A2011 4 FF Project Excecution

Automation 2011
Name
Job Title
Company
: Jigish Jepal
: Executive Manager
: Yokogawa India Limited
FFIC:Automation2011 Mumbai
2011FieldbusFoundation
Presentation Points
KeyPointsinFieldbus Project
Typicalearly(before~2004)FFprojectexecutionandlessonLearned
Presentday(after2004)FFprojectexecution
Fieldbus projectexecutionmethodology
Fieldbus projectexecutionprocedure example
Fieldbus projectsupporttools
Fieldbus segmentdesignguidelineandsegmentchecktools
Engineeringtools
FactoryAcceptanceTestprocedure
SiteAcceptanceTestprocedure
Key Points in Fieldbus Project (1/2)

UnderstandingofDifferenceofFFSystemfromConventionalSystem
Technology
Design & Engineering
Design&Engineering
FAT/SATMethodology
Installation
Commissioning
DeviceFunctions
EstablishmentofFFProjectExecutionMethodology
ProjectHandlingProcedure
g
g
g
DesignandEngineeringProcedure
DesignDocumentation
DesignInformationExchangeScheme
Key Points in Fieldbus Project (2/2)
CommonUnderstandingofFFSystemamongUsers/EPC/Licensersand
Vendor
AssignmentofExperiencedEngineersinProjectTeam
ConfirmationofDeviceInteroperabilityandAvailability
Confirmation
of Device Interoperability and Availability ofAux.
of Aux
Equipments;PowerSupply/Exi Barrier/Terminatoretc.
Typical early (before ~2004) FF project execution and lesson Learned

ConventionalI/OBasis
FeedPhase
EngineeringPhase
Basic
Design
Feed
DetailedDesign
KOM
Generation&Debug
SiteActivityPhase
FAT
SAT
Commissioning
Shipping
Spec.Freeze
FFBasis
FeedPhase
EngineeringPhase
Feed
BasicDesign
KOM
DetailedDesign
Generation&Debug
Spec.Freeze
SiteActivityPhase
FAT
SAT &
SAT&
Commissioning
RiskatSite
Shipping
FFKnowledge
ExperiencedEngineersResource
p
g
Device Interoperability
DeviceInteroperability
PJTExecutionProcedure
Device&Aux.Equipment Selection
FAT/SATProcedure
DesignDocuments
SegmentDesign
DeviceGrouping,PIDAllocation
Device Grouping PID Allocation
Macrocycle,CableLength:Trunk&Spur
Service&MaintenanceTool
ProblemsobservedinearlierstageofProject
Present day (after 2004) FF Project Execution

FFBasis
BasicDesign
Feed
DetailedDesign
KOM
Generation&Debug
FAT
Spec.Freeze
FeedPhase
Feed
SiteActivityPhase
EngineeringPhase
FeedPhase
DetailedDesign
KOM
Generation&Debug
Spec.Freeze
RiskatSite
Shipping
EngineeringPhase
Basic
Design
SAT&Commissioning
SiteActivityPhase
FAT
SAT&Commissioning
Shipping
DesignandEngineeringTools&Procedure
FieldbusTutorial
Fieldbus
Tutorial
FFTechnologyIntroduction
FFProjectExecutionGuide
FFSegmentDesignGuideline
FunctionalDesignSpecification
SegmentCheckTool
Device&Aux.Equip.SelectionGuide
SystemEngineeringGuide
BetterEngineeringTool
FATProcedure
SATProcedure
BenefitstoCustomer
MinimizeHumanErrors
PreventReworks
ShortenPJTSchedule
Fieldbus Project Execution Methodology

ProjectKOM
FFsegmentdesignin
FF
td i i
basicdesignphaseis
akeyelementintheFF
projectexecution.
BasicDesign
HardwareDesign
MainframeofFFproject
executionprocedureis
sameasconventionalI/O
system.
Eachworkitemneedssome
changesandadditionsto
implement FF technology
implementFFtechnology.
SoftwareDesign
SystemStaging
&InternalTest
FATmethodologyis
gy
differentfromthe
conventionalI/Osystem.
FAT
FAT
Needstosetup
Needs
to set up
FFsystemproject
coordinationprocedure
Designinformation
exchange scheme
exchangescheme
Delivery
Fieldbus Project Execution Procedure : Example (1/3)

DeliverablesbyCustomer
1)PJTSchedule
2) PJT Organization
2)PJTOrganization
3)InquirySpecification
4)FFDesignrequirements
Milestone
Kick Off
KickOff
Basic Systemdesign
FFSegmentDesignPhilosophy
DeliverablesbySystemVendor
1)ProjectExecutionPlan
)
g
2)PJTOrganization
3)PJTSchedule
4)QA/QCPlan
5)Technical&CommercialProposal
6)BillOffMaterials(BOM)
FFSystemDesignSpecification
FFSegmentDesignSpecification
1)InstrumentIndex
2)I/OPointList
3)LoopDrawing
DesignRequirementsfor;
1)Console&Aux.Cabinet
2)Subsystem
3)Aux.Equipment
HardwareDesign
H/WDesignSpecification
1)DCSSystemConfiguration
2) DCS H/W E i
2)DCSH/WEquipmentSpec
tS
3)EquipmentDimension
4)PowerSupply/Grounding
5)Subsystem/Aux.Equipment
A

DeliverablesbyEPCContractor
FFDesignInformation
1) D i Li & T
1)DeviceList&Type
2)FBAssignment
3DeviceGrouping
4)ExpectedCableLength
5)CableSpecification
Milestone
DeliverablesbyDCSVendor
FFSegmentDetailDesign
1)ComplexLoopSchematics
2)NarrativeofComplexLoop&FB
)
i
f
l
&
3)Sequence&InterlockLogic
4)GraphicSketch
5)SubsystemCommunicationSpec
1)H/WDesignSpecification
&Drawig
2) BOM f H d
2)BOMofHardware
3)I/OCardAssignment
4)TypicalLoopConfiguration
MaterialOrder&Manufacturing
SoftwareDesign
S/WDesignSpecification
1)ControlFunctions
2) MMI F ti
2)MMIFunctions
3)AlarmFunction
4)Access/SecurityFunctions
5)Graphic/Logging
6)SubsystemInterface
B

DeliverablesbyEPCContractor
Milestone
DeliverablesbyDCSVendor
B
1)JBScheduleforMarshallingRack
)
2)WiringDetails
3)InstallationDetails
1)LoopDrawings
2) Assignmentof
MarshallingRack
1)CommunicationPointList
1)
Communication Point List
2)GraphicDisplayData
3)LoggingFormats
4)GroupDisplayAssignment
5)TrendAssignment
S/WGeneration
SystemStaging
InternalTest
l
FATProcedure
FAT
Delivery
Fieldbus Project Support Tools (1/2)

ProjectExecutionPhase
SupportTools
Category
Feed
Phase
Engineering
Phase
GeneralSpecificationofFF
GeneralInformation
FFTutorial
GeneralInformation
FF Technology Introduction
General Information
GeneralInformation
DesignGuideline
Procedure&Manual
DesignGuideline
DesignTool
FFPJTExecutionGuideline
SystemEngineeringProcedure
SegmentCheckTool
Site
Activity
Phase
EngineeringTool
EngineeringTool
Device&Equip.SelectionGuide
DesignGuideline
FATGuideline
DesignGuideline
SATGuideline
DesignGuideline
Startup&ServiceManual
Training Manual
TrainingManual
QuotationGuideline
Procedure&Manual
Manual
QuotationGuideline
Fieldbus Project Support Tools (2/2)

9
GeneralSpecificationFFinDCS
FFTutorial
I&C
Plant/
SegmentCheckTool
AFE
System
System
Process
Process
9
Design
Design
9
9
FATGuideline
SATGuideline
g
TrainingManual
QuotationGuideline
FeedPhase
FDS
SAT Guideline
SATGuideline
StartUp&ServiceManual
SAT
Installation
Commissioning
Operation
SiteActivityPhase
DetailedDesign
Quotation/
Clarifications
Basic
Design
FF Segment Design Guideline

SWIFTPlusEngineeringTool
i &
i S l i G id
FATGuideline
SATGuideline
H/WDesign&
Manufacturing
Gen./
Debug
FAT
S/WDesign/
Configuration
EngineeringPhase
Fieldbus Segment Design Guideline
Table of Contents
1. General
1.1 FF Segment Design Methodology
2. Basic Segment Design
2.1 Hazardous Area Classification
2.2 Redundancy
2.3 Segment Loading
2.4 Spare Philosophy
3. Wiring Design
3.1 Topology
3.2 Cable Length
3.3 Cable Type
3 4 Power Consumption
3.4
3.5 Minimum Operating Voltage
4. Segment Execution Time

4.1 Macrocycle Time
4.2 Scheduling
5. Control Assignment
6. Application Specific Design
6.1 Control Valve Fail State
6 2 ESD Valve Status Equalization
6.2
6.3 Risk Assessment For Control
Loops
7. Documentation
7.1 Segment Drawing
7.2 Loop Configuration Drawing
Fieldbus Segment Check Tools
Typical Engg. Tool
CustomerDB
INtoolsRDB
Instrument
IndexModule Export
(INtools)
Source ocuments
SourceDocuments
P&ID
Control
Narratives
etc.
MS Excel
MSExcel
/Access
Crosslink
Engg.
gg
DB
Engg.Tool
Meeting
Typical
oops
loops
marking
onP&ID
Typical FAT
TypicalFAT
Autogeneration
Text DB
TextDB
Typical
Loops
DCSDB
Builder
(DCS)
w/generictag
numbers
Export
(DCS)
DCSDBw/targettag
numbers
Factory Acceptance Test Procedure
9 DeviceListVerification
9 DDFileAndCapabilitiesFileVerification
9 FieldbusApplicationVerification
:ConnectionofFunctionBlocks
9 H1CommunicationSchedulingChartVerification
9 ConnectionTestwithActualFieldDevice
( y
(byUsingRepresentativeModel)
g p
)
9 SegmentFunctionalTestforSelectedSegment
withActualFieldDevices
Site Acceptance Test Procedure
9 ConfirmPhysicalConnectionoftheFieldDevices
9
9
9
9
9
9
DownloadConfigurationDatatoFieldDevices
Download
Configuration Data to Field Devices
LoopConnectionCheck
VerifyVoltageatDeviceTerminals
Observe and Check Signal Wave
ObserveandCheckSignalWave
VerifyLoopOperation(LASRedundancyChecketc.)
AdjustLoopParameters
Note
9 ArrangementofProperSiteOrganizationforSiteActivities
(SAT&Commissioning)
9 PrepareToolsforTroubleshootingatFAT/SAT
(BusMonitor,VoltMeterandOscilloscope)
Thank You
Fieldbus Foundation
IndiaCommittee
21st September,2011
www.fieldbus.org

A2011 4 FF Project Excecution

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Automation 2011

Key Points in Fieldbus Project (1/2)

Key Points in Fieldbus Project (2/2)

Typical early (before ~2004) FF project execution and lesson Learned

Present day (after 2004) FF Project Execution

Fieldbus Project Execution Methodology

Fieldbus Project Execution Procedure : Example (1/3)

Fieldbus Project Execution Procedure : Example (2/3)

Fieldbus Project Execution Procedure : Example (3/3)

Fieldbus Project Support Tools (1/2)

Fieldbus Project Support Tools (2/2)

FF Segment Design Guideline

Fieldbus Segment Design Guideline

4. Segment Execution Time

Fieldbus Segment Check Tools

Typical Engg. Tool

Factory Acceptance Test Procedure

Site Acceptance Test Procedure

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