MTL FFieldbus HA Solutions and Diagnostics PDF

Taking fieldbus H1 into Hazardous Areas
Foundation Fieldbus H1 Introduction
Cooper Industries/MTL Confidential
How is fieldbus different from 4-20mA?

4-20mA
Power Supply
Power Supply
fieldbus
Input card
In a Fieldbus system, the power supply, field devices and input card are connected in parallel. In 4-20mA circuits, the power supply, field device and input card are connected in series.
Expanded System View
TAG VALUE UNITS STATUS ALARM 15.3 mA
= LIC-012 = 70.34 = m3 = GOOD = Y/N
DCS: Limited system view. Does not include diagnostics and other information from field devices.
FCS: Expanded view. Field devices are part of the system.
Advantages of fieldbus over 4-20mA

Measurement accuracy
Process variable is converted to digital value in the field device Value cannot be corrupted by leakage or electrical interference Allows tighter control of process
Better diagnostic information

Field device diagnostics result in maintenance savings No in range errors
Fewer wire terminations Cable savings

Multicore home run cable replaced by single twisted pair
Physical Layer - specifications

IEC 61158 Physical Layer standard 31.25kb/s Up to 32 devices per segment - depends on several factors Shielded twisted pair - can use existing field wiring Power down the bus Up to 1900 metres with best cable - more with repeaters Intrinsically safe
Device connection
Fieldbus in hazardous areas

SEGMENT Control system
24Vdc
Power supply & conditioner (FFPS) Integrated terminator

Wiring Hub
Trunk
CONTROL ROOM FIELD
Terminator
Spur
FOUNDATION Fieldbus Devices

Fieldbus Electrical Circuit Diagram
Near-End Terminator
Far-End Terminator
Power Conditioner
Field Devices
9-32V 100 W
H1 Interface
+
-
Signal Isolation Inductors
100 W 1 mF
1 mF
1,900m max. Power supply, H1 interface card, field devices and terminators are all connected in parallel
Fieldbus needs terminators
Fieldbus Host Control System
T
T
D
100W 1mF
Terminators are required, one at each end, to:

Provide matched line impedance to minimise reflections &
distortions, and
Define the impedance of the bus for conversion from current modulation to voltage modulation*
No more than 2 terminators may be used on one
segment
* FF devices transmit by modulating the current and receive by detecting the modulated voltage
Wiring topologies
Trunk
Point-to-Point
Trunk
Bus with Spurs

Trunk
Daisy-Chain JB Chicken Foot or Tree
Trunk
Preferred
Selection of Power Supplies and Wiring Components
Fieldbus in hazardous areas
Control system
24Vdc
Power supply & conditioner (FFPS) Integrated terminator
Trunk
Hazardous Area protection
CONTROL ROOM FIELD
Wiring Hub
Terminator
Spur
Hazardous Area protection FOUNDATION Fieldbus Devices

Hazardous area
Methods of protection
Method of protection FISCO Intrinsically Safe Fieldbus barrier Ex d/Explosionproof Ex e/Increased safety Ex n/Nonincendive FNICO Ex nA Non-Arcing Ex nL Energy-Limited Zone 2 Division 2 Zone 1 Division 1
Hazardous area protection

Two End user groups:
Use intrinsic safety or non-incendive field wiring
allows live working without gas clearance certificate eg. Aramco, BP, Bayer, Chevron, Mol, ONGC
Use Ex d/explosionproof or non-arcing

gas clearance certificate required for live working eg. Shell, Exxon Mobil
Live working of field devices

High Energy Trunk Features No limit on number of devices Redundant power Limitations on live working Non-incendive spurs Fieldbus barrier Fieldbus barrier Fieldbus barrier* FISCO Energy Limited Trunk Limit number of devices Simplex power Live work trunk and spurs FNICO
Zone 2/Division 2 Zone 1 Zone 22/21 Division 1

* Fieldbus barrier is located in Division 2
Non-arcing trunk with Non-incendive spurs

Control system
24Vdc 24Vdc
General purpose Fieldbus power supply

CONTROL ROOM High Energy Ex nA trunk Spur short-circuit protection in wiring hub makes spurs Ex nL FIELD
Live-workable Ex nL spurs Ex nL or Intrinsically Safe Fieldbus devices
Zone 2 Division 2
Non-incendive spurs
Field instruments may carry any of the following approvals:
Intrinsically safe Non-incendive (North America) EEx nL (IEC)
Compliance with the following parameters is required:

Ui > or = fieldbus power supply max voltage
Recommend Ui > or = 32V If Ui = 24V use F801 module If Ui > or = 30V use F802 module
Non-arcing trunk and spurs

Control system
24Vdc 24Vdc
Fieldbus power supply

CONTROL ROOM High energy Ex nA trunk FIELD No live working without power-down or gas clearance Ex nA spurs
Ex n or Ex d/Explosionproof Fieldbus devices
Zone 2 Division 2
Ex d field devices in Division 1

Control system
24Vdc 24Vdc
Fieldbus power supply
CONTROL ROOM
High energy Trunk not live-workable Junction box: Ex d/Explosionproof or Ex e
FIELD Spurs not live-workable
Ex d/explosionproof Fieldbus devices

Zone 1 Division1
Ex e/d field devices in Zone 1

Control system
24Vdc 24Vdc Fieldbus power supply
CONTROL ROOM Trunk not live-workable Junction box: Ex d/Explosionproof or Ex e FIELD
Field wiring hub EEx me approved
Spurs not live-workable
Ex d/explosionproof Fieldbus devices

Zone 1
Typical FNICO installation

Control system
24Vdc 24Vdc
FNICO power supply CONTROL ROOM
Live-workable Ex nL trunk
FIELD
Live-workable Ex nL spurs
Ex nL or Intrinsically Safe Fieldbus devices
Zone 2 Division 2
Typical FISCO installation

Control system
24Vdc 24Vdc
FISCO power supply CONTROL ROOM
GAS Zone 1 Division 1

Liveworkable Ex i trunk
DUST Zone 21
FIELD
Live-workable Ex i spurs
FISCO fieldbus devices
Multi-drop capability
Direct parallel connection on safe area side
24Vdc 24Vdc
Trunk #2
Trunk #3
Intrinsically safe FISCO Fieldbus devices
Zone 1 Division 1
FISCO for hazardous area applications

Intrinsic Safety preferred by many end users for protection of instrumentation in hazardous areas
Recognised as Safest possible technique Maintenance personnel dont need re-training on non-IS techniques Field enclosure smaller, lighter and less complex than alternative techniques using simple wiring hub
Simple safety documentation compared with earlier IS Fieldbus techniques Cable parameter calculations associated with conventional IS circuits are not needed Trunk cable lengths and segment loading adequate for many applications
Typically 8 devices with 830m trunk cable length in IIB gases Typically 5 devices with >640m trunk cable length in IIC gases
Multi-drop capability
Fieldbus Barrier
Control system 24Vdc 24Vdc

High energy Ex e trunk
Fieldbus power supply CONTROL ROOM

FIELD
DUST Zone 21
Fieldbus barrier
Zone 1/0 Division 1

FISCO or entity fieldbus devices
Zone 21/20
High Energy Trunk for hazardous areas

Benefits of High Energy Trunk concept:
Redundant Fieldbus power supply can be used Typically 12 instruments (typically limited by cycle time) Fieldbus trunk is not energy-limited, so very long segment lengths can be supported Spurs connect to FISCO or Entity instruments; simple verification of intrinsic safety
Disadvantages of existing Fieldbus Barrier implementations:

Enclosure involves many components Solution is customized Field enclosure is large, complex, expensive Mix of protection methods within main enclosure compartment (Ex e trunk and Ex ia spurs) risks maintenance errors
25
Maintenance-friendly High-Power Trunk
Legacy fieldbus barrier

Designed to provide high levels of energy in to the field by:
Using high-power FFPS Moving the IS interface into the hazardous area One Ex e trunk connection per module Enclosure needs extra terminals for:
Trunk separation to further barrier modules Field device connection
Legacy Fieldbus barrier

Control system 24Vdc 24Vdc

High energy Ex e trunk
Fieldbus power supply CONTROL ROOM

FIELD
DUST Zone 21
Fieldbus barrier
Zone 1/0 Division 1

FISCO or entity fieldbus devices
Zone 21/20
Customised FBB enclosure

Custom-designed to suit project requirements:
Enclosure material Ex-protected isolating switch option Fixed terminator options Trunk and spur surge protection options Internal cable management Field wiring terminal options
Ex protected isolating switch option Spur surge protector option
Trunk surge protection and optional combined fieldbus terminator
Additional terminals
Connections in customised systems
Number of terminals: Spur: + / - / Shield of FBB to + / - / Shield of Surge Protector. There are 12 spurs = 72 Spur: + / - / Shield of Surge Protector to + / - / Shield of screw terminal. There are 12 spurs = 72 Trunk: + / - / Shield of FBB to + / - of Ex de switch. There are 3 Trunks = 15 Trunk: + / - of Ex de switch to + / - / Shield of Ex e terminals. There are 3 Trunks = 15 Total = 72 + 72 + 15 + 15 = 174 terminals = 174 potential points of failure!
30
12-spur SS enclosure
Live pluggable trunk surge protector (optional) Live pluggable Terminator Trunk terminals Trunk Terminal Assembly (TTA) housing
Live pluggable
6-spur Fieldbus Barrier modules Spur surge protector (optional)
Screwsecured, pluggable spur terminals
6-spur GRP enclosure

Live pluggable trunk surge protector (optional) Live pluggable Terminator Trunk terminals Trunk Terminal Assembly (TTA) housing Live pluggable 6-spur Fieldbus Barrier modules
Spur surge protector (optional)
9373-FB Series Fieldbus Barrier enclosure (12 spur)
Fieldbus control system (DCS)
24V dc Bulk power input
Increased safety (Ex e) High Energy trunk
General Purpose Fieldbus Power Supply CONTROL ROOM Fieldbus Barrier enclosure FIELD Zone 1
Intrinsically Safe spurs
Intrinsically safe FISCO or Entity Fieldbus Devices

Compare size with legacy 12-spur solutions

Existing 12-spur solutions with Surge Protection 9373-FB 12-spur Fieldbus Barrier with Spur Surge Protection
All images approx. to scale
Surely not!
950mm
Replace this...
.....with this
430mm
MTLs 9370-FB is up to 50% smaller than conventional Fieldbus Barrier implementations, leading to significant savings in infrastructure and installation costs
35
But size doesnt matter!

All system components are pluggable, even in the hazardous area:
Safer, easier maintenance Allows expansion from 6 to 12 spurs per enclosure* Install trunk and/or spur surge protection modules during initial installation or as retro-fit Faster fault diagnosis by substitution
Fieldbus Barrier module
Spur surge protectors (one per spur) Fieldbus terminator Trunk surge protector
* Specify 9374-FB (12-spur) enclosure with 6 spurs

fitted; expand to 12-spurs by addition of second 9377-FB module
36
Module carrier
Supplied as part of complete enclosure assembly 6-spur and 12-spur versions Provides mechanical and electrical mounting platform for 9377-FB Fieldbus Barrier module(s) Provides pluggable connections to fieldbus spurs Robust design Supports optional Spur Surge Protection modules
Integrated high integrity ground connection
37
How are the modules hot pluggable?

Ex de plug/socket system Patented technology from Cooper Crouse-Hinds Integrated part of:
Fieldbus Trunk Terminator Trunk Surge Protector Fieldbus Barrier Module
Gas tight when inserting (Ex d) Mechanically designed for Ex e Allows removal of equipment without gas clearance or additional Ex de switches
Plug
Socket
38
Simplified maintenance
Maintenance activity Remove and replace Fieldbus Barrier module Conventional Fieldbus Barrier enclosure Remove enclosure cover Select and operate appropriate isolating switch Open trunk terminal cover on barrier module Remove trunk wiring from terminals and secure Remove spur wiring from terminals and secure Remove and replace barrier module Reinstate trunk and spur wiring and close trunk terminal cover Operate isolating switch Replace enclosure cover
39
9370-FB Series Fieldbus Barrier enclosure Remove enclosure cover Loosen module screws Remove and replace barrier module Tighten screws Replace enclosure cover
Reducing maintenance risk

I can open the enclosure door of the module main compartment and so Every and circuit within it only contains IS circuits it? is livethedoesnt shaded area
workable in the hazardous area
Mixing circuits that can be live-disconnected in a hazardous area with those that cant leads to unnecessary risks during field maintenance which is why all circuits and modules.
Reducing maintenance risk

Non-live workable circuits are confined within the Trunk Terminal Assembly compartment and protected by a lockable cover. This only ever needs to be opened during installation and when the trunk cable fails and needs to be swapped over. On both occasions there is no power. Every module and circuit within the shaded area is live-workable in the hazardous area
Mixing circuits that can be live-disconnected in a hazardous area with those that cant leads to unnecessary risks during field maintenance which is why all circuits and modules in the main enclosure compartment are designed to be replaced while powered.
Fieldbus H1 Physical Layer Diagnostics
User-Friendly Handheld, Periodic Diagnostics
Reliability of fieldbus physical layer
At commissioning a few installation and device faults require correction After commissioning fieldbus segments run reliably
on 300 segment system about one physical layer problem needs resolving/year
Relcom fieldbus testers are estimated to be used on more than 90% of segments installed
Commissioning Procedure
inspect wiring unplug power conditioner field connector
signal + to signal - >50kohm signal + to screen >20Mohm signal - to screen >20Mohm signal + to ground bar >20Mohm signal - ground bar >20Mohm screen to ground bar >20Mohm
Common Faults
Shorts (between +, -, shield, ground)
water stray wire strands cable damage, etc.
Cable
non compliant water ingress routed near noisy cable/equipment too long
Intermittent connections
broken wires improperly connected shield loose connector/wire
Component failure
Power supply
Wiring component/terminator Field device
Terminator
missing/extra/failed wrong location
Power supply is not isolated
Characteristics of user-friendly diagnostics
Easy to measure Easy to understand Gives definite indication of a problem Eliminates possible causes Actionable
Fieldbus Diagnostic Measurements

Segment Voltage
Measure voltage on segment Noise measurement at n Hz Noise measurement at 31 kHz Noise measurement at 400kHz Maximum noise at each of Low, In Band, and High frequencies
Positive Short to Shield

Short circuit between these 2 cables
Low Frequency Noise
Negative Short to Shield

Short circuit between these 2 cables
Voltage is between 0.35 and 1 volt Number of messages that need to be sent more than once on the network Displayed for 1 hour Displayed for 1 hour
In Band Frequency Noise

High Frequency Noise
Device Signal Level
Peak Frequency Noise
Retransmissions
Live Device Count

Addition or removal of device on network
New Device

Device Removed
Diagnostics using the FBT-6

Host control system Plant Resource ManagerTM (including fieldbus diagnostics)
Fieldbus power supply system
Segment 1 of 8
Field junction box
I/O & Controller
H1 Fieldbus
Basic failure alarms
FBT-6 Hand-held Diagnostic Module
Commissioning Procedure
Connect fieldbus tester at each field device and at rack room Save data to FBT-6 memory Upload fieldbus tester data to PC via USB Store segment baseline data
Typical faults found in commissioning
fieldbus shorts to cable screen due to poor installation

fieldbus cable strands shorting to cable shield
screen grounded at more than one location when no plant equipotential ground
incorrect installation with screen grounded at devices or in junction boxes poor installation practice with loose strands intermittently connecting to ground
identify by inspection and measuring groundbar to screen resistance
insufficiently tightened terminations faults in physical layer components

quality issue with batch of knife disconnects
Typical faults found in operation

water in junction box, cable or device

corroded terminals

fieldbus short to cable screen

electrical noise
welding cables on fieldbus cable trays variable speed drives installed with inadequate cable grounding

faulty fieldbus device
Periodic monitoring - pros & cons

Advantages Low cost No false alarms Monitor anywhere
Disadvantages Data collected manually Limited awareness of problems
Fieldbus H1 Physical Layer Diagnostics
User-Friendly Online, Continuous Diagnostics
On-line monitoring
Monitor diagnostic parameters all the time Diagnostic module attached to the network Reports parameters using separate bus infrastructure using fieldbus Diagnostic software standalone integrated in system instrument management software
Diagnostics Diagnosticsusing using the the FBT-6 F809F

Host control system Instrument Management System (including fieldbus diagnostics)
Fieldbus power supply system
Segment 1 of 8
Field junction box
I/O & Controller
H1 Fieldbus
Basic failure alarms
On-line FBT-6 Hand-held Diagnostic Module Diagnostic Module
MTL F809F on-line monitoring

Monitors parameters on 8 fieldbus segments Reports parameters over fieldbus
ie. It is a fieldbusTM H1 device
F809F
No Diagnostic software
Seamlessly integrated into IMS as FF H1 device
Open solution
FOUNDATION fieldbusTM H1 device easily integrates with all DCS Full device description support
F809F diagnostic module

Resource block
segment transducer blocks

Fieldbus diagnostic module
Discrete input block - any parameter in alarm
MTL F809F on-line monitoring

Future proof architecture
Fieldbus DTM support Enhanced eDDL support
Minimises total cost of ownership by integrating into fieldbus H1 system

No additional hardware costs No additional costs in installing, commissioning and maintenance of separate network Instrumentation team use same software for physical layer and fieldbus device diagnostics
F809F measured parameters

Segment voltage Average and peak noise
Low frequency band FF signalling band High frequency band
Fieldbus to shield short circuits

+/- to shield
Device signal voltage

All devices Address of device having lowest voltage
Device retransmissions
Address of devices failing to respond to Pass Token messages from LAS
Address of fieldbus device most recently connected Number of devices recognised on bus Address of LAS
F809F with Honeywell Experion PKS

Up to 10 discrete input blocks can be configured F809F device 8 segment transducer blocks
systems transducer blocks
Resource block
F809F in Yokogawa PRM
Segment noise
Device 1 quality
F809F in ABB 800xA
Power feed B voltage 0.4V
Power feed B low voltage alarm
F809F trending in Invensys
Trending of fieldbus segment noise
Segment alarms in Emerson Delta V
Troubleshooting questions...
So what does the data all mean? Is anyone capable of diagnosing the data provided? What does the scope trace show us? Does anybody know what jitter is and what it means? Where do we look next? Can anybody find the manual? ?
Characteristics of user-friendly diagnostics
Easy to measure Easy to understand Gives definite indication of a problem Eliminates possible causes Actionable
User-friendly presentation
What we need is:
Home view for status summary Technicians view for current values , alerts and corrective actions Advanced configuration and set up view
Simple: Home Page

Home view gives overview about system (FFPS) and all segments
Diagnostic module is a device on the Fieldbus port
Simple: Technicians View
Device shows out of specification alarm.

Simple: Advanced User

The Config/Setup tab allows to configure warning and alarm limits for each device.
76
Simple: Advanced User

The Config/Setup tab provides a wizard to optimise alarm limits
Open standards: NAMUR NE107

Diagnostic Categories
Failure Function Check
Out of Specification
Maintenance Required
Namur NE107
Device overview lists all devices with tag and status. Only 3 devices on segment, only 3 devices displayed. Symbols and designations as per FF-912 and NAMUR NE107.
79
Device OK
Device is ok.
80
Device needs maintenance
Device shows needs maintenance alarm.
81
DTM Segment View
DTM Graphical View
Out of Specification Current value Needs maintenance
Good
Enhanced EDDL
System TB block shows data for power supply
84
Enhanced EDDL
System TB block config allows to set limits for fieldbus power supply
85
Select segments to be monitored

Select which segments are monitored*
Cooper Industries/MTL Confidential 86 * Segments without field wiring (and hence without second terminator) would give alarm as terminator is missing.
FF Methods
EDDL can execute methods (wizards) Alarm optimisation wizard sets alarms for users set up
87
Network diagnostic data: DTM
Device alarm help

88
Troubleshooting guide
2009 General Assembly Yokohama, Japan
Export Baseline
Segment Commissioning Report
Namur NE107 status symbols Current values Alert limits

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Taking fieldbus H1 into Hazardous Areas

Foundation Fieldbus H1 Introduction

Cooper Industries/MTL Confidential

How is fieldbus different from 4-20mA?

Cooper Industries/MTL Confidential

Expanded System View

TAG VALUE UNITS STATUS ALARM 15.3 mA

= LIC-012 = 70.34 = m3 = GOOD = Y/N

FCS: Expanded view. Field devices are part of the system.

Cooper Industries/MTL Confidential

Advantages of fieldbus over 4-20mA

Better diagnostic information

Fewer wire terminations Cable savings

Cooper Industries/MTL Confidential

Physical Layer - specifications

Fieldbus in hazardous areas

Power supply & conditioner (FFPS) Integrated terminator

CONTROL ROOM FIELD

FOUNDATION Fieldbus Devices

Fieldbus Electrical Circuit Diagram

Signal Isolation Inductors

Cooper Industries/MTL Confidential

Fieldbus needs terminators

Fieldbus Host Control System

Terminators are required, one at each end, to:

No more than 2 terminators may be used on one

Bus with Spurs

Daisy-Chain JB Chicken Foot or Tree

Taking fieldbus H1 into Hazardous Areas

Selection of Power Supplies and Wiring Components

Cooper Industries/MTL Confidential

Fieldbus in hazardous areas

Power supply & conditioner (FFPS) Integrated terminator

CONTROL ROOM FIELD

Hazardous Area protection FOUNDATION Fieldbus Devices

Cooper Industries/MTL Confidential

Hazardous area protection

Use Ex d/explosionproof or non-arcing

Cooper Industries/MTL Confidential

Live working of field devices

Zone 2/Division 2 Zone 1 Zone 22/21 Division 1

Cooper Industries/MTL Confidential

Non-arcing trunk with Non-incendive spurs

General purpose Fieldbus power supply

Live-workable Ex nL spurs Ex nL or Intrinsically Safe Fieldbus devices

Cooper Industries/MTL Confidential

Compliance with the following parameters is required:

Non-arcing trunk and spurs

Fieldbus power supply

Ex n or Ex d/Explosionproof Fieldbus devices

Cooper Industries/MTL Confidential

Ex d field devices in Division 1

Fieldbus power supply

High energy Trunk not live-workable Junction box: Ex d/Explosionproof or Ex e

FIELD Spurs not live-workable

Ex d/explosionproof Fieldbus devices

Ex e/d field devices in Zone 1

24Vdc 24Vdc Fieldbus power supply

CONTROL ROOM Trunk not live-workable Junction box: Ex d/Explosionproof or Ex e FIELD

Field wiring hub EEx me approved

Spurs not live-workable

Ex d/explosionproof Fieldbus devices

Typical FNICO installation