2011 General Assembly

Mumbai, India
Implementation of FF in KGD6
Harvindar Gambhir/Madhuri
Allika
Vice President/Manager
Reliance
Place Company
Logo Here
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
2
KGD6-General information
Onshore Gas Plant and Offshore Platform.
Distance between them is 25KM.
Master Control system used for Well Controls.
FF technology for Control.
IS design
Total no of DCS/ECS controllers: 68, distributed
over 12 buildings
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
3
Integrated Control system block Diagram
SUBSEA CONTROL CENTRE HO
OFFSHORE PLATFORM

Data Transfer to HO
(via Fibre)
CENTRAL CONTROL ROOM (CCR)
Distributed Control System (DCS)
Emergency Shutdown System (ESD)
Sub-sea Control System
(SCS)
Fire & Gas Detection (F&G)
CCTV System
M
05
M
0
9
M
0
7
M
0
6
M
04
M
0
3

Safety Guarding System

(ESD, F&G CCTV)
BACKUP CONTROL ROOM
BACK-UP
COMMUNICATION
(MICROWAVE)
FIBRE OPTIC LINK
SCADA for pipeline
Emergency Shutdown System (ESD)
Fire & Gas Detection (F&G), CCTV
System
F
I
B
R
E

O
P
T
I
C

L
I
N
K
R
E
D
U
N
D
A
N
T
ON SHORE TERMINAL
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
4
IO Count
System Conventional
(including HART)
FF Serial
DCS 7500 1300 135000
ESD 3600
FGS 1200
220 FF Segments
250 Cabinets (including System, Marshalling,
Server, Network and PDB cabinets)
Few critical control loops taken on HART
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
5
FF General Challenges faced
Verification of segment design prior to installation
During Design Phase
During Construction Phase
Foundation Fieldbus required work practices and
knowledge that did not fully exist in the workforce
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
6
FF General Challenges
DURING DESIGN PHASE
Grouping of devices --Quantity of Devices,
Location of devices, loop criticality
Critical Valves
H-1 Redundancy
Macro cycle Execution Time
Power Consumption
Segment Length
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
7
FF General Challenges
During Construction:
Wiring & Terminations
Cable lengths of segments
Grounding/shielding --- Noise
Pre-commissioning activities configuration,
loop checks
What is needed to test, Calibrate & Configure
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
8
Solution
Upfront collaboration of design with Consultant
and System vendor to avoid design problems.
DCS supports EDDL (Electronic Device
Description language) & FDT (Field device
Tool). So field devices --vendor independent.
Used High Power Trunk concept.
4 H1 segments per interface Card, so reduced
cabinet foot print.
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
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Solution
Used DCS Vendor interoperability test lab in US
and Mumbai for upfront device type testing and
creation of templates.
Training for all Project, O&M personnel.
Used Advance Diagnostic module
One Team of RIL(Project, Constr, Maintenance)
& DCS vendor during implementation.
Audits
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Mumbai, India
1994 2011 Fieldbus Foundation
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Design Pre-requisites
P&IDs
Plot Plan, 3D model
Area Classification
Foundation Field bus Specification (Project
Specific)
List of Critical Control Loops
Control Narratives (process control strategy)
I/O Lists
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Mumbai, India
1994 2011 Fieldbus Foundation
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Segment Design
Segment length (Total of the trunk and all the spurs)
Device Assignments to Segments
Critical Loops : Use of redundant H1 interface cards &
power supplies.
Primary and Backup LAS
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Mumbai, India
1994 2011 Fieldbus Foundation
12
When a control loop has multiple inputs, all the input
devices shall be on the same segment.
This shall also apply to Cascade loops where the
master/slave shall reside on the same segment.
Transmitters on duty/standby pumps, assigned to two
different segments.
Segment Design
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
13
The voltage at each device should not be less than
13 VDC. The minimum for any device to operate is 9
VDC. The additional 4 vdc provides for segment
growth.
Make sure the total current draw for all devices on
the segment is well within the capacity of the
segment power supply about 350 mA.
Segment Design
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Mumbai, India
1994 2011 Fieldbus Foundation
14
Segment Design-Loop Criticality
Level 1 Failure of Level 1 loop results in
shutdown of entire plant
Level 2 Failure of Level 2 loop results in shutdown
of one unit/ equipment.
Level 3 Failure of Level 3 loop does not result in
plant/unit shutdown
Level 4 Level 4 loop only contain Monitoring
signals.
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Mumbai, India
1994 2011 Fieldbus Foundation
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KGD6 Design Features
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Mumbai, India
1994 2011 Fieldbus Foundation
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KGD6 Design Features
Maximum of 12 devices per segment.
Maximum 3 Control Valves per segment.
However installed 2 control valves in most
of the segments
Macro cycle for all the segments is
maintained at less than 1200 msec
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Mumbai, India
1994 2011 Fieldbus Foundation
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KGD6 Design Features
Only 1 Fieldbus device per spur
Max segment(trunk + all spurs) length - 1600 m
Spur length - 90 m
All FF devices are Entity compliant
No Repeators
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Mumbai, India
1994 2011 Fieldbus Foundation
18
The method of protection is a high power trunk Hybrid
concept. This method uses Increased Safety (Ex e)
protection for the Field bus Trunk.
IS spurs by using field mounted 4 channel Field Barriers.
This implementation allows full access to the field devices
when they are energized inside the hazardous area.
The spurs are galvanically isolated from the trunk and from
each other, have spur surge protection.
KGD6 - Design Features
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
19
KGD6 - Design Features
DCS system in KGD6 is I/A system.
Segment Allocation carried out by Engineering
Consultant and approved by RIL
Segment macro-cycle validation carried out by DCS
vendor and approved by RIL
Control functionality in DCS, not in field.
Primary FBM 228 module is acting as a link active
scheduler; secondary FBM 228 module as back up LAS
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Mumbai, India
1994 2011 Fieldbus Foundation
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MacroCycle Calculation Tool
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Mumbai, India
1994 2011 Fieldbus Foundation
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Selection of Cables
Cable type: in accordance with IEC-61158-2
At KGD6 we have used Type A 1.5 mm2 cable
Type A B
Attenuation at 39KHz 3dB/Km 5dB/Km
Characteristic
impedance at
31.25KHz
10020% 10030%
Capacitance 2nF/Km 2nF/Km
Resistance 44 ohm/Km 112 ohm/Km
Description Individual Shielded
Pairs+ overall
shield
Multiple Pairs with
Overall Shield
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Mumbai, India
1994 2011 Fieldbus Foundation
22
FF JB
It may be installed in a Zone 1 T4 IIC hazardous area.
12 intrinsically safe spurs. EEx ia IIC spur connections. Bus powered
Fieldbus barrier modules replaceable under power in Zone1 hazardous area
EEx e trunk wiring connection
Integrated fixed fieldbus terminator
Compatible with Entity and FISCO field devices
Spur surge protection provided for extra safety
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Mumbai, India
1994 2011 Fieldbus Foundation
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Spur
Trunk
FCP270
FBM228
FF Segment Interconnection
ADM
23
I-JB
FP32 Surge
Protectors
FCS-8351
12-way JB
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Mumbai, India
1994 2011 Fieldbus Foundation
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.
Integrated Base plate
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Mumbai, India
1994 2011 Fieldbus Foundation
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ADM (Advanced Diagnostic Module)
809FMTL --for physical layer diagnostics
Installed on the base plate and provides
diagnostics of 8 segment.
Diagnostic information of FF devices is also
available in Asset Management System
through Block error parameter
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Mumbai, India
1994 2011 Fieldbus Foundation
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5-pair or 10-pair overall and individually shielded
Trunk cables from system cabinets to intermediate
junction boxes located within the various plant areas
Single pair cable run between the Intermediate FF
J-Box and the FF Spur J-Box and to the devices
Cables and Grounding
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Mumbai, India
1994 2011 Fieldbus Foundation
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Earthing Arrangement
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Mumbai, India
1994 2011 Fieldbus Foundation
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Shield are cut and taped to avoid any possibility of inadvertent
grounding at the device end
Safety (case) ground of FF devices, Intermediate FF Junction
Boxes and FF Spur Junction Boxes are made at each
component.
Cables and Grounding
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Mumbai, India
1994 2011 Fieldbus Foundation
29
Interoperability-Field Devices
Devices shall have a Check mark logo which signifies
that the device is approved by Foundation Field bus
Device shall be certified as passing the ITK 4.61 or
later
Latest version of DD (Device Description), CFF
(Common File format) files shall be provided by the
Seller.
Hand Held Communicator shall be upgraded at
regular intervals
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
30
Interoperability-DCS
Ensure DCS supplier with the FF solution have
been tested extensively
The Field bus Foundation does not give a tick
marking(Logo) for host systems.
Host Interoperability Support Test in accordance
with FF-569.
DCS FAT included verification of interoperability of
the HOST system with each type of FF Device
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
31
Devices tested in FAT for Interoperability
Sr. No. Supplier Description Model
1 Emerson Radar Level Transmitter 5402AF
2 Emerson Radar Level Transmitter 5301FA
3 Emerson Radar Level Transmitter 5402AH
4 Emerson Radar Level Transmitter 5301HA
5 Emerson Pressure & DP Transmitter 3051S
6 Emerson Pressure & DP Transmitter 3051CD
7 Emerson Temperature Transmitter 644HF
8 Emerson Temperature Transmitter 3144PD
9 Emerson Coriolis Mass Flow meter 2700R
10 Emerson Vortex Flow meter 8800DF
11 Emerson pH Transmitter XMT-P-FF-10-73
12 Emerson FF Valve Positioner DVC 6000f
13 K- Patents MEG Analyzers IT-RM-GP
14 Chemtrols O2 Analyzers 3020T-H
15 GE Sensing Ultrasonic Flowmeters GF868
16 GE Sensing Ultrasonic Flowmeters XMT868
17 Dresser Valves Displacer type Level Transmitter 12322-058
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Mumbai, India
1994 2011 Fieldbus Foundation
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Device Installation and Commissioning
What we used to test, calibrate and configure?
HART 375- Used for Addressing, tagging &
Configuration of FF devices
MTL Relcom FBT 6- Used for segment parameters
and diagnostics
Beamex MC5: For Calibration, tagging , Addressing
and configuration
32
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Mumbai, India
1994 2011 Fieldbus Foundation
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Installation Practices
Some contents and photographs in
this section are from various
audits conducted at KGD6 site.
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Mumbai, India
1994 2011 Fieldbus Foundation
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Installation Practices
Bring the inner jacket through the cable gland into the JB. This is to make sure
the overall shield and any individual pair shield do not accidentally make contact
with the gland and the JB ground
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Mumbai, India
1994 2011 Fieldbus Foundation
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Cable Termination in FF cabinet
Inside jacket removed close to the
termination points such that the min. amt. of
individual pair shield is exposed.
At the point where the jacket is
Removed, place a 2 heat shrink
section over the area to maintain integrity
and label the cable.
4 of the 5 Pair terminate at the FP32 Surge protectors. The extra Pair terminates to the
standalone Grounded terminations below the FP32s. Overall shield terminates to the
standalone Grounded terminations
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Mumbai, India
1994 2011 Fieldbus Foundation
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Cable Termination in FF cabinet
Ensure that the shields
of individual pairs are
maintained.
Place sleeve over each
individual pair shield drain wire
and the overall drain wire
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
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Installation Practices
Each motherboard should be connected
directly with a minimum 1.5 mm wire
to the Instrument Ground Bar only.
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
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Installation Practices
The shield drain wire must be cut back to
the shield foil and isolated under heat
shrink so it does not touch the instrument
case.
Cut the signal lines as short as possible to
make the instrument connection. Spare
wire has the possibility of getting caught in
the threads and cutting the insulation thus
shorting out the signal to the case.
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
39
Lessons Learnt
Take care of grounding
Avoid sharp bends as same can distort the
shield and also may cause shorts.
Do not untwist the Twisted pair cable
Do not loop the FF wiring in the tray and in
cabinets
Turn off the barrier Terminators
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
40
Lessons Learnt
Ensure that device addresses are unique and
between 18 and 247
To reduce Commissioning time each FF device
shall be pre-configured by the Device seller with
Device tag and Channel address setting.
While removing a live FF device for
maintenance, take the device in OOS mode (Out
of Service mode) and then remove the device
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
41
Dedicated specifications for FF implementation &FF cables
Ensure all field devices procured are type tested
Ensure all devices with FF check mark
Training on installation and maintenance by experts
Ensure proper cable laying and terminations
Criticality study/Control risk assessment
Audit by FF expert, by experts within the company and by
DCS vendor experts. Implementation of audit points
Macro cycle verification
Snap shots of all segments for record ADM report
Summary -Implementation steps KGD6
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
42
Consider using control in the field for non-critical loops.
As long as the segment retains power (and one device
has backup LAS), automatic control can be maintained
in the field devices.
Non-Redundant FF H1 cards can be used on all non-
critical segments; however a spare slot shall be left
adjacent to each H1 card to allow for redundant card in
the future if required.
Future suggestions
2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
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2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation
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Thank You
This presentation is dedicated to
the team comprising of :
RIL, Vendors, Consultants &
Contractors
who made it happen