Andreas Agostin Installation Solutions

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Best Practices for Fieldbus Installation

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Andreas Agostin Installation Solutions

  1. 1. 111 Successful Implementation & Improved OperationInstallation – Issues and SolutionsAndreas AgostinIndustrial Network Sales Specialist Asia PacificMTL Instruments Singapore, part of Cooper Crouse-Hinds15.05.2013 Perth
  2. 2. 222 Successful Implementation & Improved OperationIntroductionFieldbus is in use since 19981, yet still new formany customers today.This presentation will look at the installation issuesand the “lessons learned”, so that you canbenefits from their experience.1 Shell Malampaya is one of the early, larger projects. 1600 FF instruments are in use. The project produced first gas inOct 2001. Source: J. Seaver, Shell Philippines Exploration B.V., “Malampaya Deep Water Gas-to-Power Project:Malampaya Subsea Development”, Offshore Technology Conference, 6 May-9 May 2002, Houston, Texas.
  3. 3. 333 Successful Implementation & Improved OperationIntroductionThe pictures you will see are collected from “real”projects; they are neither simulated nor “demo”.We will look at– Control room: cabinet design and wiring– Field: Wiring, field junction boxes, field device installation.Processes typically involve explosion protection methods“intrinsic safety” (I.S. / Ex i; energy limitation by a ‘barrier’)or “explosion proof” (Ex d; protection by explosionproofenclosure).Many examples use “IS” as this is a key product of mycompany and that is where I get involved.
  4. 4. 444 Successful Implementation & Improved OperationDisclaimerAll products shown serve as EXAMPLE only.In particular, problems shown in conjunction with a productserve as example only.The brand/make/model of the product serving as exampleis IRRELEVANT.Problems highlighted serve as example only, are do in noway express problems with a particular product,model or brand.
  5. 5. 555 Successful Implementation & Improved OperationThe conventional system
  6. 6. 666 Successful Implementation & Improved OperationControl room – Conventional wiring2nd level 1st leveljunction box Marshallingand barrierControl system
  7. 7. 777 Successful Implementation & Improved OperationControl room – Conventional wiringMarshalling: to group AI / AO / DI / DO / etc
  8. 8. 888 Successful Implementation & Improved OperationControl room – Conventional wiring
  9. 9. 999 Successful Implementation & Improved OperationControl room – Conventional wiringLong wires, standard lengthAllows pre-fabrication of wire(ferrules, mounting)Conventional signals (4-20mA,RTD, thermocouple, 0-5V/10V/24V) – slow, hardwarefiltered, length less important
  10. 10. 101010 Successful Implementation & Improved OperationField – Conventional wiringQuality (material)SafetyLocation / accessWeight/size, …10
  11. 11. 111111 Successful Implementation & Improved OperationFieldbus versus conventional
  12. 12. 121212 Successful Implementation & Improved OperationControl room – DCS wiring EXAMPLESFieldbusConventional
  13. 13. 131313 Successful Implementation & Improved OperationControl room – DCS wiring EXAMPLESInstallations do not haveto look messy. Theycan be very nice, too.FieldbusConventional
  14. 14. 141414 Successful Implementation & Improved OperationControl room – DCS wiring EXAMPLESFieldbus Conventional
  15. 15. 151515 Successful Implementation & Improved OperationControl room – DCS wiring EXAMPLESFieldbusFieldbus
  16. 16. 161616 Successful Implementation & Improved OperationControl room – DCS wiringImportant:do not use individual wires towire cabinet. Use fieldbus cableand shield properly.Why?Higher signalfrequency – protectthem againstdisturbances.Individual wires willcause crosstalk fromone wire to another –communication faultscan occur.??
  17. 17. 171717 Successful Implementation & Improved OperationFieldbus CableRecommended:Type A cable: Shielded twisted pairOther cable is possible, but there are limitations in termsof achievable cable distance and electromagneticcompatibility (EMC).Fieldbus is a digital “high speed” (31kBit/s)communication, a current modulated signalsuperimposed on the DC power.
  18. 18. 181818 Successful Implementation & Improved OperationFieldbus CableShielded pairprincipleFoilshieldFoil plusbraidedshieldSWANot round – Not recommendedIdeally round – RecommendedFillers (solid or fiber)
  19. 19. 191919 Successful Implementation & Improved OperationFieldbus CableSWA Multi-pairMulti-pair (multi-trunk)
  20. 20. 202020 Successful Implementation & Improved OperationPlease not this wayImages obscured – Brand is irrelevant.
  21. 21. 212121 Successful Implementation & Improved OperationControl room – DCS wiring
  22. 22. 222222 Successful Implementation & Improved OperationFieldbus system – Field wiring??•• Parallel wiringParallel wiring(terminals)(terminals)•• special wiringspecial wiringblocksblocks•• (daisy chaining)(daisy chaining)
  23. 23. 232323 Successful Implementation & Improved OperationFieldbus system – Field junction boxesPrinciple of wiring distribution in junction box:all devices are in parallelSource: FF AG 140 Rev. 1
  24. 24. 242424 Successful Implementation & Improved OperationFieldbus system – Field junction boxesPlease not this way
  25. 25. 252525 Successful Implementation & Improved Operation25Fieldbus system – Field junction boxesUse dedicatedwiring blockswith built-inelectronicshort circuitprotection.LEDs: - built-in s/c protection
  26. 26. 262626 Successful Implementation & Improved OperationGood Wiring PracticesTest segment wiring before connecting componentsAvoid damaging the wire when removing insulationGround the cable shield only at one point (at the controlroom end)Insulate the ungrounded end of the cable shield (at theinstrument)Ground armor on both sides (potential equalization)Use crimp ferrules– Ferrule diameter must fit wire– Crimp tool must fit ferrule– Ferrule must fit terminalsMaintain polarity and associated color codes throughoutthe segment
  27. 27. 272727 Successful Implementation & Improved OperationGood Wiring PracticesLessons learned:Torque screwdriverWire end ferrulesRight (!) wire strippersFieldbus testerHarmswire strandsChooseright sizeAWG ..
  28. 28. 282828 Successful Implementation & Improved OperationFieldbus Design Tools(Examples)
  29. 29. 292929 Successful Implementation & Improved OperationProject ProcedureBest practice:Bench testFunctional tests and interoperability testFATSAT
  30. 30. 303030 Successful Implementation & Improved OperationInstallation GuidelinesCable Tests– Experience has shown that new cable irregularities areso infrequent that it is more efficient to check cableafter installationCable Installation– Verify that cable is properly installed, bypassing impactfrom wiring componentsSegment Checkout– Check of proper wiring of wiring componentsDevice installation– Check of proper device installationLoop checkout– Functional test
  31. 31. 313131 Successful Implementation & Improved OperationInstallation toolsPortable fieldbus diagnostic test equipment(Handhelds)Measures relevant fieldbusparametersEstablish baselineafter commissioning
  32. 32. 323232 Successful Implementation & Improved OperationHandheld diagnostic toolsHandheldDiagnosticToolDevice 1 Device 3Device 2TDevice Coupler& Terminator(non-IS) SpursFFPSTFF Power Supply& Conditioner&Terminator24VDCHostComputerH1 InterfaceConnect at respective location to obtain accurate measurement.
  33. 33. 333333 Successful Implementation & Improved OperationHandheld diagnostic toolsHandheldDiagnosticToolFFPSTFF Power Supply& Conditioner&Terminator24VDCHostComputerH1 InterfaceFieldbusbarrierDevice 1 Device 3Device 2Fieldbus barrier& TerminatorIntrinsicallySafe SpursTFieldbusbarrierTo measure at fieldbus barrier/IS segments, Handheld needs to be Ex i approved.Important since the galvanic isolation of fieldbus barrier impacts on measurement.
  34. 34. 343434 Successful Implementation & Improved OperationEarthing/GroundingGrounding in the control roomOne point grounding onlyContinuous shield from control room to the fieldShield not connected at the field instrumentConnect cable armor at both ends (potentialequalization)
  35. 35. 353535 Successful Implementation & Improved OperationEarthing/GroundingDevice 1 Device 3Device 2TWiring Block& TerminatorFFPSTFF Power Supply& Conditioner&Terminator24VDCHostComputerH1 Interface
  36. 36. 363636 Successful Implementation & Improved OperationFieldbusbarrierDevice 1 Device 3Device 2Fieldbus barrier& TerminatorIntrinsicallySafe SpursTFieldbusbarrierEarthing/GroundingFFPSTFF Power Supply& Conditioner&Terminator24VDCHostComputerH1 Interface
  37. 37. 373737 Successful Implementation & Improved OperationLocal field junction box for 4instruments. Rust preventedproper grounding, so thatseparate ground connectionwas required
  38. 38. 383838 Successful Implementation & Improved OperationField – Fieldbus wiringGreen: fieldbusRed: Power (Motors, etc)For easy maintenance
  39. 39. 393939 Successful Implementation & Improved OperationTroubleshooting
  40. 40. 404040 Successful Implementation & Improved OperationDaisy chaining – not recommended
  41. 41. 414141 Successful Implementation & Improved OperationTroubleshootingElectrical welding can generate significant surges
  42. 42. 424242 Successful Implementation & Improved OperationBend radius too tight, Upward facing gland risks water ingressTwo cables into one glandprevents sealing of gland
  43. 43. 434343 Successful Implementation & Improved OperationWater ingress caused corrosion of wire and terminals
  44. 44. 444444 Successful Implementation & Improved OperationCable jacket stripped back too farTroubleshooting
  45. 45. 454545 Successful Implementation & Improved OperationWires coming out of ferrules
  46. 46. 464646 Successful Implementation & Improved OperationTroubleshootingEarth stud not connected – internalsurge protectors not working
  47. 47. 474747 Successful Implementation & Improved OperationTroubleshootingGround not connected
  48. 48. 484848 Successful Implementation & Improved OperationTroubleshootingPoor cable (shield) quality
  49. 49. 494949 Successful Implementation & Improved OperationTroubleshootingGrounding concept failure-prone
  50. 50. 505050 Successful Implementation & Improved OperationTroubleshootingWater marks, fungus inside junction box
  51. 51. 515151 Successful Implementation & Improved OperationTroubleshootingWire squeezed by enclosure lid – water ingress
  52. 52. 525252 Successful Implementation & Improved Operationhttp://forums.fieldbus.org/showthread.php?t=1298
  53. 53. 535353 Successful Implementation & Improved OperationConclusionFieldbus is robust if the installation is adjusted tothe requirements of a digital communication lineDo not simply copy 4-20 methodsUse fieldbus smartly (e.g. eliminate marshalling)Good wiring practices are more important thanon 4-20 due to bus structureTrain your installers on fieldbus practices
  54. 54. 545454 Successful Implementation & Improved OperationInstallation – Issues and SolutionsAndreas AgostinIndustrial Network Sales Specialist Asia PacificMTL Instruments Singapore, part of Cooper Crouse-Hindsandreas.agostin@cooperindustries.comPh: +65 97585161

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