111 Successful Implementation & Improved OperationInstallation – Issues and SolutionsAndreas AgostinIndustrial Network Sales Specialist Asia PacificMTL Instruments Singapore, part of Cooper Crouse-Hinds15.05.2013 Perth
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.
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.
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.
555 Successful Implementation & Improved OperationThe conventional system
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.??
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.
181818 Successful Implementation & Improved OperationFieldbus CableShielded pairprincipleFoilshieldFoil plusbraidedshieldSWANot round – Not recommendedIdeally round – RecommendedFillers (solid or fiber)
222222 Successful Implementation & Improved OperationFieldbus system – Field wiring??•• Parallel wiringParallel wiring(terminals)(terminals)•• special wiringspecial wiringblocksblocks•• (daisy chaining)(daisy chaining)
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
242424 Successful Implementation & Improved OperationFieldbus system – Field junction boxesPlease not this way
252525 Successful Implementation & Improved Operation25Fieldbus system – Field junction boxesUse dedicatedwiring blockswith built-inelectronicshort circuitprotection.LEDs: - built-in s/c protection
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
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
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.
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.
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)
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
545454 Successful Implementation & Improved OperationInstallation – Issues and SolutionsAndreas AgostinIndustrial Network Sales Specialist Asia PacificMTL Instruments Singapore, part of Cooper Crouse-Hindsandreas.firstname.lastname@example.orgPh: +65 97585161