Foundation Fieldbus, Fourth Edition
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About this ebook
Part of the field network evolutionary process includes a need to understand better how the changes in Electronic Device Description Language (EDDL), Field Device Tool (FDT), and Field Device Integration (FDI) will affect the way Fieldbus and other networks work together with asset management systems of the future, and your interaction with field devices.
More comprehensive step-by-step procedures are discussed for each stage of a typical FF installation: Inspection and electric commissioning to ensure cable integrity, H1 Network commissioning, configuration, and communications tests in the segments and the spurs. Several new photographs and explanations help emphasize the proper installation procedures so you can quickly identify and prevent potential problems when installing Fieldbus systems.
The contents of the entire book are then put to use with a full sample network design. The example is based on a typical simplified distillation tower and includes sample calculations/documentation-based.
The fourth edition explains Foundation Fieldbus in a convenient, easy-to-understand way, regardless of your level of experience; a novice wanting to learn what FF is all about or an experienced user looking for a few more tips and a single handy reference.
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Foundation Fieldbus, Fourth Edition - Ian Verhappen
Foundation Fieldbus
Fourth Edition
Foundation Fieldbus
Fourth Edition
by Ian Verhappen and Augusto Pereira
Notice
The information presented in this publication is for the general education of the reader. Because neither the author nor the publisher has any control over the use of the information by the reader, both the author and the publisher disclaim any and all liability of any kind arising out of such use. The reader is expected to exercise sound professional judgment in using any of the information presented in a particular application.
Additionally, neither the author nor the publisher has investigated or considered the effect of any patents on the ability of the reader to use any of the information in a particular application. The reader is responsible for reviewing any possible patents that may affect any particular use of the information presented.
Any references to commercial products in the work are cited as examples only. Neither the author nor the publisher endorses any referenced commercial product. Any trademarks or tradenames referenced belong to the respective owner of the mark or name. Neither the author nor the publisher makes any representation regarding the availability of any referenced commercial product at any time. The manufacturer’s instructions on use of any commercial product must be followed at all times, even if in conflict with the information in this publication.
Copyright © 2012
ISA—The International Society of Automation
All rights reserved.
Printed in the United States of America.
10 9 8 7 6 5 4 3 2
ISBN: 978-1-937560-20-1
ebook ISBN: 978-1-937560-40-9
No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publisher.
ISA
67 Alexander Drive
P.O. Box 12277
Research Triangle Park, NC 27709
www.isa.org
Library of Congress Cataloging-in-Publication Data in process.
For my wife Michele, who has supported me throughout my career and through the original development of this book and its revisions, while also raising our daughters Ashley and Madeline. You are the glue that keeps it together.
Thank you also to everyone who has supported me during my Fieldbus development and continued growth, providing opportunities to expand my knowledge and apply what I have learned. You have made it possible to be able to share this knowledge.
—Ian Verhappen
For my wife Margareth and my sons Sergio and Fabio, who gave me the support to write this book and helped me during the revisions.
Thanks to everyone who taught me the Fieldbus concepts since the early years and all the people who, during the several projects that I have been involved in, followed my suggestions for getting their projects working successfully.
—Augusto Pereira
Table of Contents
List of Figures
List of Tables
Ian Verhappen, P. Eng., CAP
Augusto Pereira, Eng
Chapter 1 — Fieldbus Layers
1.1 Topology
1.1.1 Application Layer
1.1.2 User Layer
1.1.3 Testing and Registration
1.1.4 Interoperability Test System
1.1.5 Physical Layer
1.1.6 Topologies
1.2 Communications
1.3 Parameter Classes
1.3.1 EDDL
1.3.2 FDT/DTM
1.3.3 Field Device Interface (FDI)
Chapter 2 — Fieldbus Cabling
2.1 Segment Protection
2.2 High-Speed Ethernet
2.3 Grounding/Earthing
2.4 Surge Protection
2.5 Cable Installation
Chapter 3 — Fieldbus Power Supplies
3.1 Intrinsic Safety
3.2 Fieldbus Intrinsically Safe Concept
3.2.1 Architecture with FISCO installed in the DCS cabinet
3.2.2 Redundant FISCO
3.3 Fieldbus Non-Incendive Concept (FNICO/FISCO Ex ic)
3.4 High Energy Trunk – Fieldbus Barrier
3.5 DART (Dynamic Arc Recognition and Termination)
3.6 Selecting the Right Power Supply
Chapter 4 — Documentation
4.1 Segment Loading Calculation
Chapter 5 —System Integration
5.1 Configuration
5.1.1 Client-Server VCR Type
5.1.2 Report Distribution VCR Type
5.1.3 Publisher–Subscriber VCR Type
5.1.4 Fail Over
Strategies and Design Considerations
5.2 Scheduling
Chapter 6 — Commissioning
6.1 Physical Layer Checks
6.1.1 Cable Testing
6.1.2 Electronic Commissioning
6.1.3 Configuration Commissioning
6.1.4 F OUNDATION Fieldbus Digital Communication Certification
6.1.5 Typical Installation Problems
6.2 Device Configuration
6.2.1 Configuration of the Resource Block
6.2.2 Configuration of the Transducer Block
6.2.3 Configuration of the Analog Input Function Block
Chapter 7 — Troubleshooting
7.1 Optimization Tools
7.1.1 Physical Fault Symptoms
7.2 Communications and Configuration
7.3 Tuning
Chapter 8 — Operations & Maintenance
8.1 Operations
8.2 Maintenance
Chapter 9 — New Developments
9.1 Fieldbus Safety
9.2 Wireless & Remote I/O (WIO)
9.3 Wireless
9.4 Host System Interoperability
Appendix A — Nomenclature
Appendix B — Fieldbus Foundation Specification List
Appendix C — Bibliography
Appendix D — Acronyms
Appendix E — FF Segment Design Example Exercise
Index
List of Figures
Figure1-1 Digital control system architecture
Figure1-2a OSI model compared with Fieldbus model
Figure1-2b Fieldbus data transfer packets
Figure1-3 Manchester encoding
Figure1-4 Device description hierarchy
Figure1-4a Analog Input Block (AI)
Figure1-4b Analog Output Block (AO)
Figure1-4c PID Block (PID)
Figure1-5 Fieldbus bridge capability
Figure1-6 Maximum length of Fieldbus network
Figure1-7 Fieldbus network with repeaters
Figure1-8a Physical layouts – Single combined segment
Figure1-8b Wiring practices – Cable efficiency
Figure1-9 F OUNDATION Fieldbus node addresses
Figure1-10a Function block scheduling and macrocycle
Figure1-10b LAS algorithm
Figure1-11 SCADA layer Fieldbus traffic management
Figure1-12 Radar level gauge
Figure1-13 Valve signature with best fit line
Figure1-14 Field device interface communications
Figure1-15 FDI Flow Device and Host
Figure1-16 Device Package showing documents to be updated
Figure2-1 Short circuit protection sizing
Figure2-2 Spur overcurrent failure indication
Figure2-3 Fieldbus connector blocks
Figure2-4 Fieldbus wiring with conventional terminal blocks
Figure2-5 Terminator inside junction box
Figure2-6 Termination guidelines
Figure2-7 HSE profile functional areas
Figure2-8 Ethernet wiring
Figure2-9 Wiring H1 devices to a linking device
Figure2-10 Integrated fieldbus system
Figure2-11 Continuity of ground
Figure2-12 Plant ground and instrument ground
Figure2-13 Cable shield grounding
Figure2-14 Recommended fieldbus grounding
Figure2-15 High frequency capacitive ground
Figure2-16 Equipotential bond
Figure2-17 Segregation of cable classes
Figure2-18 Segregating cables in trays
Figure2-19 General cable installation guideline
Figure3-1 Protective systems incendive limits
Figure3-2 Typical FISCO network
Figure3-3 FISCO calculation for area classification IIC
Figure3-4 FISCO calculation for area classification IIB
Figure3-5 FISCO repeater wiring to field
Figure3-6 Typical fieldbus power conditioner
Figure3-7 Typical fieldbus barrier installation
Figure3-8 High-energy trunk calculation
Figure3-9 Typical spark behavior
Figure3-10 DART extinguished spark
Figure3-11 Power supply selection
Figure4-1 Network diagram with repeater
Figure4-2 Fieldbus data sheet: individual device
Figure4-3 Fieldbus data sheet for multiple devices
Figure4-4 Digital communication signal symbols
Figure4-5 Multivariable Device Representation on P&ID
Figure5-1 Fieldbus VCR communications
Figure5-2 Host configuration screen
Figure5-3 Loop configuration
Figure5-4 Multiple loop function block scheduling
Figure5-5 Segment bandwidth calculation
Figure5-6 Typical fieldbus architecture
Figure5-7 Fieldbus Foundation Network with control in the field
Figure5-8 Macrocycle – control in valve
Figure5-9 Fieldbus Foundation Network with control in the DCS
Figure5-10 Macrocycle – control in host
Figure5-11 Control in output device
Figure5-12 Control in input and output device
Figure5-13 Control in Host
Figure5-14 Control in the DCS – when there are delays
Figure6-1 H1 network analysis tools
Figure6-2 Electrical cable test meters
Figure6-3 Reel of Fieldbus cable
Figure6-4 Correct H1 packet waveform
Figure6-5 Change in base frequency and amplitude
Figure6-6 Effects of inductive components on waveform
Figure6-7 Complete signal distortion
Figure6-8 Check sheet
Figure6-9 Correct transmitter installation
Figure6-10 Correct installation of Fieldbus junction boxes
Figure6-11 Field device grounding error
Figure6-12 Cable cross-section exceeds 40% of conduit area
Figure6-13 Failure to maintain required mechanical separation
Figure6-14 Coiled signal cables
Figure6-15 Corrosion caused by liquid entry
Figure6-16 Corrosion in a junction box
Figure6-17 Excess cable length
Figure6-18 Two installation errors
Figure6-19 Device display on first connection
Figure7-1 MTL diagnostic system
Figure7-2 P+F on-line diagnostics solution
Figure7-3 Turck on-line diagnostic solution
Figure7-4 R. Stahl diagnostic module
Figure7-5 PID Function Block internal functions
Figure8-1 Emerson handheld communicator
Figure8-2 Beamex Fieldbus calibrator
Figure8-3 Fieldbus signal jitter
Figure9-1 SIS (Safety Instrumented System) user layer extensions. .
Figure9-2 Example SIS application analog 2 out of 3 voter
Figure9-3 Device Mapping Diagram (Channel Mapping of other Protocols to FF Flexible Function Block)
Figure9-4 National Instruments USB H1 modem
FigureE-1 Simplified P&ID of a distillation tower
FigureE-2 Fieldbus system design – plot plan
FigureE-3 Instrument location drawing
FigureE-4 Fieldbus system design – area classification
FigureE-5 Junction box location drawing
FigureE-6 Instrument Segment Drawing 01-Seg-1
FigureE-7 Instrument Segment Drawing 01-Seg-2
FigureE-8 Instrument Segment Drawing 01-Seg-3
FigureE-9 Segment 1 macrocycle calculation
List of Tables
Table 1-1 Fieldbus Function Blocks
Table 2-1 Fieldbus cable characteristics
Table 2-2 Cable type specifications
Table 2-3 HSE class summary
Table 3-1 Characteristics of network-energized devices
Table 3-2 Networks’ power supply requirements
Table 3-3 Equipment classification guide
Table 3-4 Default function block information for all designs
Table 3-5 FISCO parameters
Table 3-6 Characteristics of FISCO and FNICL networks
Table 4-1 System decision analysis
Table 4-2 Network decision analysis
Table 4-3 Device criticality decision matrix
Table 4-4 Connector decision analysis
Table 4-5 FISCO installation
Table 4-6 IS/NIS installation
Table 4-7 Configuration worksheet/checklist
Table 5-1 VCR types and their uses
Table 5-2 Configuring a network for safety vs. availability
Table 5-3 Fieldbus operating mode priorities
Table 5-4 Fieldbus alarm levels
Table 5-5 Macrocycle requirements for different configurations . . .
Table 6-1 Examples of identifying signal and block type
Table 7-1 IF communication errors
Table 8-1 Instrument Index
Table 8-2 Device characteristics summary
Ian Verhappen, P. Eng., CAP
B.Sc. Environmental Science and B.Sc. Chemical Engineering
Certificate in Oil Sands Technology
FF Certified Professional and Certified FF Instructor
ISA Certified Specialist in Analytical Technology
ISA Certified Automation Professional
Ian Verhappen is an ISA Fellow and a Professional Engineer, and is Director of Industrial Automation Networks Inc., a global consulting firm focused on Making Industrial Networks Easy.
Prior to starting Industrial Automation Networks, Verhappen worked as the Director of Industrial Networks for Measurement Technology Limited (MTL) where he was responsible for their global digital communications product line. He has been working in the automation industry since 1987 and has been actively involved in FOUNDATION Fieldbus technology since 1995, when he led the first Host Interoperability demonstration project at Syncrude Canada Ltd., where he worked for 20 years.
Verhappen is an acknowledged expert in FOUNDATION Fieldbus technology and is an active member of the global standards community. He has authored numerous technical papers on Fieldbus and is a regular columnist for several industry trade journals including Manufacturing Automation, Industrial Networking, Offshore, and Process West. He is co-author with Augusto Pereira of ISA’s popular book Foundation Fieldbus. Verhappen also wrote the chapters on Industrial Networking for the 4th Edition of the Instrument Engineer’s Handbook, published by Taylor and Francis Group, and the Fieldbus chapter for ISA’s book, A Guide to the Automation Body of Knowledge.
He has been the keynote speaker at numerous conferences around the globe, where he has shared his knowledge of industrial networking and field level networks. Verhappen is also an FF Certified instructor and the developer of the FOUNDATION Fieldbus Certified courses at the Southern Alberta (Canada) Institute of Technology (FF Certified Training Center) as well as an instructor in IDC Technology’s on-line diploma program.
In addition to serving as chairman of the Western Canada End User Council, Verhappen was chairman of the Fieldbus Foundation Global End User Advisory Council from 2002 to 2006, reporting directly to the Board of Directors twice per year and in the process helping set the direction of Fieldbus technology. Under his guidance, the End User Advisory Council prepared the Engineering Design Guide, FOUNDATION Fieldbus Document AG-181
for which he was the editor. AG-181, now in Revision 2, has been translated into German, Japanese, Chinese, and Russian and is widely used as the basis for many corporate and project Fieldbus specifications.
Verhappen has been active on a number of Fieldbus specifications committees, including being an outside expert reviewer for the Safety Fieldbus Committee and Program Manager of the HSE Remote I/O development team. Verhappen is a past Vice-President Standards & Practices, a Managing Director on ISA’s Standards & Practices Board, Chair of ISA-103 (FDT), and is past Vice-President Strategic Planning for ISA. He is the 2011–2012 Director of the ISA Communications Division. In addition, he is the Canadian Chair of IEC 65E, 65B and the TC65 Committee as well as a participating member of Canada’s IEC 65A and 65C and ISO TC1 WG7 subcommittees.
In addition to his expertise in industrial network technology, Verhappen is also a trained HAZOP and Risk Assessment facilitator, having conducted such investigations for several billion-dollar projects.
Verhappen has served as project lead, engineer/designer or external review consultant for a number of companies in industries around the world, including pulp and paper, mining, food processing, water and wastewater, oil sands processing, petrochemicals, and refining.