Download - 6 Implementing FF in KGD-6 Gambhir
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2011 General AssemblyMumbai, India
Implementation of FF in KGD6
Harvindar Gambhir/MadhuriAllika
Vice President/Manager
Reliance
Place Company
Logo Here
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation2
KGD6-General informationOnshore 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
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation3
Integrated Control system block Diagram
SUBSEA CONTROL CENTRE HOOFFSHORE 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
M05M0
9
M07
M06
M04
M03
Safety Guarding System(ESD, F&G CCTV)
BACKUP CONTROL ROOM
BACK-UPCOMMUNICATION
(MICROWAVE )
FIBRE OPTIC LINK
SCADA for pipeline
Emergency Shutdown System (ESD)Fire & Gas Detection (F&G), CCTVSystem
F I B R E
OP T I C L I N K
R E D
U N D A N T
ON SHORE TERMINAL
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation4
IO CountSystem 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
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation6
FF General ChallengesDURING DESIGN PHASE
Grouping of devices --Quantity of Devices,Location of devices, loop criticalityCritical Valves
H-1 RedundancyMacro cycle Execution TimePower ConsumptionSegment Length
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1994 2011 Fieldbus Foundation8
SolutionUpfront collaboration of design with Consultantand 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.
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation9
SolutionUsed 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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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation10
Design Pre-requisitesP&IDs
Plot Plan, 3D model
Area Classification
Foundation Field bus Specification (ProjectSpecific)
List of Critical Control LoopsControl Narratives (process control strategy)
I/O Lists
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1994 2011 Fieldbus Foundation11
Segment DesignSegment 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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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation12
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
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation13
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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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation15
KGD6 Design Features
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation16
KGD6 Design Features
Maximum of 12 devices per segment.
Maximum 3 Control Valves per segment.
However installed 2 control valves in mostof the segments
Macro cycle for all the segments is
maintained at less than 1200 msec
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation17
KGD6 Design FeaturesOnly 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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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation18
The method of protection is a high power trunk Hybridconcept. 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
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation19
KGD6 - Design FeaturesDCS 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 activescheduler; secondary FBM 228 module as back up LAS
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation20
MacroCycle Calculation Tool
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation22
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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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation23
Spur
Trunk
FCP270
FBM228
FF Segment Interconnection
ADM
23
I-JB
FP32 SurgeProtectors
FCS-835112-way JB
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation25
ADM (Advanced Diagnostic Module)
809FMTL --for physical layer diagnostics
Installed on the base plate and providesdiagnostics of 8 segment.
Diagnostic information of FF devices is also
available in Asset Management System
through Block error parameter
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation26
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 FFJ-Box and the FF Spur J-Box and to the devices
Cables and Grounding
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation27
Earthing Arrangement
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1994 2011 Fieldbus Foundation28
Shield are cut and taped to avoid any possibility of inadvertentgrounding 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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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation29
Interoperability-Field DevicesDevices 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
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation30
Interoperability-DCSEnsure 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
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation31
Devices tested in FAT for InteroperabilitySr. 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 6000f13 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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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation32
Device Installation and CommissioningWhat 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
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation33
Installation Practices
Some contents and photographs in
this section are from variousaudits conducted at KGD6 site.
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2011 General AssemblyMumbai, India
1994 2011 Fieldbus Foundation34
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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2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation35
Cable Termination in FF cabinet
Inside jacket removed close to the
termination points such that the min. am t. of
individual pair shield is exposed.
At the point where the jacket is
Removed, place a 2 heat shrinksection 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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2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation36
Cable Termination in FF cabinetEnsure that the shields
of individual pairs are
maintained.
Place sleeve over eachindividual pair shield drain wire
and the overall drain wire
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2011 General Assembly
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1994 2011 Fieldbus Foundation38
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.
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2011 General Assembly
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1994 2011 Fieldbus Foundation39
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
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2011 General Assembly
Mumbai, India
1994 2011 Fieldbus Foundation40
Lessons LearntEnsure 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 formaintenance, take the device in OOS mode (Out
of Service mode) and then remove the device
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2011 General Assembly
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1994 2011 Fieldbus Foundation41
Dedicated specifications for FF implementation &FF cables
Ensure all field devices procured are type tested
Ensure all devices with FF check markTraining 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
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2011 General Assembly
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1994 2011 Fieldbus Foundation42
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 inthe future if required.
Future suggestions
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1994 2011 Fieldbus Foundation43
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Thank You
This presentation is dedicated tothe team comprising of :
RIL, Vendors, Consultants &Contractors
who made it happen