Mr. Wei Hua, Equipment Technology Manager for China Blue Chemical discusses the procedures for a smooth installation and commissioning of a FOUNDATION fieldbus project. Mr. Wei Hua talks about the importance of the physical layer especially with regards to grounding and shielding.
1. 基金会现场总线
Foundation Fieldbus
——安装与调试
—Installation and commissioning
魏 华
WEI HUA
中海石油化学股份有限公司
China Blue Chemical Ltd.
2. 概 述 /Brief introduction
我不是Ff专家,没有高深的理论基础
I'm not a Ff expert, and don’t have deep theoretical knowledge
我也不是产品销售人员,虽然讲述的案例中有某些产品有关
I am not a sales man, although some products are mentioned in the presentation
工作生涯中使用过气动仪表、电动仪表、DCS、DCS+HART、Ff
I used Pneumatic/ Electrical instrument, DCS DCS+HART Ff in my career
全程参与了4套基金会现场总线项目的设计、安装、调试及维护工作
Full participation in 4 Ff projects, including design, installation, commissioning and maintenance
安装和调试案例全部来自于工程实践
Cases mentioned in the presentation all come from engineering practice
3. 演讲提纲/AGENDA
基金会现场总线的安装
1 Foundation fieldbus installation
基金会现场总线调试
2 Foundation Fieldbus commissioning
安装案例分析
3 Case analysis of on-site installation
4. 基金会现场总线安装指南
Foundation Fieldbus Installation Guide
对Ff施工管理的三点建议:
Three suggestions for Ff construction management:
严格区分信号地(Signal grounding)和保护地(Protection grounding),信号地按照
小于1.5Ω标准
Strict distinction between the Signal grounding and Protection grounding, Grounding
resistance of signal grounding should be less than 1.5Ω
对施工单位单独进行基金会现场总线施工和接线培训,培训的内容可以参考
PEPPERL+FUCHS公司的《Wiring And Installation Guide For Foundation Fieldbus》
和基金会现场总线的文件《Fieldbus Foundation 31.25kbit/s Wiring and Installation
Guide》
Provide workers with specialized training on installation and wiring, the content of the
training can refer to <Wiring And Installation Guide For Foundation Fieldbus> from
P+F and <Fieldbus Foundation 31.25kbit/s Wiring and Installation Guide>
严格按照基金会现场总线设计文件进行施工和检查,对于现场电缆长度和总线设备的
位置变更都必须得到仪表首席工程师(Instrument Leader Engineer)的书面批准
Construction and inspection must strictly comply with Foundation Fieldbus design
file, the modification of cable length or location of Field device must be approved in
writing by the Instrument Lead Engineer
5. 屏蔽与接地(一)
Shielding and grounding 1
屏蔽/Shield 屏蔽/Shield
+ +
现场设备 现场设备
- /Field - /Field
device device
接地 接地
机柜 /Ground 机柜 /Ground
Cabinet Cabinet
图2 机柜电容接地、设备硬接地
图1 机柜硬接地、设备硬接地
Field side is earthed directly and
Direct grounding at both sides
cabinet side capacitively
6. 屏蔽与接地(二)
Shielding and grounding 2
屏蔽/Shield
屏蔽/Shield
+ +
现场设备 现场设备
- /Field - /Field
device device
接地
接地
机柜 /Ground
机柜 /Ground
Cabinet
Cabinet
图3 机柜硬接地、设备电容接地 图4 机柜单点接地
Cabinet side is earthed directly Only cabinet side of the
and field side capacitively shield is earthed
7. 屏蔽与接地(三)
Shielding and grounding 3
北美安装规范(North America Specification):
北美绝大部分的工程设计和安装都按照图4所示的接地方式进行设计和
施工,这种接地安装方式在传统的DCS系统中普遍采用。
In North America, most of the projects’ grounding systems are designed as
shown in Figure 4, this grounding method is commonly used in traditional
DCS.
欧洲安装规范(Europe Specificaiton)
在欧洲的工程设计和安装一般都要求按照图3所示的接地方式进行设计
和施工,Ff接地推荐采用图3的方式。
In Europe, normally the projects’ grounding systems are designed as
shown in Figure 3. For Ff project, this grounding method is recommended.
注意:Ff现场运行中故障的80%-90%都是由于接地或者屏蔽原因导致的!!!
Note: 80% -90% of the Ff operation failures are due to bad grounding or
shielding! ! !
8. 基金会现场总线电缆
FOUNDATION fieldbus cable
IEC 61158-2对现场总线电缆的要求:
Specifications of the fieldbus cable according to IEC 61158-2
分布电阻率 信号衰减值
型号 米 Meters / 英 阻抗/Impedance
/Resistivity /Attenuation 说明/remark
Type 尺 Feet (Ω)
(ohm/km) (db/km)
互相屏蔽对
A 1900/6270 100 22 3
Individual shielded pairs
全屏蔽的多线对
B 1200/3960 100 56 5 Multiple pairs with
overall shield
无屏蔽的多线对
C 400/1320 未知/unknown 132 8 Multiple pairs with no
shield
多导线,非线对
D 200/660 未知/unknown 20 8 Multi-conductor, no
pairing
10. 基金会现场总线电缆
Foundation Fieldbus Cable
多对铠装
Multi-pair, armored
铠装
Armored cable
金属箔加编织屏蔽
Metal Clad plus braid shield
金属箔屏蔽
双绞线屏蔽
Metal Clad shield
Twisted pair
多对 (多线)
Multi-pair
11. 电缆桥架的布置
Cable tray layout
F3:现场总线电缆桥架
F3: For Fieldbus
I3:本安信号电缆桥架
I3: For IS signals
N3:非本安电缆桥架
N3: For Non-IS signals
电缆桥架布置建议:
Some advices of Cable tray:
1、Ff和本安、非本安信号分开
Separation between Ff, IS and Non-
IS.
2、强电信号和弱电信号分开
Separation between Power supply
Lurgi公司设计的电缆桥架
Cable tray design from Lurqi
system and Control System
3、桥架间距大于400mm
Tray spacing greater than 400mm
12. 现场总线安装费用对比(Ff)
Comparison of Installation Costs(Ff)
2000年安装工程预算定额海南省基本价(海南省建设厅)》
Basis price, By Department of construction of Hainan Province,2000
单位价值(人民币/元)
total cost per unit
定额号 工程名称
单位/Unit 其中/including
File NO. Items 单价合计/Total
人工费 材料费 机械费
cost per unit
Labor cost Material cost Machine cost
Ff压力/差压变送器
10-560 Press. /diFferential press. 台/piece 1133.56 354.05 49.76 729.75
transmitter
Ff温度变送器
10-561 台/piece 519.06 206.37 44.59 268.1
Temperature transmitter
气动薄膜调节阀
10-276 台/piece 119.68 70.81 5.74 43.13
Pneumatic Diaphragm CV
Ff气动阀门定位器
10-563 台/piece 389.57 99.42 21.2 268.95
Pneumatic valve positioner
Ff总线电缆铺设(米)
10-616 100M 102.56 78.09 17.65 6.82
Cable installation
10-622 现场总线电缆头安装终端头 个/piece 14.06 5.33 5.95 2.78
现场总线安全栅
10-564 个/piece 19.32 15.28 0.84 3.2
Field barrier
14. 演讲提纲/AGENDA
基金会现场总线的安装
1 Foundation fieldbus installation
基金会现场总线调试
2 Foundation Fieldbus commissioning
安装案例分析
3 Case analysis of on-site installation
16. 基金会现场总线调试的重点
Main focuses of the Foundation Fieldbus commissioning
物理层安装调试Physical
layer component installation
& commissioning
控制功能和参数优化
Ff调试内容 控制功能检查
Control strategy and Ff Main Control function
parameter focuses test
optimization
诊断功能测试
Diagnostic
function test
19. 物理层安装调试
Physical Layer Installation and Commissioning
P+F HD2-DM-A
1、可以在主控室诊断电脑完成所
Take HD2-DM-A(Advanced Diagnostic Tool for Fieldbus, by 有的物理层诊断工作
P+F)for example: The physical layer diagnosis can
be done in CCR.
2、诊断结果可以对物理层设备安
装进行全面检查,精度提高
The diagnosis conducts a
comprehensive inspection of the
physical layer components
installed
3、效率极大提高,使用移动测试
工具可以节约95%的时间,采用在
线先进诊断工具可以节约99%的时
间
A very eFficient way, Reduces
commissioning time by up to 95%
20. 控制功能调试
Control Function Test
功能测试:功能测试是对基金会现场总线网段设备的
全套功能测试,包括系统即插即用互连性测试、功能
块的访问确认测试、控制功能块的功能测试、现场总
线设备的运行测试。
Functionality Test: This test will include, but is not
limited to, plug and play interconnectivity to the Host
system, verifying access to all Function Blocks being
used in the project, actual device operation.
21. 控制功能调试
Control Function Test
标定测试:标定测试是通过主机系统无障碍的对现场
总线网段设备进行标定和设置,标定测试要求在对现
场总线设备进行标定和设置时,不影响现场总线网段
其它设备的运行。
Calibration Test: The test shall include a calibration
and setup for each type of device. The calibration
and setup procedures for each device shall be done
by Host system and available asset management
tools, and it does not aFfect the operation of other
device of fieldbus network.
22. 控制功能调试
Control Function Test
冗余切换测试:冗余切换测试是测试H1接口卡和现场
总线电源调节器的冗余故障报警、切换测试,确保在
故障情况下能够实现冗余设备的无扰动切换。
Redundancy Switch-over Test: Where redundant
FOUNDATION fieldbus interface cards and/ or
power supplies are used, the redundant operation of
each component shall be tested. The test shall
verify that automatic fail over shall not cause an
upset. All FOUNDATION fieldbus interface cards and
power supplies shall be tested.
23. 控制功能调试案例
Control function commissioning case
1、试验PT011224A/B/C的高选功能和PID控制功能
Test high selection function and PID function of PT011224A/B/C
2、试验PT011224A/B/C量程修改和PV011224自动标定功能
Test scale modification and automatic calibration of PT011224A/B/C
3、测试电源冗余、接口卡冗余、设备的离线和在线功能、短路保护功能、即插即用功能
Test power redundancy, interface card redundancy, equipment oFfline and online
features, short circuit protection, plug-and-play functionality
25. 现场总线的诊断功能
Fieldbus diagnosis
主机诊断功能 物理层诊断功能
HOST system Physical layer
diagnosis diagnosis
现场设备诊
断功能
Field device
diagnosis
26. 控制功能和参数优化
Control strategy and parameter optimization
物理层设备优化 控制功能位置优化 智能设备的自整定优化
Physical layer Control Self-tuning
Functionality
components Location optimization of
optimization optimization intelligent devices
27. 演讲提纲/AGENDA
基金会现场总线的安装
1 Foundation fieldbus installation
基金会现场总线调试
2 Foundation Fieldbus commissioning
安装案例分析
3 Case analysis of on-site installation
28. 屏蔽与接地故障案例
Shielding and Grounding Fault Cases
故障描述
Fault Description :
阀门PV015708在运行过
程中经常出现5%的跳变,
设备在网段上经常显示瞬
间离线,然后在线! 噪音及抖动异常
Noise and Jitter is out of spec
In normal operation , the
signal of PV015708 is
always unstable( 5%
signal skipping).
Equipment status is often
displayed for an instant
oFfline, then online.
示波器图形
Oscilloscope Display
29. 屏蔽与接地故障案例
Shielding and Grounding Fault Cases
整改后的噪音及抖动
Noise and Jitter after
corresponding improvement
Shielded cable is not grounded
整改后的示波器图形
Oscilloscope Display
Earthbar is not grounded after corresponding improvement
30. 电缆及终端电阻故障案例
Cable and Terminator Fault Case
故障描述
Fault Description :
现场总线网段S060.03调试过程
中发现该网段的现场总线设备通
讯不稳定,经常出现通讯故障
(CNF,CONNECTION
STATUS FAILURE ALARM)导
噪音及抖动异常
致设备离线。
Noise and Jitter is out of spec
During the commissioning of the
fieldbus segment S060.03 ,field
device communication is
unstable, and it
(CNF, CONNECTION STATUS
FAILURE ALARM) often results
in the device oFfline.
示波器图形
Oscilloscope Display
31. 电缆及终端电阻故障案例
Cable and Terminator Fault Case
Terminator is OFf
整改后的噪音及抖动
Noise and Jitter after
corresponding improvement
Not grounded
Not specific Ff cable
整改后的示波器图形
Oscilloscope Display
after corresponding improvement
32. 接线不当故障案例
Bad wiring fault case
故障描述
Fault Description :
现场总线网段41-TFN-3018
的现场总线变送器PT3407
经常掉线,导致工艺测量参
数失真。Ff transmitter
PT3407 on segment 41-TFN-
3018 often shows oFfline, and 噪音及抖动异常
it resulted in distortion of the Noise and Jitter is out of spec
process value.
示波器图形
Oscilloscope Display
33. 动力电缆信号干扰
Power Cable Signal Interference
信号波形 实际接线情况
Signal waveform Actual wiring