data from all field equipment, reporting and analysis.
FF shall not be utilized for ESD applications, F&G applications, Compressor anti-surge control, discrete signals (switches), MCC signals and any process/machinery controls requiring high speed control. FF shall not be utilized for mechanical package Instrumentation where control is implemented from a Package Unit Control Panel (UCP). 8.2 SEGMENT DESIGN CONSIDERATIONS
Prior to allocating Fieldbus segments, the process control strategy should be complete, the P&IDs should be available 'Approved for Design', and instruments should be selected with locations determined . Although the FOUNDATION™ Fieldbus specification allows up to 32 devices per segment, there are practical constraints to abide by.
Factors to be considered during segment Design include: • Macro cycle time • Control loops, function blocks and scan rates • Complex loops, speed of process, fast-acting loops • Cable type and lengths • FOUNDATION™ Fieldbus Power supply output voltage • Power consumption of field Instruments • Voltage drop (Calculated voltage at device shall exceed device minimum voltage ratings by 4 Volts) • Instrument current, additional current consumption due to one spur short circuit fault, approx. 50mA
• Control system capability • Intrinsic Safety I Non-Intrinsic Safety application • Hazardous Area Installation Options - High Power Trunk (HPT) with field barriers. 8.3
CONFIGURATION GUIDELINES
8.3.1
SEGMENT DESIGN
8. 3. 1. 1 Transmitters and Control Valves grouping FOUNDATION™ Fieldbus (FF) segments shall be designed to accommodate 12 devices with a minimum of 3 spare where all other devices on the segment are input devices, i.e. smart transmitters.
There shall be a minimum of 3 spares where the segment includes output devices, i.e. smart valve positioners. Expansion beyond 12 devices shall be reserved for future use based on actual performance.
A Segment shall contain no more than 2 final control elements (i.e., control valves, modulating damper actuators, etc.). MOVs are not part of final control element. Not more than 3 remote operated MOVs shall be included in single segment.
Segments shall be designed with adequate spare capacity for future addition of one control loop (i.e. one transmitter and one final control element). This requirement is consistent with maximum loadings with 1-second loop execution.
The default macrocycle time shall be one second; the macrocycle shall have a minimum of 50% unscheduled time. The macrocycle shall allow for the addition of one transmitter and one final control element and still ensure that the minimum of 50% . unscheduled time is met. Minimum ITK revision shall be 6.0 or higher.
a) Possible segment grouping combinations for segment with 1 sec macrocycle are; •
All Open loops - 9 Transmitters + 3 spare
•
One Close loop - 7 Open Loop Transmitters +1 Close Loop Transmitter + 1 Control Valve + 3 spare
•
Two Close loop- 5 Open Loop Transmitters +2 Close Loop Transmitter+ 2 Control Valve + 3 spare
I~
Loop requiring faster scan time for e.g macrocycle 250 ms shall not be implemented in Foundation fieldbus.
8.3.1.2 Motor Operated Valves MOV's operating on Fieldbus shall be assigned to the respective segments. As a greater number of schedule communications is required for MOVs, the maximum number of MOV in a segment shall be limited to three (3) with additional one (1) as spare. 8.3.2 CONTROL All PID control algorithm shall be implemented in the PCS controller as per project philosophy.
Transmitters for the process measurement on redundant equipment such as pumps shall be distributed to reside on separate H1 segments. However, multiple measurements used to provide a calculated value shall be assigned to a common segment. Network/segment design shall be such that loss of a network/segment does not affect more than one of the parallel (redundant/spare) process units or equipment items. Final control elements shall have a configured fail-lock or Hold last position on loss of segment communication.
Standard FOUNDATION™ Fieldbus software algorithms shall be available to perform regulatory control functions. These process control functions shall be performed by predefined algorithms with configurable parameters in Host system. • Upper and lower clamps on all set points shall be available. • Algorithm calculations shall be performed in floating point engineering units or other such equivalent methods that do not require scaling. • Control functions that include integral action shall provide windup protection. Windup protection shall inhibit the integral action when the control block output is constrained by conditions such as: a) Output at high or low limits of span. b) Output at high or low clamps.
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No additional configuration shall be necessary to provide this
functionality. 8.4
BULK POWER SUPPLIES
The bulk power supply shall be redundant 24 VDC dedicated solely for Fieldbus network. The UPS distribution panel shall be considered as the common point where these two separate circuits originate. Over current protection shall be provided for each feed supplying power to an individual or group of FFPSU. 8. 5
SCHEDULING
Cyclic communication (publish/subscribe) shall only be used for control applications including process indication points.
Updating of graphics, faceplates, configuration and diagnostic information for maintenance shall be implemented via acyclic communication (client/server). Multi-scheduling allows selected loops to run faster than the macrocycle. The COMPANY shall approve multi-scheduling as it will reduce the number of devices per segment depending on the applied schedule. 8.6
LINK ACTIVE SCHEDULER (LAS)
The Link Active Scheduler (LAS) is responsible for coordinating all communication in a Fieldbus network. The primary LAS resides in the H1 interface card in the PCS, the redundant H1 interface card will take over in case of failure of the first card. In addition, a FF field device can also function as backup LAS. Only one device with backup LAS shall be enabled in one segment. 8. 7
DESIGN DOCUMENTATION
Fieldbus systems require broadly the same design documentation that is required for conventional control systems. The main differences are H1 segment diagrams and FF specific
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instrument datasheets. Documentation alterations, additions and deletions required for FF use are defined below. 8.7.1 PIPING & INSTRUMENTATION DIAGRAMS (P&ID's)
The line identification for FF signal wiring shall be as per the P&ID legends. The control or logic function balloons shall be shown independent of the hardware in which it is contained. 8.7.2 INSTRUMENT SEGMENT DIAGRAM
The segment drawing is a hardware-wiring diagram intended to show the physical connections and layout of the segment. If loops are in multiple segments, a traditional loop drawing is required in addition to a segment drawing.
Following guidelines shall be followed for segment drawings: • Soft data including display, function blocks and configuration data shall not be shown • Title block shall contain segment name. Segment name shall consist of 'Controller name', 'Card number' & 'port number' Example: ISD-01 0801 means controller name-01, card number-08, and port-1 • Drawing should include all network connections including H1 interface card, Bulk Power supply, FF Power supply, through to field devices, terminations, junction boxes, terminators, etc. • Indicate all segments, spur and field device tagging • Cable distance with voltage drop calculation results • Backup LAS device identification • Terminator locations
Refer to Appendix 1 for Fieldbus Segment with field barriers (for IS spurs) and to Appendix 2 for Fieldbus segment with Device coupler (for NIS spurs). 8.8
FIELDBUS DEVICE REQUIREMENTS
Field instruments and devices to be used in fieldbus application shall be an approved device for use in FOUNDATION™ Fieldbus.
Following are the general requirements which should be met:
• All FF devices shall be registered with the FOUNDATION 11'1 Fieldbus having passed the latest interoperability tests and bear FF "check mark" logo. Minimum acceptable ITK revision is 6.0 or higher. • Selected FF devices must be fully interoperable with the host system , including maximizing the associated advanced diagnostic features and fully coupled to the Asset Management Capabilities. • FF certified device is required to be capable of operating between 9 to 32VDC. • View block for all diagnostics and other relevant transmitter and sensor information • Backup LAS capability. • Incremental device description for extra functionality and/or software revisions in device memory. • Capable of performing continuous diagnostics, including self-test functions and providing specific diagnostic information . • Support for Trend Function Blocks and Alert Function Blocks. • Support for multivariable container parameter for tagging facilities. This shall also be supported in the host-end.
8.8. 1
FUNCTION BLOCKS All control strategies shall be implemented in the PCS and shall not be implemented in a FOUNDATION™ Fieldbus device.
18
Field input/output devices should include the minimum capabilities as given in the table below: Minimum Requirement
Device Type Pressure
AI (1)
Temperature
AI (1)
Mass Flow I Specific Gravity, percent solids & viscosity
AI (4)
Device Type
8.8.2
Minimum Requirement
Vortex Flow
AI (2)
Magnetic Flow
AI (2)
Ultrasonic Flow
AI (2)
Ultrasonic Level
AI (2)
Positioner
AO (1 ), PID, Dl (2)
Multivariable transmitter
AI (1 per variable minimum)
FIELD DEVICE DIAGNOSTIC The following types of diagnostics should be provided in the field device:
8.8.2.1 Public diagnostics Output device diagnostics that are viewable from any process control host. They help determine problems with valve, actuator and host. 8.8.2.2 Advanced diagnostics Full output device diagnostics that determine output device's health without removing it from the line. Advanced diagnostics come in two forms which are the dynamic scan and the step scan. 1)
Dynamic scan (online or offline method): Cycles output device and in one test collects all parameters for drive signal, dynamic error band, output signal, and output device signature.
2)
Step scan (online or offline method): Test moves output device in unique patterns, which help examine device's action in specific areas of travel. This action shall be password
protected
and
require
approval
of a process
operator
before
implementation. 8.8.2.3 Process diagnostics Process diagnostics are the tests which are conducted during process operation. This test moves an output device within a range until the process exceeds its configured maximum deviation. It allows maintenance personnel to compare host action, actuator action, output
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device action, and process action. Process diagnostics provide key information on the
impact that an output device has on the process, including but not limited to:
8.8.3
1)
Position accuracy
2)
Operating resolution
3)
Total valve travel
4)
Packing friction and hysteresis
5)
Static and sliding friction
6)
Dead band
FIELD DEVICE POWER
Generally, fieldbus devices should be bus powered, with the exception to device design that is externally powered (e.g. 4-wire devices). Externally powered FF devices (e.g. 4-wire devices) shall have isolation between external power and Fieldbus signal inputs. Bus powered devices should be specified to work with a minimum of 9 V DC. Any segment designed to operate below 13 V normally should carry a warning about additional loads in the network documentation. The total current draw from all devices on the segment shall not exceed the rating of the FOUNDATIONm Fieldbus Power Supply. The segment design shall take into account: a) Total device quiescent current draw b) One spur short circuit fault (i.e. - 50 mA additional current draw) c) 25%additional current load above the two previous requirements Devices should work with 60 mA current limiting short circuit protection, through a limit of 40 mA is preferred. 8.8.4
FIELD DEVICE SPECIFICATION
Applicable FF device data sheets shall be prepared similar to conventional instruments, but with additional FOUNDATION™ fieldbus information. The required VENDOR information for FF devices shall include, but not limited to, the following : a. Function block requirement b. Minimum Power required c. Device current draw (mA) d. Device inrush current (mA) e. Device (lift off) minimum voltage f. Block Execution time
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g. Polarity sensitivity h. Link Active Scheduler (LAS) capability i. Diagnostic requirements
j. Virtual communication relationships (VCR) k. Device capacitance
l. Fieldbus locator m. Software revision i. DD Revision ii. CFF Revision iii. ITK Revision with which device was tested (Minimum 6.0) Device manufacturer shall include information on non-standard or enhanced function data, and unique VENDOR diagnostic/advance diagnostic capabilities. 8.8.5
FIELD DEVICE TAGGING
Each FF device shall have a unique physical device tag and corresponding network address. FOUNDATIQN 11.1 Fieldbus device tag shall match the Instrument Tag indicated on P&ID. 8.8.6
FIELD DEVICE CONFIGURATION
All FF devices shall be configured by the device manufacturer with the following information: • Serial number • Tag name • Process Description as specified on the Instrument Datasheet Device addressing should follow ICSS specified ranges . Addressing used by ICSS Vendor shall be as follows: •
Assigned Address: from 20 to 247, 0 to 19 (Reserved) These are used for devices on the network except the temporary devices. Addresses 20 and 21 are assigned for the redundant H1 interface cards
• Default addresses: from 248 to 251 These are used for devices that have not been assigned an address by the master Configuration device. • Visitor addresses : from 252 to 255 These are used for devices that are not continuously present on the system such as hand held communicator, configuration tools or diagnostic equipment.
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Third-party systems or configuration tools connected through a communications interface to an H1 network shall not be used to: • Interrupt the operation of any device within the system • Change device address • Affect link schedule
For FF devices , the manufacturers shall supply the following: • Device Descriptors (DDs) files according to FF-524 • Common File Format according to FF-103 Standard device description language (DDL) provided by the Vendors shall be used throughout. 8. 9
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HOST REQUIREMENTS • Host FF lnteroperability: All FF Host systems shall have completed Host lnteroperability Support Testing (HIST) at FOUNDATION 11·' Fieldbus facilities , based on HIST Procedures document FF-569. FF Host systems shall support all features specified in the HIST. • Host FF Feature Integration: All Host FF functions, including engineering , configuration, maintenance, and operational display functions shall be integrated into a single seamless Host system. • Host-To-Device Revision Download Capability: Hosts shall have the capability to download software revisions to FOUNDATION 11·' Fieldbus devices. • Host Configuration Features: Host FF configuration shall be consistent in method and 'look and feel' with conventional configuration. • The Host configuration tool shall be capable of Offline FF configuration, e.g. to configure FF strategies with no segment or FF devices connected. The Host shall be capable of configuring all FF function blocks and parameters and support of Device Description (DD) services and Common File Format (CFF) specification. • Host Commissioning and Maintenance Functions: The Host shall be capable of commissioning, setup, and maintaining all FF devices. All standard functions must be integrated into the Host and available from Host workstations.
Asset Management Systems separate from the Host operator I engineering workstations will be used to manage and display real-time and historical diagnostic & maintenance information. However, it may not replace commissioning and maintenance function integrated into the Host as described above. 8.10 FAT
FAT for FOUNDATION™ Fieldbus should include sample testing of at least one of each type of device being used in the project. Details of FAT shall be part of ICSS FAT Procedure or Inspection Test Plan. FAT is an essential quality assurance check to verify that all the components of the HOST are working properly. The ICSS vendor shall develop and submit a separate written test plan and test procedure for integrated control system for FF networks for approval. The Following tests shall be conducted as a minimum for the FF networks. • A complete functional test shall be conducted for each type of FF device used in the project. This test will include, but not limited to, plug and play interconnectivity to host control system & verification of access to all device functional blocks and actual device operation (e.g. stroking of valves/ MOVs, simulation of process inputs for transmitters, etc.). • Calibration and setup of each type of FF device to verify the access to calibration wizards and setup procedures via the HOST system. • Changing RTD sensor types • Calibrating transmitter span • Zeroing transmitters • Zero and elevation adjustments on DP transmitters used for level applications • Setup and calibration of new positioners. • All calibration and setup procedures, for each FF device type, shall be documented in detail. • The ICSS vendor shall develop a redundancy fail-over test procedure for the H1 interface cards and FFPSU. The tests shall verify that automatic fail over shall not cause an upset (i.e., 1/0 signal bumps, loss of operator view, mode changes, etc.). All H1 interface cards and FFPSU shall be tested. • Each segment, including spares, shall be operationally tested by live connection of at least one FF device and one coupler device. The Test segment shall be connected to the terminal block designated for the field wiring.
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• A fully loaded segment shall have one spur short circuited, while confirmation is made that all connected devices still continue to operate properly. • Each FF segment wiring configuration shall be required to be tested with typical FF device on the link. 8.11 REDUNDANCY
To maximize availability, all H1 segments shall incorporate redundant components which include: • PCS Controller • PCS Controller Power Supply • H1 Interface Card • FF PSU & Power Conditioning module. 8.12 FF PSU REQUIREMENTS
• Redundant configuration • Backplane mounting to support 8 segments • Physical layer backplane mounted diagnostic module 8. 13 TOPOLOGY
Fieldbus segment components can be connected together in various architectures known as topologies, for example Tree (Chicken Foot), Spur or Combination topology. However, Tree (chicken foot) shall be the standard topology used for this project and is depicted below. Figure 2: Tree Topology
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8.14 HAZARDOUS AREA INSTALLATION OPTIONS The Intrinsically Safe (IS) concept utilizes a certified intrinsic safety interface to limit the available electrical energy to the circuit in the hazardous area.
The intrinsic safety interface is traditionally located in the safe area. Entity certified devices; Fieldbus Intrinsically Safe Concepts (FISCO) and Fieldbus Non-lncendive Concept (FNICO) follow this approach.
The High-Power Trunk (HPT) and Field Barrier approach locates the intrinsic safety interface in the field.
In general , • IS design and installation shall comply with IEC 60079-11 • IS Barriers should be isolated and have built-in repeater
High-Power Trunk with Field Barriers I Device Couplers shall be used for this Project.
The High-Power Trunk concept utilizes an Ex (e) trunk to provide power to field devices via Field Barriers and Device Couplers which are housed in FOUNDATION™ Fieldbus Junction Boxes (FFJB). The field barriers provide power to Ex (i) certified devices for IS applications. For Non-IS applications, device couplers provide power to Ex (d) certified devices.
Field barrier units provide intrinsic safety spur connections from a non-intrinsically safe trunk. When installed in a suitable enclosure, the units can be installed in Zone 1 with the trunk wiring implemented using suitably protected cable and increased safety [Ex(e)] connection facilities. Each unit normally supports six intrinsically safe spurs which may be connected to FISCO or 'Entity' certified Fieldbus devices in aZone 1 or Zone 0 hazardous areas.
Characteristics: • Intrinsic safety interface is located in the field. • Field Barriers and Device Couplers are powered by non-IS Ex (e) trunk. • Field Barriers and Device Couplers incorporate spur short circuit and current limitation protection.
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8. 15 DESIGN CRITERIA 8.15.1 Components of a Segment A typical H1 segment consists of the components identified in the figure below. Figure 3: FF Segment
H1 Card
FF JB
Trunk
DEVICE COUPLER
FF devices
COMPONENT
DESCRIPTION A Physical interface between a trunk and spur with built
Device Coupler
in short circuit protection with visual indication for each spur
FF Devices FFJB
FF Transmitters, Valves, etc. FF Junction boxes houses the field barriers or device couplers FF
I~
FF PSU
PSU's
incorporate
power
supplies
and
power
conditioners, the latter provide impedance matching at the
field bus
signaling
frequencies.
FF
PSU's
may
incorporate segment diagnostic capability. H1 Card Spur
H1 Card connects a H1 Segment to the Host (PCS) A Spur is a H1 Branch line that connects a device to the trunk A Trunk is the main communication highway between
Trunk
devices on an H1 network. The trunk acts as a source of main supply to the spur network
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DESCRIPTION An impedance matching module used at the end or near
Terminator (T)
the end of a transmission line to minimize signal distortions
8.15.1.1 Segment Length Maximum allowable cable length of an H1 segment for Type A cable is 1900 meters. This total segment length is computed by adding the length of the main trunk line and all the spurs that extend from it.
That is, Total Segment Length =Trunk length + the sum of all Spur Lengths. •
Maximum allowable Segment length (Trunk+ Spur)= 1700 meters
•
Maximum allowable spur length = 1100 meters
Note - Suitable type of configuration shall be adapted for well head instruments. 8.15.1.2 Spurs Only one FF device shall be connected to each spur. The recommended spur length is 40m or less and maximum spur length shall be limited to 100m.
8.15.1.3 Trunks Trunk cable running parallel to high power cables shall be minimized, and adequate spacing and shielding shall be employed to lower noise to acceptable levels. Cable segregation requirements are the same as 4-20mA signals. 8.15.2
WIRING DESIGN The following diagram depicts the typical scheme for the wiring concept of a FF based control system as applied to this project.
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PCS
Trunk Cable (5 or 10 pair)
FFJB
JB (Level 1)
CCR/ Substation
FIELD
Spur Cables ( t pair)
PCS Marshalling Cabinets located in the Instrumentation Room within the substation/CCR will be connected via Multipair FF cables to junction boxes in the field. Typically, two levels of junction boxes will be utilized.
Level 1 - Individually shielded 10 pair cables with 50% spare capacity routed from Marshalling Cabinets in the substation/CCR will be terminated in level 1 JBs .
Level 2 - Two pair cables will be routed from level 1 JBs to FFJBs (level 2 JBs), and a minimum of 20% spare capacity. Spur cables will be routed from FF JBs to each field device on the segment. However in cases having less instrument density, there will only be a single level of junction box which is level 2. All cables shall enter the enclosure from bottom I side and shall terminate at 1/0 termination strips residing within the Junction Box.
8.15.3
CABLE SPECIFICATION
FF cable shall be 1.13mm\ shielded twisted pair which meets the requirements of IEC 61158-2 Clause 22.7 .2 Type 'A'. Cable specification details are described in the Datasheet for Instrumentation cables (15050901-71 O-OO-IC-DAS-0033),Project specific criteria to KOC standard for Instrument Cables (KOC-1-011) 11 C8972-00-IC-SPC-0011 & KOC standard for Instrument Installation KOC-1-002.
8. 15.4
FF JUNCTION BOXES FF JBs shall be made of 55316, suitable for outdoor installation with minimum ingress protection of IP 65. FF JBs shall be in accordance with the Standard 'KOC-1-002'. 4 spur I 8 spur I 12 spur FF JBs shall be used in the project. Four (4) spur shall be mainly used for MOV. The following two types of FFJB shall be provided.
8.15.4.1 FF - Intrinsically Safe Junction Box FF Junction Boxes shall comply with the standardized design requirements specified below: •
House fieldbus barrier(s) that provides 12 spurs suitable for Ex 'ia' certified devices; each spur shall incorporate integral short circuit protection (max 40mA) with LED indicators for power & status • Be designed to facilitate live maintenance, to include replacement of the fieldbus barriers • Incorporate a terminator • Be certified for use in a Zone 1, Gas Group liB T3 hazardous area location • Incorporate dedicated screw type terminations for the trunk and spur connections to suite wire size i.e. 1.13mm2 • Incorporate dedicated screen terminations for trunk and spur screens • Incorporate pre-drilled gland arrangement c/w blanking plugs, bottom \ side entry • Incorporate a hinged lid, latches, back panel, grounding & mounting accessories.
8.15.4.2 FF- Non Intrinsically Safe Junction Box FF Junction Boxes shall comply with the standardized design requirements specified below • House one device coupler that provides 12 spurs that are suitable for Ex(d) certified devices; each spur shall incorporate integral short circuit protection (max 56mA) • Incorporate a terminator
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FOUNDATION FIELosus PHILosoPHY PAG E
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• Certified for use in a Zone 1 Gas Group liB T3 hazardous area location Incorporate dedicated terminations for the trunk and spur connections to suite wire size of 1.13mm2 • Incorporate dedicated screen terminations for trunk and spur screens • Incorporate LED indicators for power & status • Incorporate pre-drilled gland arrangement c/w blanking plugs, bottom \ side entry • Incorporate a hinged lid, latches, back panel, grounding & mounting accessories.
8.15.5
SCREEN & GROUNDING Cable screen shall be grounded using the FF Class A single point shielding method. This method requires the screens of spur cables to be connected to the trunk screen in the junction box. The screen shall be grounded at the Marshaling cabinet side only with continuity maintained at JBs, and the screen cut & taped back at each field device.
Instrument signal conductor shall not be used as an earth. If an instrument safety earth is required, it shall be made through a separate conductor. The conductor may be in the =
same cable as the instrument signal conductor and screen , but shall be located outside the screen in the multi pair cable.
8.15.6
SURGE PROTECTOR DEVICE (SPD) All H1 segment trunks shall be protected with surge protectors at the marshalling cabinet. Surge protectors shall not attenuate the fieldbus signal. Devices with lowest insertion loss should be selected. For Fieldbus applications, the SPD should: • Facilitate quick installation/ change-outs • Have a low impedance ground connection Surge protection should comply with IEC 61643 -1, IEC 61643-21 , and IEEE STD 1100.
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8.15. 7
LO'o'IEA FARSHEAVYOILOEVELOPMENT PROGRAM
___
TERMINATORS
A Terminator is an impedance matching module used to minimize signal distortion , which can cause data errors by converting between current and voltage variations.
Each
segment shall have two terminators, one installed at the far end (Junction box) and the other installed at the power supply (some power supply units are equipped with terminators) . Terminators shall not be installed on the field device. Terminators shall be designed with characteristics in accordance with IEC 61158-2. They should be clearly indicated to differentiate them from other terminal assemblies. Terminators shall be identical on the Power Supply and on the Junction Box end.
8.15.8
H1 SEGMENT DIAGNOSTICS
The infrastructure required for facilitating online H1 segment monitoring should be incorporated in the ICSS, on the basis that H1 segment monitoring is integrated with the AMS.
Online H1 segment diagnostics should include the following parameters: • Voltage per segment • Segment noise • Min I Max Fieldbus signal (communications) level • Unbalanced to negative I positive signal pole • Fieldbus noise and jitter on the segment • Communications packet count and packet errors • Min I Max FF PSU voltage supply and operational status • Min I Max segment current Benefits of online diagnostic tools include the ability to historize the data, and provide real-time alarming and trending of the data. Online diagnostic tools shall only be considered if they are well integrated with the host system.
9.0
INSTALLATION, TESTING AND CALIBRATION
Installation, testing & Calibration details are described in the Specification for Instrument Installation and Specification for Instrument Installation Testing documents KOC-1-002.
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