3210-8550-FS-0008 Foundation Fieldbus Functional Requrement

A
JOINT PROJECT MANAGEMENT TEAM

PROJECT SPECIFICATION
3210-8550-FS- 0008
FOUNDATION FIELDBUS FUNCTIONAL
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CONTENTS
SECTION SUBJECT
1 SCOPE .................................................................................................. 4
2 PURPOSE.............................................................................................. 4
3 DEFINITIONS AND ABBREVIATIONS ................................................. 4
3.1 Definitions ............................................................................................ 4
3.2 Abbreviations ....................................................................................... 7
4 FIELDBUS SYSTEM OVERVIEW ......................................................... 9
4.1 Project Objectives ................................................................................ 9
5 FIELDBUS APPLICATION .................................................................... 9
5.1 Field Device Selection ....................................................................... 10
5.2 Critical Loop Definition and Application ........................................... 12
5.3 Control Assignment ........................................................................... 13
5.4 Segment Grouping ............................................................................. 13
5.5 Temperature Multiplexer Transmitters ............................................. 13
5.6 Hazardous Area Classification .......................................................... 14
5.7 Redundancy........................................................................................ 14
5.8 Segment Physical Device Loading Requirements on the H1 bus ... 15
5.9 Segment Spare Philosophy Requirements........................................ 15
5.10 Segment Execution Time Requirements........................................... 15
5.11 Segment Wiring Design Requirements ............................................. 15
6 INTOOLS REQUIREMENTS................................................................ 19
6.1 INtools Parameters Configuration ..................................................... 20
6.2 Fieldbus Tag Numbers ....................................................................... 22
6.3 Fieldbus Segments............................................................................. 23
6.4 Fieldbus Wiring .................................................................................. 23
6.5 INtools Fieldbus Validation................................................................ 24
6.6 Diagnostics......................................................................................... 25
6.7 Testing................................................................................................ 25
6.8 Device Maintenance .......................................................................... 26
6.9 Workstations ...................................................................................... 27
6.10 Alarm and Message Handling ........................................................... 27
7 DOCUMENTATION REQUIREMENTS ............................................... 28
8 FIELDBUS SYSTEM DESIGN GUIDELINES ....................................... 30
8.1 General ............................................................................................... 30
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8.2 Main Differences between Fieldbus & Traditional Installation........ 31
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1 SCOPE
This project procedure defines the Foundation Fieldbus System Design

Requirements for the Paradip Refinery Project for the Indian Oil Co. Ltd. Orissa
State, India.
Any deviation from the philosophies, criteria and/or standards within this
procedure shall be subject to approval by PMC/IOCL.
2 PURPOSE
The purpose of this specification is to define the Foundation Fieldbus System

Design Requirements to:
• Ensure consistency across the entire project
• Minimise the design effort required by all parties
• Minimise the validation requirement
• Minimise commissioning related problems
3 DEFINITIONS AND ABBREVIATIONS
3.1 Definitions
3.1.1 General
The following defines the meaning of specific words used in this specification:
Contractor / Vendor Means the firm, company or other corporate entity

(including its successors and / or permitted assigns)
contracted to supply the Equipment / Services to IOCL
IOCL Means Indian Oil Corporation Ltd. And its legal successors
and assigns
Shall Refers to a mandatory requirement
Should Refers to a recommendation
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May Refers to one acceptable course of action.
3.1.2 Foundation Fieldbus Definitions

The following represent definitions of Fieldbus terms used within this procedure,
however, a comprehensive list of definitions can be found at the Foundation web
site www.Fieldbus.org.
Term Definition
Bus A H1 Fieldbus cable between a host and field devices
connected to multiple segments, normally through the
use of repeaters.
Common File Format A software file used by the Host to know the device
(CFF) detailed FF capabilities without requiring the actual
device.
Device Description A Device Description (DD) provides an extended
(DD) description of each object in the Virtual Field Device
(VFD), and includes information needed for a control
system or host to understand the meaning of data in
the VFD.
Fieldbus A Fieldbus is a digital, two-way, multi-drop
communication link among intelligent 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.
FF device (Fieldbus An H1 Field Device is a FF device connected directly
device) to an H1 Fieldbus. Typical H1 Field Devices are
valves and transmitters.
FISCO Fieldbus Intrinsically Safe Concept. Allows more
power to an IS segment for approved FISCO devices,
allowing for more devices per IS segment.
H1 H1 is a term used to describe a Fieldbus network
operating at 31.25 kbit/second.
HIST Host Interoperability Support Testing performed by the
Foundation to approve Host conformance to the FF
specifications.
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Term Definition
Interchangeability Interchangeability is the capability to substitute a
device from one manufacturer with that of another
manufacturer on a Fieldbus network without loss of
functionality or degree of integration.
Interoperability Interoperability is the capability for a device from one
manufacturer to interact with that of another
manufacturer on a Fieldbus network without loss of
functionality.
ITK Interoperability Test Kit used by the Foundation to tick
mark devices
Link A Link is the logical medium by which FF devices are
interconnected. It is composed of one or more
physical interconnected segments. All of the devices
on a link share a common schedule which is
administered by that link's current LAS.
Link Active A Link Active Scheduler (LAS) is a deterministic,
Scheduler (LAS) centralized bus scheduler that maintains a list of
transmission times for all data buffers in all devices
that need to be cyclically transmitted. Only one Link
Master (LM) device on an H1 Fieldbus Link can be
functioning as that link's LAS.
Link Master (LM) A Link Master (LM) is any device containing Link
Active Scheduler (LAS) functionality that can control
communications on an H1 Fieldbus Link. There must
be at least one LM on an H1 Link; one of those LM
devices will be elected to serve as LAS.
Resource Block (RB) A Resource Block (RB) describes characteristics of
the FF device such as the device name, manufacturer
and serial number. There is only one Resource Block
(RB) in a device.
Schedules Schedules define when Function Blocks (FBs)
execute and when data and status is published on the
bus.
Segment A Segment is a section of an H1 Fieldbus that is
terminated in its characteristic impedance. Segments
can be linked by Repeaters to form a longer H1
Fieldbus. Each Segment can include up to 32 H1
devices.
Spur A Spur is an H1 branch line connecting to the Trunk
that is a final circuit. A Spur can vary in length from 1
m (3.28 ft.) to 120 m (394 ft.).
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Term Definition
Standard Function Standard Function Blocks (FBs) are built into FF
Block (FB) devices as needed to achieve the desired control
functionality. Automation functions provided by
Standard FBs include Analogue Input (AI), Analogue
Output (AO) and Proportional/Integral/Derivative (PID)
control. The Fieldbus Foundation™ has released
specifications for 21 types of Standard FBs. There can
be many types of FBs in a device. The order and
definition of Standard FB parameters are fixed and
defined by the specifications.
Terminator A Terminator is an impedance-matching module used
at or near each end of a transmission line. Two
Terminators must be used on each H1 segment.
Tick Marked Tick marked FF devices are those with validated
compliance with Foundation Fieldbus specifications:
ITK. The resource block contains the device approved
ITK level.
Topology The Segment structure; Tree, Daisy Chain, etc. are
examples.
Transmitter A Transmitter is an active FF device containing
circuitry, which applies a digital signal on the bus.
Trunk/Home-run A Trunk is the main communication highway between
devices on an H1 Fieldbus network. The Trunk acts as
a source of main supply to Spurs on the network.
3.2 Abbreviations
The following list gives the used abbreviations in this document.
Abbreviation Description
AI Analogue Input
AO Analogue Output
AWG American Wire Gauge
CCR Central Control Room
CFF Common File Format
DCS Distributed Control System
DI Discrete Input
DD Device Description
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Abbreviation Description
DO Discrete Output
EI Early Involvement
EPC Engineering, Procurement & Construction
ESD Emergency Shutdown
FB Function Block
FDAS Fire Detection and Alarm System
FF Fieldbus Foundation
FISCO Fieldbus Intrinsically Safety Concept
GDS Gas Detection System
HART Highway Addressable Remote Transmitter
HIST Host Interoperability Support Testing
HMI Human Machine Interface
IAMS Instrument Asset Management System
INtoolsTM Control & Instrumentation Database System
I/O Input/Output
IS Intrinsic Safety
ITK Interoperability Test Kit
LAN Local Area Network
LAS Link Active Schedule
MAI Multiplexed Analogue Input
MOV Motor Operated Valve
PID Proportional / Integral / Derivative Control
PLC Programmable Logic Controller
SRR Satellite Rack Room
UOM Units Of Measurements
UPS Uninterrupted Power Supply
All field instrumentation purchased and installed with Foundation Fieldbus must
meet the minimum applicable requirements set forth by the International
Electrotechnical Commission (IEC) applicable standards listed below.
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Material or equipment supplied to this specification shall comply with the latest
edition of the references listed below, unless otherwise noted.
International Electrotechnical Commission

IEC 61158-2 Foundation Fieldbus Standard for Use in Industrial Control
Systems - Physical Layer Specification and Service Definition
National Fire Protection Association

NFPA 70 National Electrical Code
4 FIELDBUS SYSTEM OVERVIEW
4.1 Project Objectives

The Distributed Control System for the Paradip Project will be based on the
Open System Architecture concept with Foundation Fieldbus (FF) interfacing
capabilities to smart devices in the field.
5 FIELDBUS APPLICATION
The use of Fieldbus shall be maximised for all regulatory process control
devices where a suitable FF device is available and in addition, shall also apply
to all Packaged Equipment. The regulatory process control loops shall typically
include the following:
• Monitoring loops (including bearing temperatures)
• Multiplexed temperature monitoring loops (Excluding bearing temperatures)
• Simple PID loops
• Cascade loops
• Sequence loops
• Complex loops
Deviation from the above shall be subject to JPMT/ IOCL approval on a case by
case basis.
Fieldbus shall not be used for the following applications:
• Emergency Shutdown Systems, Fire Detection and Alarm System (FDAS)
and Gas Detection System (GDS) signals due to safety reasons
• Discrete signals, i.e. digital signals due to limited availability and lack of
enhanced functionality of such devices.
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• Analogue DCS type inputs defined as critical control closed loops (i.e. loops
which may lead to shutdown).
• FF junction box in a Zone 1 Area. The field junction box shall be located in a
Zone 2 or safe area.
5.1 Field Device Selection

5.1.1 Interoperability
The Fieldbus devices have to be fully interoperable with the DCS, including
maximising of the associated advanced diagnostic features coupled to asset
management capabilities within DCS System.
Based on the above objective, the following selection method shall be applied
for Fieldbus devices excluding valve positioners (in order of preference):
Any other FF device and/ or positioner shall, as a minimum, have the following
‘features’ available:
• Foundation Fieldbus Certification as having passed the Interoperability Test
Kit (ITK), revision 4.01 (or later) and are listed on the approved devices list
maintained on the FF web site: www.Fieldbus.org
• The FF device shall be capable of performing continuous diagnostics,
including self-test functions, to provide specific diagnostic information to the
Asset Management System.
In addition, a ‘sample’ device shall be submitted to DCS Supplier for
interoperability testing with both the DCS and IAMS systems (unless not already
proven). On successful completion of these tests, JPMT/ IOCL shall provide the
necessary approval for use and shall update the ‘Approved Device Listing’
accordingly.
5.1.2 Fieldbus Function Blocks
The Function Blocks (FB) as defined by the FF is grouped into Standard,
Enhanced and Additional blocks, but not all of these FB’s are appropriate for use
in field devices, and some are not available and/ or do not have interoperability
tests.
In order to simplify the process of FF device procurement, the Contractor does
not need to specify any additional FB functionality other than as follows:
• Transmitter - AI for each required process variable
• Positioners - AO
• Temperature Multiplexers - MAI
However, if the device is a valve positioner, then the device shall be specified
and delivered with ALL available FBs including advance diagnostic FBs.
All function blocks supplied with the device shall be instantiated by the device
manufacturer.
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In addition, these devices will be specified and delivered to site with the following
default parameters settings:
Parameter Setting
• Boot_Class - BASIC (For all FF devices)
• STATUS_OPT (Propagate Fault)
Monitoring loop - AI Propagate Fault Forward: OFF
Local Control loop - AI Propagate Fault Forward: ON
- AO Propagate Fault Backward: ON
• Pressure & Differential Pressure Transmitter
L_TYPE - Direct
PV_FTIME - 2 sec.
• Level Transmitters
L_TYPE - Indirect
PV _FTIME - 2 sec.
• Flow Transmitters
L_TYPE - Indirect SQRT
PV_FTIME - 2 sec.
AI block execution time shall be better than 45ms and PID block execution time
shall be better than 60msec.
5.1.3 Field Device Management
The Physical Device (PD) Tag must be set prior to installation to enable
connection of multiple devices during construction and commissioning. This
shall be achieved either by the device manufacturer, prior to shipment, or the
EPC prior to connection.
5.1.4 Field Device Power
FF devices may be powered either from the segment, or locally powered,
depending on the device design.
Bus-powered devices typically require 12 – 30 mA of current at between 9 and
32 volts, but devices requiring more than 30 mA shall be subject to PMC/IOCL
approval.
FF devices should be polarity insensitive.
Externally powered FF devices shall be specified with isolation between external
power and Fieldbus signal inputs.
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For this project, the bus-powered method shall be preferred.

5.1.5 Link Master Devices
No FF device needs to be specified to have the Link Master capability, as the
redundant H1 interface cards within the DCS will provide both the active and
back-up LAS functionality.
5.1.6 Device upgrading
FF devices use internal software of a certain revision. At present FF device
software is quite often improved and upgraded, while the hardware is left
unchanged.
To accommodate easy device upgrading, the devices shall, where available, be
specified to have flash memory that can be on-line flashed with the latest device
software (firm-ware).
Furthermore it is essential to record the applied device revision, DD and CFF
revision.
The Contractor shall, in addition, to the normal Instrument Data Sheet(s),
provide the FF devices detail as per the INtools Fieldbus Data Sheet.
5.2 Critical Loop Definition and Application

The Contractor shall classify; by HAZOP study, control loops into 3 criticality
levels. The study should take into consideration factors such as the material and
energy capacity of associated vessels, geographic location, and elevation/
accessibility of valves.
Level 1 Failure of a control loop will result in a shutdown of an entire plant, or

damage to non-spared vital or essential equipment.
Level 2 Failure of a control loop will result in an emergency situation, where

prompt operator action would be required to “save” the plant from
imminent total shutdown
Also, failure of a level 2 control loop will result in a shutdown of the
entire plant, but where process dynamics allow time for quick recovery
from the failure.
Level 3 Failure of this loop will not result in any short-term risk of total unit
shutdown. Level 3 valves can go to their fail position.
All loops that fall into the Level 1 or Level 2 category shall not use Fieldbus
technology.
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All loops that fall into the Level 1 or Level 2 category shall use Smart (Hart
protocol) field instruments and valve positioners.
4-20mA shall be used for AI/ AO signals with the HART signal superimposed.
Level 3 control loops can reside on H1 segments with the following limitations:
• Up to 3 FF valve positioners per H1 segment.
• Total FF devices (Txs and positioners) not to exceed 10 (inclusive of
spares)
• Note that the number of control and critical loops per segment is given on
the basis of loop criticality and macrocycle requirement of the segment.
• Indicator, monitoring only loops may be assigned to Fieldbus segments
freely up to 10 loops (inclusive of spares) per segment.
5.3 Control Assignment

Control on the wire may be considered for simple control loops where the control
valve and transmitter associated are on the same segment.
Generally the control function blocks for these loops shall be located in the
positioner of the control valve.
For complex control loops (more complicated than a simple cascade loop) or
control loops where the transmitter and control valve are on different segments
the control function blocks shall reside in the DCS.
Where control is to be implemented in the field device, contractor is to provide
justification to JPMT/IOCL for this strategy over implementing control in the
DCS.
5.4 Segment Grouping
In order to maximise the benefits from FF technology, grouping all devices of a
particular control loop within the same segment is preferred. For cabling reasons
it is allowable to host control loops across different segments, however this is
not preferred. In all cases the Contractor is responsible to ensure that the speed
of response for the loop is not unduly impacted by the use of Foundation
Fieldbus.
Control loops shall not be split across different segments where the segments
are connected to different DCS processors without approval of the JPMT/ IOCL.
5.5 Temperature Multiplexer Transmitters
5.5.1 FF temperature multiplexer transmitters may be used where high density
temperature measurements are required for DCS indication, excluding rotating
machinery bearing temperature measurements. Temperature multiplexers shall
not be used for control without permission of JPMT/ IOCL.
Two different methods of segment design may be implemented:
• Where additional monitoring devices can be connected to a segment, as
defined in section 5.2, the quantity of temperature multiplexer transmitters
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shall be limited to three per segment. The Contractor shall take the following
into consideration:
• Communication of the temperature signals from the MAI FB will be performed
during the unscheduled communication period of the macrocycle and a delay
of up to four seconds may be experienced between a change in measured
variable and when that change is displayed at the HMI. The Contractor shall
ensure this delay is acceptable for the particular process application.
The Contractor may also dedicate a segment to be used for temperature
multiplexers only; in this case eight multiplexers may be connected to one
segment, leaving two spare ways for future use.
The failure of an individual temperature multiplexer shall not impact on the ability
to monitor an item of plant equipment, to ensure this the Contractor shall
allocate measurements to different multiplexers, each connected to separate FF
segments. Where the density of temperature measurements makes this
approach uneconomic, the design shall revert to individual FF temperature
transmitters.
5.6 Hazardous Area Classification

Refer to specification 3210-8550-SP-0001 ‘Instrumentation for General
Hydrocarbon and Utility Services’, for details regarding hazardous area
protection preferences.
For the Foundation Fieldbus implementation the field instruments shall generally
be certified intrinsically safe suitable for the hazardous area. The Foundation
Fieldbus topology recommended utilises an increased safety trunk (EExe) to
Foundation Fieldbus Field barriers located in stainless junction boxes in Zone 2
and intrinsically safe field instruments (either entity or FISCO certification
acceptable if suitable for the hazardous area in which they are located).
5.7 Redundancy
The host system DCS shall incorporate the following redundant equipment to
enhance the overall availability:
• Redundant DCS Bulk Power Supply Feeds
• Redundant DCS System Controller Power Supply units
• Redundant DCS System Controllers
• Redundant FF H1 Cards
• Redundant FF Power / Conditioners
FF Segments with monitoring devices only shall use redundant H1 Cards to
allow for the possibility of future inclusion of level 3 control loops to the segment.
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5.8 Segment Physical Device Loading Requirements on the H1 bus

The FF specification states that a maximum of 32 devices per segment can be
connected. In practice it is demonstrated that only up to 16 devices per segment
are feasible.
In order to minimise the Fieldbus design effort, e.g. validation and
commissioning related problems, the number of devices shall be limited to 10
devices (inclusive of spares) per segment.
The Contractor shall ensure that the loading on the segment does not impact
process operability or necessary speed of response for the DCS system and
field instruments selected (This may limit the number of devices to less than 10).
5.9 Segment Spare Philosophy Requirements

The total number of devices per segment will not exceed 10 as detailed in
section 5.8. However, to include for the 20% pre-wired spare capacity, the
maximum number of installed devices shall be 8 per segment.
Deviation of the above maximum number of 8 devices requires JPMT/ IOCL
approval.
5.10 Segment Execution Time Requirements

5.10.1 Segments Used For Regulatory Control or Monitoring
All segments will operate with a macrocycle of 1 second or better as specified by
process licensor requirements (including an idle time of more than 500mS per
macrocycle).
Any deviation to the above will require additional validation and shall be subject
to JPMT/ IOCL approval.
5.10.2 Segments Used For Temperature Multiplexer Transmitters
Temperature multiplexers shall only be used on segments dedicated for use of
temperature monitoring only.
The segments used for temperature multiplexers shall operate with a
macrocycle of up to 4 seconds with an idle time of more than 60 % (process
variables are typically transmitted during idle time for multiplexers). Exact
macrocycle times to be reviewed with the selected DCS supplier to minimise the
macrocycle time as much as possible.
Any deviation to the above will require additional validation and shall be subject
to JPMT/ IOCL approval.
5.11 Segment Wiring Design Requirements

Overall Wiring Design Philosophy
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For a traditional implementation the trunk cable between the marshalling and the
field junction box is typically a 20 pair twisted cable with overall screen. The
junction box can then accommodate up to 20 field devices including the 20%
spare philosophy.
In order to simplify the Fieldbus implementation, the field end shall mimic the
traditional implementation method as follows:
• The trunk cable shall be a 3 pair overall and individually screened cable with
the 1st pair used for the 1st H1 Segment, the 2nd pair for the 2nd H1 segment
and the 3rd will be an installed spare.
• The field junction box shall therefore accommodate 2 off H1 segments with
each accommodating up to 10 FF devices as detail in section 5.8 and section
5.9
• Each FF device shall be connected to the Fieldbus junction box via a single
pair screened spur cable
Any deviation from the above described arrangement shall be subject to
approval by JPMT/ IOCL.
5.11.1 Topology
The Chicken-Foot or Tree topology consists of a Fieldbus segment connected to
a common JB via the trunk cable from the Marshalling Cabinet as detailed
below.
Example of Tree (Chicken Foot) Topology
PSU
Fieldbus
Junction Box
Spur Cables
H1 Card
Trunk Cable
In order to simplify the Fieldbus implementation effort, this topology which

mirrors a traditional implementation method, shall be used.
Any deviation from the above shall be subject to approval by JPMT/ IOCL.
5.11.2 Cable Type
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In order to get maximum performance for Fieldbus network, individually shielded

twisted-pair cable designed especially for FF may be used (see table 5.11.2 (1)
for typical cable characteristics).
Table 5.11.2 Typical FF Cable Characteristics per IEC Physical Layer Standard
Wire Size 18 AWG (0.8 mm²)

Shield 90% coverage
Maximum Attenuation 3 db/km at 39 kHz
Maximum Capacitance 150 pF/m
Characteristic Impedance 100 Ohms +/- 20% at 31.25 kHz
Maximum dc Resistance 22 Ohms / Km
However, specially designed FF cable does not provide significant benefits over
standard cable that is available at a more attractive price and as such, for this
project standard instrument cables shall be used as follows:
Cable Type Specification (BS 5308 Part 1 or better)
Trunk Cable - Two twisted pairs, PE insulated, overall and

individually screened, SWA, PVC sheath,
1.0mm²
Spur Cable - Single twisted pair, PE insulated, screened,

SWA, PVC sheath, 1.0mm²
5.11.3 Cable Length

According to the FF specification (ISA S50.02) the maximum allowed length of a
Fieldbus segment is limited to 1900 metres. This total segment length is
computed by adding the length of the main trunk line and all the spurs that
extend from it.
• Total Segment Length = Trunk + All Spurs
From experience it is found that these lengths are conservative. The length of a
segment is limited by voltage drop and signal quality (i.e. attenuation and
distortion).
In order to eliminate the need to calculate the physical loading of each segment
and to reduce the validation requirement, the following limits shall apply for this
project:
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• Trunk cable length ≤ 750 metres

• Spur cable length ≤75 metres
Any deviation from these lengths shall be subject to JPMT/ IOCL approval.
5.11.4 Power Consumption
The maximum segment current is limited to 350 mA by the segment power
conditioners.
For this project, the maximum current required by a FF device shall not exceed
30mA (see section 5.4.4).
5.11.5 Minimum Operating Voltage
For this project, minimum voltage at the FF device shall be 10 Vdc which
includes a 1 Vdc safety margin.
5.11.6 Attenuation
FF operates at a frequency of 39 kHz where a standard FF cable has an
attenuation of 3 dB/Km at 39 kHz or about 70% of the original signal after 1 Km.
A Fieldbus ‘transmitter’ can have a signal as low as 0.75 volts peak-to-peak and
a Fieldbus ‘receiver’ must be able to detect a signal as little as 0.15 volts peak-
to-peak.
Based on a 3 dB/Km attenuation, the Fieldbus signals can be attenuated by 14
dB. This normally does not provide a problem for Fieldbus installation especially
based on the cable limits detailed above.
5.11.7 Grounding of Screens
All Fieldbus signal cores shall be preserved differentially throughout the network,
as grounding either conductor would cause all FF devices on that segment to
lose communications for the period that the conductor is grounded.
The instrument screen/shield shall be terminated at the host (power conditioner)
end of the segment in the marshalling cabinet and shall not be connected to
ground at any other place.
5.11.8 Segment Design Validation Tool
Within INtools all of the above segment wide parameters shall be entered with
the required default and/or maximum values specified within this procedure.
In order to minimise the Fieldbus implementation effort, the Contractor shall be
responsible to only change these default values when the actual device
parameters/values exceeds these default values, i.e. by exception only.
However, the ‘calculated’ length for all trunk/homerun cables shall be specified
as is the case for a traditional implementation.
Segment design validation shall be carried out by running the INtools Segment
Validation Report that require no additional effort by the Contractor other than
running the report.
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However, any ‘failed’ statuses on these reports shall be investigated by the

Contractor and shall be brought to the attention of JPMT/ IOCL.
5.11.9 Junction Box Requirements
A Fieldbus junction box shall be adequately sized to contain two Fieldbus
segments each with 10 off spur connections (see section 5.11).
The Fieldbus junction box shall follow the same principle and standards as for
traditional junction box and shall include 2 rows of ‘Termination Blocks’, one for
each segment.
Each ‘Termination Block’ shall be specifically made for FF networks with the
following minimum requirements:
• 1 dedicated connections for the Fieldbus homerun / trunk cable
• 10 dedicated connection for each spur cable
• Built-in Fieldbus Terminator
• Dedicated grounding termination points will be provided to ground the
individual cable screens for each cable (trunk and spur)
• Spring Clamp Terminals for all termination points
• Integral short circuit protection for spur connections*
• Current limiting to a maximum of 40mA per spur*
• Spur LED indicator to indicate when a spur is shorted/over current mode
• Bus power LED to indicate when bus power is available
• CENELEC approved EEx (n); or Zone 2, IIB, IIC
• Wire capacity: 0.5mm2 to 1.5mm2
• Temperature range –45 to +70°C
• DIN rail mounting
*Segment protector: To avoid breakdown of a segment in case of short on the spur or field device,
the wiring block shall support short circuit protection (Spur Guard or similar).
6 INTOOLS REQUIREMENTS
INtools provides the ability to design and maintain the Fieldbus system of a
plant, starting with the creation of Fieldbus tag numbers in the Instrument Index
module, generation of instrument data sheets in the Instrument Specifications
module and the generation of segment maps and other deliverables at the end
of the process.
The Segment Manager provides for the creation and management of Fieldbus
segments, association of instruments with the appropriate segments and the
creation and management of virtual tags (multi-process variable instruments).
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The Fieldbus feature in the Wiring module is used to create the required
Fieldbus cables (home-runs and spurs), manage the termination accessories
and various apparatus types and create the required strips or junction boxes.
At the end of the process, segment I/O maps and Fieldbus SmartLoop drawings
can be generated.
6.1 INtools Parameters Configuration

6.1.1 Segment-Wide Parameter Profile
The segment-wide parameter profile defines sets of defaults that serve as
design rules for Fieldbus segments. INtools validates the design according to
these parameters.
The following parameters shall be defined as defaults for INtools Fieldbus
segments:
Table 5.1.1 (1) - Physical Limits and Bandwidth Defaults
Maximum Number of Devices per Maximum Number of Assigned

Function Blocks per
Spur Segment IS Segment I/O Card Segment
1 10 6 -- 16
Table 5.1.1 (2) - Power Limits
Electrical Parameters
Power Allowable Allowable Minimum Maximum
Supply Current per non Current per IS Receiver capacitance
IS Segment segment Voltage
(V p-t-p)
26 V 350 mA 80 mA 1V 165 nF
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Table 5.1.1 (3) - Cabling Limits
Spur Cable Lengths (Meters)

Number of Devices Number of Devices per Spur
per Segment
1 2 3 4
1-10 75 m (*) (*) (*)
(*) Not applicable - only 1 device per Spur shall be used.

6.1.2 Fieldbus Instrument Type Profiles
No additional instrument type profiles for Fieldbus instruments are required.
Fieldbus instruments shall be created based on the traditional instrument type
profile. Upon creation of the Fieldbus tag, by identifying the I/O type as Fieldbus,
the instrument will inherit the Fieldbus properties.
6.1.3 Cable Parameters
A successful Fieldbus validation is dependant on the cable parameters, such as
capacitance, resistance, length and attenuation of cable. INtools provides the
facility to define default properties for each Fieldbus cable type.
The following parameters shall be defined as defaults for INtools Fieldbus cable
type:
Table 5.1.3 – Default Fieldbus Cable Type
Cable Type Parameters

Cable Type Maximum Attenuation Capacitance Cable
Fieldbus length Factor Factor Resistance
m db/km pF/m Ohm/km
Home-run & 1500 3 150 22

Spurs
Spurs 750 3 150 22
However, Contractor shall ensure the project cable specification shall meet the
above properties.
6.1.4 Termination Blocks
INtools provides the facility of creating Fieldbus termination blocks, such as the
Relcom Fieldbus connection system. This facility enables one to generate a
predefined configuration in order to create new Fieldbus termination blocks.
For this project, the 10-drop Fieldbus Termination Block with an internal
terminator shall be used, see section 5.11.9.
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6.2 Fieldbus Tag Numbers

6.2.1 Adding New Fieldbus Tag Numbers
New Fieldbus instruments are added exactly the same as creating new tag
numbers in the Instrument Index module. The instrument type profiles are the
same for Fieldbus instruments as those for traditional instruments.
Once an instrument type has been defined for the new tag number and the
system I/O as been defined as Fieldbus, the instrument will automatically
acquire all the appropriate properties that have been set for that tag number.
Figure 5.2.1 – Fieldbus Tag Number Properties
Fieldbus Tag Number Properties

Fieldbus tag name Not required – use instrument TAG
Field device address Required – Defined by TAG
Device ID Required
Standard Foundation Fieldbus
DC consumption 30 mA
Capacitance 5 nF
Minimum transmission level (V p-t-p) 1V
Operating Voltage 10 Vdc minimum (9 to 32 Vdc)
6.2.2 Associating Function Blocks to Fieldbus Instrument

INtools provides a set of most common function blocks whose properties are
defined by the Fieldbus Foundation. These function blocks cannot be deleted or
renamed, but their definitions can be modified if needed. User-defined function
blocks can also be created and can be modified or deleted as required.
Function blocks are associated with a particular instrument type. This
association will then enable the creation of new tag numbers that will
automatically be associated with that particular function block.
6.2.3 Virtual Tags
Virtual tags are signals created internally in field devices. These signals can be
secondary process measured variables that are measured by the same physical
instrument where these signals originated. After assigning a tag number to a
segment, add the required virtual tags to an instrument that has been associated
with a function block. If this association does not exist for a particular tag
number, no virtual tag can be created.
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6.2.4 Associating tags to specification sheets

Tags can be associated to Fieldbus specification sheets in the same way as non
Fieldbus tags are associated to specification sheets. The Fieldbus specification
form contains the regular specifications sheet with an additional page containing
the Fieldbus requirements for that particular instrument.
6.3 Fieldbus Segments

The Fieldbus Segment Manager provides for the creation and management of
Fieldbus segments, association of instruments with the appropriate segments
and the creation and management of virtual tags (multi-process variable
instruments). You can also display and print out the detailed wiring of a
segment.
6.3.1 Creating Fieldbus Segments
When creating new segments, the segments are associated to the required
segment-wide parameter profile. Segments are defined as intrinsically safe or
non-intrinsically safe.
INtools warns if any instruments currently associated with an intrinsically safe
segment are not intrinsically safe and any instruments currently associated with
a non-intrinsically safe segment are intrinsically safe.
6.3.2 Associating Tags to Segments
Once the segment has been created, instruments can be associated with the
segment.
A Fieldbus instrument can be associated only with one Fieldbus segment.
However, you can associate multiple tag numbers with one Fieldbus segment.
The segment association of an instrument can be changed, if needed. Before
making a new segment association, the instrument will have to be disassociated
from its current segment.
6.3.3 Fieldbus Segment Naming Convention
Refer to (HOLD).
6.4 Fieldbus Wiring

The Fieldbus features in the wiring module of INtools enable the installation of a
Fieldbus network wiring and attachment of the Fieldbus control devices.
6.4.1 Home-Run/Trunk Cables
INtools differentiates home-run cables from regular cables, as home-run cables
propagate and connect the individual device spurs to the DCS. INtools provides
the facility of defining cables as home-run, enabling then these cables to be
associated to segments.
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6.4.2 Junction Boxes

Termination Blocks are added to junction boxes by creating the terminal blocks
based on the configured termination blocks. Where internal terminators are
used, ensure that the internal terminator check box has been selected.
6.4.3 Segment Wiring Drawings
Once the Fieldbus network connection is complete, segment wiring drawings
can be generated.
6.5 INtools Fieldbus Validation

INtools validates Fieldbus segments according to basic connection rules and
according to parameters set for a given segment:
6.5.1 On-the-Fly Connection Validations
Upon attempting to connect, the software verifies that:
• An instrument to be connected is not associated with another segment.
• A home-run cable to be connected is not already connected to another
segment.
• You are not trying to connect a non-Fieldbus instrument to a Fieldbus
segment.
• You are not associating or wiring a non-intrinsically-safe instrument to an
intrinsically safe segment. In this case, INtools will warn, but allow.
6.5.2 Segment-Report Validations
Other validations are performed by running a report from the Fieldbus Segment
Manager. INtools reports a failed validation in the following cases:
• There are Fieldbus tags that are associated with a segment but not wired
• There are Fieldbus tags that have wiring, but are not yet connected to a
segment
• There is a connection discontinuity between the field and a DCS or an I/O
terminal strip
• The number of instruments in a segment exceeds the maximum specified for
that segment
• The number of devices on a given spur exceeds the segment-wide parameter
profile
• A spur length is exceeds the maximum set for that spur
• Total cable length exceeds the maximum you defined for the segment profile
• There are no terminators or less than two terminators in a segment
• Actual voltage at instrument terminals is below the minimum operating
voltage
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• Total segment current consumption exceeds the maximum specified value

• Total capacitance exceeds segment maximum specified capacitance
6.5.3 Validation Requirements
In order for the Fieldbus validation to be performed successfully, the following
should be taken into account:
• To define a cable type that supports Fieldbus validation, make sure that in the
Cable Type Properties dialog box, you enter the required values for
capacitance, capacitance UOM (unit of measure), cable resistance, cable
resistance UOM, length UOM, and maximum Fieldbus length.
• To define an instrument tag that supports Fieldbus validation, make sure that
in the Tag Number dialog box you enter valid information under Fieldbus Tag
Number Properties.
INtools validation supports basic Fieldbus networks consisting of a single
segment with no parallel branches and no repeaters.
6.6 Diagnostics
On-line and off-line diagnostics shall be provided to assist in system
maintenance and troubleshooting. Diagnostics shall be provided for every major
system component and peripheral. This shall include segment as well as device
diagnostics and firmware diagnostics in the devices. If diagnostics do not exist
for particular peripheral devices (for example printers and terminals,) the system
must detect and provide an error indication for the failure of these devices.
In case of Foundation Fieldbus transmitters all the diagnostic functionalities shall
be integral part of DCS without the need for a separate sub-system, i.e.
diagnostic functionalities as indicated for AMS should be an integral part of DCS
functionalities in case of Foundation Fieldbus field transmitters.
It shall be possible to configure, monitor, and troubleshoot Foundation Fieldbus
devices from the DCS. The DCS shall be capable of storing calibration
information and device status history for each field device. It shall also be
possible for the DCS to upload field device configuration changes implemented
in the field. Once the configuration information is stored in the DCS, it shall be
possible to download it to any other similar device, whether a new or
replacement device. Diagnostic software shall be as per IEC 61804 for
Foundation Fieldbus interoperabilities.
6.7 Testing
Vendor shall develop a separate written test plan and test procedure for the
FOUNDATION Fieldbus FAT.
6.7.1 Test Requirements
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Factory acceptance test shall be per the DCS specification with the following
additions for FOUNDATION Fieldbus:
A complete functional test shall be conducted for one of each FF device used on
this project (i.e. third-party and F-R products). This test will include, but is not
limited to, plug-and-play interconnectivity to Host system; verify access to all
device function blocks, and actual device operation, (i.e. simulate process inputs
for transmitters, etc.).
The test shall include a calibration and setup for each type of FF device.
Examples are changing RTD sensor types, calibrating transmitter span, zeroing
P & DP transmitters, zeroing elevation on DP level transmitters. The intent of
this requirement is to verify the ease of access to calibration wizards and setup
procedures via the Host system.
All calibration and setup procedures, for each device, shall be documented in
detail by the Vendor and approved by PMC/Owner
Vendor shall develop a redundancy fail-over test procedure for the H1 interface
cards and Fieldbus power supplies. The test shall verify that automatic fail over
shall not cause an upset, (i.e. I/O signal bumps, loss of operator view, mode
changes, etc.). All H1 interface cards and FFPS shall be tested.
Each segment (port), including spares, shall be operationally tested by live
connection of at least one Fieldbus device. The Fieldbus device shall be
connected to the terminal block designated for the field wiring or system cable.
The FAT/IFAT procedure should be submitted to PMC/IOCL for approval one
month before commencement of FAT/IFAT.
6.8 Device Maintenance

When Fieldbus devices require replacement, it must be possible to accomplish
this replacement within the following parameters:
All other devices on the Fieldbus segment continue to operate and report data to
the Control System
No engineering access to the Control System is necessary
The system shall auto-sense a properly configured replacement device based
on the device tag. This shall be sufficient for the Control System to complete
any further tasks automatically, however the device blocks will be placed out of
service.
The operator responsible for the device (based on the control strategy that is
part of) shall be notified that the device is on-line and ready to be placed back
into service.
Vendor shall offer the services of the installation team which would install the
equipment in the control room, lay the interconnecting cabling inside the control
room, check out, test and commission the system.
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6.9 Workstations
Engineering Workstations Software and Hardware
Predictive Maintenance Management System shall be integrated into the
engineering workstation to provide predictive maintenance like valve diagnostic
and assist in commissioning activities like trim and calibration management.
Minimally this module should be capable of diagnosing on-line device health
monitoring and alert generation, with event capture and logging capabilities of all
connected intelligent field elements. Vendor shall furnish details of functionality
along with quotation/ offer.
Event module which provides ability to capture and log both operator and control
system events with time and date stamping. Minimally the event types this
module should capture include; operator initiated changes, alarm activity (e.g.,
initial active, acknowledged but active, and clear), configuration changes,
controller downloads, control system device status changes (e.g., device “good-
to-bad” status change, device “bad-to-good” status change), and intelligent field
device status change (e.g., device “good-to-bad” status change, device “bad-to-
good” status change).
Engineering module which provides a pre-configured library of process control
objects to assist in developing application specific Distributed Control System
solutions. The engineering module shall be capable of conducting both on-line
and off-line control system applications. Minimally this module should be
capable of developing full-function graphic displays, development of complex
control strategies, sequences, and reports.
6.10 Alarm and Message Handling

Process Alarm Initiation
To minimize analogue input "chattering" (a point going in and out of an alarm
condition rapidly) there shall be configurable dead band parameters, on an
individual tag basis.
For analogue tags, the configurable triggers for process alarms shall include:
• Process variable high limit exceeded
• Process variable high high limit exceeded
• Process variable low limit exceeded
• Process variable low low limit exceeded
• Process variable rate-of-change high
• Process variable deviation from setpoint
• Process variable invalid value
For digital tags, the configurable triggers for process alarms shall include:
• Either state
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• Change of state.
A list of inhibited alarms shall be available to be displayed and printed.
System Alarm Initiation

All devices connected to the DCS communication network shall be monitored for
failures. A system alarm shall be generated for each failure detected.
Process and System Alarms History Retention

All alarms shall be stored in history files with the capability to archive these to
removable media. Capability shall be provided to recall these alarms in visible
display lists and printed lists according to selectable filtering options.
Process and System Alarms Audible Annunciation

All alarms for a process area may be assigned to any workstation at
configuration time. All alarms shall be displayed on the workstation(s)
designated. The audible alarm shall be user configurable for different tones or
patterns. The system shall have an adjustable volume control. The system shall
use global alarm acknowledgement allowing a single acknowledgement from
any workstation to acknowledge that alarm on all workstations and to silence the
audible alarm.
Process and System Alarms Visible Annunciation

Alarms shall cause visible display annunciation at, and only at, a Workstation
configured for those alarms. The annunciation shall occur within 3 seconds of
detecting the initiating event. It shall be possible to acknowledge process alarms
only from a Workstation configured for those alarms. It shall be possible for an
operator to acknowledge any alarm configured at his Workstation by no more
than two actions. An alarm shall be acknowledgeable only if it is shown on a
visible display.
7 DOCUMENTATION REQUIREMENTS
Documentation requirement for FF system design is the same as for a traditional

system with the following additional documents/drawings:
• Segment Validation Report
• Segment Drawing
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INtools supports both the above documents as standard features and as such,
no additional effort is required by the Contractor other than running the reports
from INtools.
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Appendix-A
8 FIELDBUS SYSTEM DESIGN GUIDELINES
8.1 General
Foundation Fieldbus is an all-digital, serial, two-way communication protocol that
interconnects devices in the field such as sensors, actuators, and controllers.
Foundation Fieldbus has also the capability to distribute control applications
across its network in the field. Furthermore it enables advanced diagnostics and
asset management tools resulting in higher plant availability. A typical Fieldbus
installation provides connection from a network of field devices to a host system
via a two way, serial communication link. The cabling and connections are
arranged in a multi-drop fashion, requiring only a single pair wire with parallel
connections to field devices. This is quite different from the traditional approach
of connecting 4 to 20 mA devices to a DCS system using dedicated pairs of
wires for each device.
Fig. 8.1.1 (1) shows the traditional dedicated pair approach. Fig.8.1.1 (2) shows
a typical Fieldbus arrangement.
Fig. 8.1 (1): Traditional Approach to Instrument Connection
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Fig. 8.1 (2): Typical Fieldbus Approach to Instrument Connection
Two-way, multi-drop, digital
Each Fieldbus run from the host system to the field is known as a segment.
Each segment consists of a trunk or home-run running from the host system
(DCS) and out through the processing plant with parallel connected spurs linking
to field devices such as transmitters and control valves. Junction boxes are
preferred to connect the trunk to the individual spurs.
A power supply connected to the trunk provides conditioned power to all devices
on the Fieldbus segment.
8.2 Main Differences between Fieldbus & Traditional Installation
8.2.1 Hardware
The difference in cabling is one of the beneficial features of Fieldbus technology.
In FF the power and communication is provided over the same cable with some
exceptions such as Magflow meters.
In addition, as a result of the network configuration there are less I/O cards, I/O
interface racks and marshalling cabinets required both in CCR’s and in the
SRR’s.
Also more sensors can be integrated in one FF device leading to a reduction in
field devices and/or enhanced diagnostic features.
8.2.2 Communication
FF technology is tag driven, which means that the host will check and
commission devices on basis of tags in the database and with the auto
addressing of devices, a reduction in the loop check effort can be realised.
The data transfer is fully digital which eliminates the need for re-ranging and re-
calibration because of drift.
Furthermore a higher accuracy in process control can lead to less variability and
less product give away.
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8.2.3 Protocol
The FF protocol enables the adequate transfer of all sorts of messages such as,
Process Variable, status, diagnostics, etc. This coupled with the ability of the
host to convert all these basic data into information leads to higher plant
availability and reduced maintenance costs.
However, there is a need for well-trained and qualified personnel to handle the
technology changes and exploit all the advantages.
8.2.4 Engineering
The Fieldbus system design process itself is similar to the traditional system
design. However, for traditional systems the device layouts and cable schedules
are used mainly for marshalling cabinet design, and the DCS system will be
designed based on I/O lists and process operation procedures, irrespective of
the cable schedule or the location of the devices and junction box.
Whereas, in case of a Fieldbus based system, the field side details, i.e. segment
design, do affect the DCS system design. This means that the DCS system
design is dependant on device layout, cable detail, i.e. segment design details.
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Fig. 8.2 Main Difference between Traditional and Fieldbus System
Conventional I/O System
1) Analogue (4 - 20mA)
2) 1 :1 Cable Connection
3) Function Block in DCS
CONT
MARSHALLING
CABINET
CONT
Multi-Core Cable
Conventional
I/O Type Field
Devices
Local JB
Fieldbus System
1) 2 way Digital Communication

Communication Cycle
LAS Allocation
Cable Spec & Cable Length Redundant
Fieldbus Interface
2) Multi-Drop Cable Connection MARSHALLING

Device Grouping CONT CABINET
Wiring Topology Fieldbus Cable Fieldbus JB
JB Configuration & Location (2 Pair)
Power Supply for Multi Devices Terminator
No Marshalling Function in MDF
Redundant FF devices
3) Function Block in Device & DCS PS/Conditioner
Basic Function Block
Advanced Function Block
Multi-vendors Devices
8.2.5 Example Calculation

To aid understanding the following example considers cable length, voltage
drop, and power consumptions:
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Figure 8.13.9 Example Calculation

Fieldbus
Junction Box
Total 24Vdc
Trunk Cable
PSU (1) 22 ohm/Km
(2) Length 750 m
Power Consumption
= 0.03 x 10 devices
= 0.3 Amps
Segment Power
=0.3 < 0.35 Amps of PSU
Spur Cable
(1) 22 ohm/Km
10(2)FFLength:
devices75 m per Spur
Voltage Drop 1 (30mA(3)
/ device at 10mV)(10 devices x 75m)
Total: 750
= Total Power in Trunk x Resistance
= 0.3 x (22 ohm/1000m) x (750 m x 2 wires)
= 9.9 Vdc
Voltage Drop 2
= Total Power
= 0.03A x (22 ohm/1000m) x (75 m x 2
wires)
0 1 Vd
Total Required Voltage

= Voltage Drop 1 + Voltage Drop 2 + Min Device Voltage + 1Vdc Signal
= 9.9 + 0.1 + 10 + 1
= 21 Vdc
= 21 Vdc < 24 Vdc of PSU
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JOINT PROJECT MANAGEMENT TEAM

8.2 Main Differences between Fieldbus & Traditional Installation........ 31

This project procedure defines the Foundation Fieldbus System Design

The purpose of this specification is to define the Foundation Fieldbus System

3 DEFINITIONS AND ABBREVIATIONS

Contractor / Vendor Means the firm, company or other corporate entity

Should Refers to a recommendation

May Refers to one acceptable course of action.

3.1.2 Foundation Fieldbus Definitions

International Electrotechnical Commission

National Fire Protection Association

4 FIELDBUS SYSTEM OVERVIEW

4.1 Project Objectives

5.1 Field Device Selection

• STATUS_OPT (Propagate Fault)

Monitoring loop - AI Propagate Fault Forward: OFF

Local Control loop - AI Propagate Fault Forward: ON

- AO Propagate Fault Backward: ON

• Pressure & Differential Pressure Transmitter

L_TYPE - Indirect SQRT

For this project, the bus-powered method shall be preferred.

5.2 Critical Loop Definition and Application

Level 1 Failure of a control loop will result in a shutdown of an entire plant, or

Level 2 Failure of a control loop will result in an emergency situation, where

5.3 Control Assignment

5.6 Hazardous Area Classification

5.8 Segment Physical Device Loading Requirements on the H1 bus

5.9 Segment Spare Philosophy Requirements

5.10 Segment Execution Time Requirements

5.11 Segment Wiring Design Requirements

Example of Tree (Chicken Foot) Topology

In order to simplify the Fieldbus implementation effort, this topology which

5.11.2 Cable Type

In order to get maximum performance for Fieldbus network, individually shielded

Wire Size 18 AWG (0.8 mm²)

Cable Type Specification (BS 5308 Part 1 or better)

Trunk Cable - Two twisted pairs, PE insulated, overall and

Spur Cable - Single twisted pair, PE insulated, screened,

5.11.3 Cable Length

• Trunk cable length ≤ 750 metres

However, any ‘failed’ statuses on these reports shall be investigated by the

6.1 INtools Parameters Configuration

Table 5.1.1 (1) - Physical Limits and Bandwidth Defaults

Maximum Number of Devices per Maximum Number of Assigned

Table 5.1.1 (2) - Power Limits

Table 5.1.1 (3) - Cabling Limits

Spur Cable Lengths (Meters)

(*) Not applicable - only 1 device per Spur shall be used.

Table 5.1.3 – Default Fieldbus Cable Type

Cable Type Parameters

Home-run & 1500 3 150 22

6.2 Fieldbus Tag Numbers

Figure 5.2.1 – Fieldbus Tag Number Properties

Fieldbus Tag Number Properties

6.2.2 Associating Function Blocks to Fieldbus Instrument

6.2.4 Associating tags to specification sheets

6.3 Fieldbus Segments

6.4 Fieldbus Wiring

6.4.2 Junction Boxes

6.5 INtools Fieldbus Validation

• Total segment current consumption exceeds the maximum specified value

6.8 Device Maintenance