End User Conf. Mumbai (19.06.09)

Field Bus Foundation :
State-of-the-art Technology,
Feasibility and Practicability

Jasbir Singh
Essar Oil Jamnagar
jasbirsingh@essar.com

2009 FFIEUC-Mumbai Conference
1
© 2009 Fieldbus Foundation

Essar Group - Mission

To create enduring value for customers and stakeholders in core
manufacturing and service businesses, through world-class
operating standards, state-of-the-art technology and the ‘positive
attitude’ of our people

2

Businesses
Essar Group

Shipping Ports
Steel Energy Power Communications Projects
& Logistics

Essar Steel Ltd Essar Oil Essar Power / Vodafone Essar Essar Shipping Essar Construction
4.6 MTPA integrated 12.5 MTPA refinery Bhander Power 60 million subscribers Fleet of 26 vessels, - Engineering
steel plant complex 1,015 MW combined DWT of 1.49 mn - Fabrication
cycle Essar Telecom - Construction
Essar Steel (Hazira) Over 1,000 retail Infrastructure Vadinar Oil Terminal
4 MTPA integrated outlets Vadinar Power 3,500 telecom towers Terminal facility of 32
steel plant 125 MW co-generation; operational; 20,000 MTPA – Liquid Cargo Fully geared to execute
(under implementation) Refinery expansion to expanding to 1250 MW planned by 2010 turnkey EPC jobs in
34 MTPA in two Bulk Terminal India and overseas
Essar Steel Orissa phases Essar Power MP The MobileStore Dry bulk port facilities
6 MTPA pellet plant 1,200 MW coal based Over 1,300 outlets Essar Offshore
(under implementation) Exploration & (under implementation) operational; 2,500 Essar Oilfields Subsea
Production Assets planned by 2010 A drilling company with Expertise in marine
Algoma Steel, Canada E&P rights in valuable Essar Power Gujarat 13 rigs construction
4.0 MTPA integrated oil & gas blocks in 1,200 MW coal based Aegis - BPO
steel plant India and abroad (under implementation) 30,000 people in offices Essar Logistics Global Supplies
in the Philippines, Costa Owns and operates (UAE) FZE
Minnesota Steel Essar Power Rica, USA and India transshipment assets Global procurement
6 MTPA pellet plant Jharkhand company
(planned) 1,200 MW coal based BPL Mobile
(under implementation) More than 1.8 million
1.4 billion tonne iron subscribers Heavy Engineering
ore reserves Services

PT Essar Indonesia Project Management
0.4 MTPA cold rolling Consultants
complex
Asia’s largest
equipment bank

200207 2009 FFIEUC-Mumbai Conference
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Energy

From Rig to Retail
Essar Oil is a fully-integrated oil company of
international standard and scale

4

Aligning Performance Improvement
Opportunities with Business Objectives

$$$ Field Bus Foundation
provides the way to bridge
the gap between business
goals and specific Plant
performance factors

5

Support of Engineering and Project
Management Consultancy in Field Bus System:
1. Purchase Specification
• Data Sheets
• Technical note
2. Design Basis
• Standard Specification
• Design Guidelines
• Design Notes
• Simple Safety guidelines / documentations
• FAT Guidelines
• Error Measurement and control guidelines
• Installation, commissioning procedure and
Check Sheets
6

Capital Expenditure CAPEX Excellence (Lowest
Cost of ownership):

1. Level of Redundancy
2. Selection of Segment components
3. Optimum FF Segment design
4. Error measurement and Control
5. Hardware selection for Installation

7

1. Level of Redundancy

 Probability of failure
 Recovery time
 Loss per failure
 Level of Confidence

8

1. Segment components
 Essential component selection and design for use
• Remote I/O
• Field barriers
• Surge Protector
• Repeaters
 Defines rules for
 Selecting and installing FISCO networks
 Rule for additional components to increase safety factor
• Redundant FISCO Power supply
• Free ports in Field barrier
• Additional Empty segments
 Selection of devices based on requirement
• LAS function
• PID function
• Local display
9

1. FF Segment design
 Optimize number of Devices per segment (use of
segment design software)
 Control loop devices in same segment (optimum
loop performance)
 Use of multiple information (multivariable devices)
 Device selection proper to hazardous area
classification only
 Use updated changes in standards and hazardous
area practice
 Guidelines for selection between Explosion proof
& Intrinsic safe System / Devices
 Use of Ex ic/FNICO (Fieldbus Non-Incendive
Concept) for Zone 2 hazardous areas

10

1. Error Management (monitor and control)

 Design
 Development
 Implementation
 Maintenance

11

1. Hardware Selection & Installation
 Good Installation practices of Field barriers / Segment
Protector
 Close to Main cable duct / tray
 Easy termination
 Hazardous area and weather protection
 Installation of device at ground level based on process
requirement – should not be made as General Rule
 Use of optical fiber for long distance data transfer
 Revamping plant
• Use of hybrid positioner with existing valve
• Verify the interference issue and use of existing cables
• Use of Hybrid concept for plant revamping

12

1. Hardware Selection & Installation
Cont.:
Requirements: Solutions, Benefits:
long distance (up to > 8000 m)  remote I/O
 fiber optic
hazardous locations  remote I/O for Zone 2 with IS inputs/
outputs
high amb temperature (>50 °C)  special „cabinet“ design

high availability  redundancy
 fiber optic ring structure
HART + FF  connect remote I/O to DCS´s HART
+ FF management tool
IS and non IS signals  handled by remote I/O
13

Support of Engineering and Licensers:
Capital Expenditure CAPEX Excellence:
1. Loop identification:
• Philosophy for Super critical, critical, semi
critical and non critical loops of plant
• Simple close loop
• Open loop
• Transmitters (devices) with indicator /
without indicator
• Local indicator with multiple parameters
2. Physical Location of devices in field
3. Physical Location field bus barrier in field
4. Use strength of other field bus such as ASi,
devicenet or others

14

Identification of control loops that can be considered in FFB:

Super Critical Control Loops: Fast response loops are considered in
super critical loops eg. Anti surge loops, Drum level control etc
causing safety concern and / or major equipment damage.

• Critical Control Loops
• Semi Critical Control Loops
• Non Critical Control loops

• Critical Control Loops:

(Level 1) Failure of level 1 loops will result in a total system trip,
causing a shutdown of the entire unit, or other unavoidable losses.
Normal Valve failure mode is to be used for this classification.

15

• Semi Critical Control Loops

(Level 2) Failure of a level 2 loops will result in a total system trip,
causing a shutdown of the entire unit, or other unavoidable
losses. However, the Level 2 valve’s process dynamics allows
time for the quick recovery from the failure, either by quickly
fixing a fault or by taking manual control. The material and
energy capacity of associated vessels, geographic location,
and elevation/accessibility of such a valves should be
considered. The difference in Level 1 and Level 2 valves are
dependent on operations ability to respond to single failure.
• Non Critical Loops:

(Level 3) Failure of this valve will not result in any short term risk
of total unit shutdown or major operation loses. Level 3 valves
can go to their fail position without requiring immediate
operator action. 2009 FFIEUC-Mumbai Conference
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User’s perspective:
General Consideration for the use of FF in Essar:
 Field Bus is not used for Separator pressure control
and reciprocating makeup gas pressure control loops,
because of all the split ranges and signal selectors
involved in those loops

 Field Bus is not used Steam FI, steam generator
LIC and BFW FIC on steam generators

 Field Bus is not used for Anti-surge, etc. as those
types of controllers may required faster response
times.

 Field Bus is not used in shutdown systems or for
complex control loops.
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Fb Type – 2 Type – 3
Type – 1 (Two device (Three device
(One device per output) per output)
per output)
Fb Power
Fb Conditioner

T - ON

Bulk Power
Supply
Safe Area

Hazardous Area

Barrier-Fb
Field18

Device Manufacturer in Field Bus systems:

1. Hardware design & Level of Redundancy
2. Software
3. Commissioning Tools

19

System & Device Manufacture support:

1. Hardware design & Level of Redundancy
Easy cable connection of H1 card with Field bus power supply
and replacement on fault
Rugged construction of FF components for easy cabinet
mounting and resistance to shock and vibration
Robust field-proven and reliable Field Bus components
LEDs indicators to identify failed module,
Hot swapping of components to allow replacement under
power
Support multiple LAS devices
FF Basic-to-LM device wizard
“Safe” way to enable/disable Backup LAS
Provides wizard to step through sequence

20

Device Replacement

1. Software
Device Replacement by Operator
 Quick Auto replacement
 From Operator Station or Engineering Station
 Support for:
o like device, and,
o like devices with revisions

21

DD file addition & Device Configuration

1. Software
Ability to Add DD Files Integrated into Engineering tool
 Easy tool for adding DD files
 Easy Parameter Data Entry tool to edit
 New DD file for similar devices should be possible to be
used with existing devices
Code Download
 Allows upgrading devices on-line
 Includes enhancements to current capability and file
management
Easy device Configuration
 Plug and play tool for device addition
 Device configuration wizard

22

Device management in Field Bus:
• Device Checking software (Maintenance /
Management Tool)
• Configuration changes from DCS
• Calibration from DCS
• Maintain Audit trail of devices
• Taking device signature at the time of initial startup
• Workshop tools for FF

23

Easy Commissioning and Help
Commission device without pre-configuration
 Easy way to add a device in an existing installation
 Directly from Uncommissioned Device tab
 Easy to Build and loads device

System Comprehensive Help option
 Dynamic and comprehensive help at every step
 During adding devices, help information from the manufacturer
should be possible to add into system
 From any parameter in a device, hit F1 to get help information!

24

Device Management:
TAF Device on FF-H1 Bus Information Basic Information Detail Information

FCS 1001
Device Tag Name: PT 2002
NODE 01 Device ID:594543000CJ000856 MANUFAC_ID:
Device Class: BASIC DEV TYPE:0X0
Update Time: Friday, September 22,2006 10:00:00 AM DEV_REV:0X0
ALF 111 240
PT 2002

Friday, September 22,2006 10:00:00 AMDevice Tag Name: CV 4001
ALF 111-1 1ALF111-1 Device ID:5945430001J009185 MANUFAC_ID:
Device Class: BASIC DEV TYPE:0
Update Time: Friday, September 22,2006 10:00:00 AM
PT 2002 DEV_REV:0X0
241
CV 4001 CV 4001
Friday, September 22,2006 10:00:00 AM
CV 4002
Device Tag Name: CV 4002
Device ID:5945430001J008277 MANUFAC_ID: 0
Device Class: BASIC DEV TYPE:0X07
L 6001 Update Time: Friday, September 22,2006 10:00:00 AM DEV_REV:0X03
242
TE1001 CV 4002
Device Tag Name: L 6001 MANUFAC_ID: 0
Device ID:56474B0770 DEV TYPE:0
Device Class: BASIC DEV_REV:0X030
ALF 111-2 243 Update Time: Friday, September 22,2006 10:00:00 AM
L 6001
ALF 111-3 Friday, September 22,2006 10:00:00 AM

Device Tag Name: TE1001 MANUFAC_ID: 0
ALF 111-4 Device ID:594543000550011361 DEV TYPE:0X07
244
TE1001 Device Class: BASIC DEV_REV:0X03

245



Device Management:

Device on FF-H1 Bus Information Basic Information Detail Information
MANUFAC_ID: 0X00594543(Yokogawa Electric)
Device ID:594543000CJ000856 DEV TYPE:0X0770()
240 Update Time: Friday, September 22,2006 10:00:00 AM
PT 2002
1ALF111-1 Device Tag Name: CV 4001 MANUFAC_ID: 0X00594543(Yokogawa Electric)
Device ID:5945430001J009185 DEV TYPE:0X001()
241
CV 4001
Device Tag Name: CV 4002 MANUFAC_ID: 0X00594543(Yokogawa Electric)
242
CV 4002

MANUFAC_ID: 0X0056474B(VEGA)
Device Tag Name: L 6001
Device ID:56474B0770 DEV TYPE:0X0770()
243
L 6001
MANUFAC_ID: 0X00594543(Yokogawa Electric)
Device Tag Name: TE1001 DEV TYPE:0X001()
Device ID:594543000550011361 DEV_REV:0X03
Device Class: BASIC
TE1001

245

26

Device Management:
MANUFAC_ID:0X00594543(Yokogawa Electric)
PT 2002
1ALF111-1
RB(RESOURCE_01) Auto
TB(TRANSDUCER_01) Auto
FB(AI_01) Auto
FB(AI_02) O/S
FB(AI_03)
FB(PID_01)
FB(SC_01)
FB(IT_01)
FB(IS_01)
FB(AR_01)

241 Device ID:5945430001J009185 DEV TYPE:0X001()
CV 4001 Device Class: BASIC DEV_REV:0X03
Device Tag Name: TE1001
Device ID:594543000550011361 MANUFAC_ID: 0X00594543(Yokogawa Electric)
Device Class: BASIC
Update Time: Friday, September 22,2006 10:00:00 AM DEV TYPE:0X002()
DEV_REV:0X03
242
CV 4002

Device Tag Name: L 6001 MANUFAC_ID: 0X0056474B(VEGA)
243 Device Class: BASIC DEV_REV:0X03
L 6001 Update Time: Friday, September 22,2006 10:00:00 AM
Device ID:5945430001J008277
Device Class: BASIC MANUFAC_ID: 0X00594543(Yokogawa Electric)
244 TE1001 Update Time: Friday, September 22,2006 10:00:00 AM DEV TYPE:0X001()
Friday, September 22,2006 10:00:00 AM DEV_REV:0X03
245


Device Management:
PT 2002
1ALF111-1
RB(RESOURCE_01) Auto
FB(AI_01) Auto
FB(AI_02) O/S
FB(AI_03)
FB(PID_01)
FB(SC_01)
FB(IT_01)
FB(IS_01)
FB(AR_01)

Device Class: BASIC
DEV_REV:0X03
CV 4002

Device ID:5945430001J008277
Device Class: BASIC MANUFAC_ID: 0X00594543(Yokogawa Electric)
TE1001 Update Time: Friday, September 22,2006 10:00:00 AM DEV TYPE:0X001()
Friday, September 22,2006 10:00:00 AM DEV_REV:0X03



Device Management:


PT 2002
1ALF111-1

Device Class: BASIC
DEV_REV:0X03
CV 4002

TE1001

29

Device Management:


PT 2002
1ALF111-1

Device Class: BASIC
DEV_REV:0X03
CV 4002

TE1001

30

Support for Network Design

Network Safe and Trouble Free operation
Network System Design & Layout
Network Communication / Software Safety

31

Fundamental considerations/Fault Avoidance

Information collection and safely processing
Enterprise
Secure Access
Network to Enterprise Network

Link
Aggregation

Dual Homing

RSTP HiPER Ring

Secure Access
to Plant Floor

32
OCTOPUS

Fundamental considerations/Fault Avoidance

Design Considerations / Fault Avoidance

• Industrial Ethernet
Industrial Networking

• Optical Fiber Interfaces

Industrial Connectors • Industrial Connectors

• Load Moment Indicator
Electronic Control
• Control Systems and Sensors
and Management
Systems • Graphic Control Panels and Displays

33

Networking at Multiple layers
Multilayer Safety
 Network

 Operating System

 Application

 FF accessories

 Device

34

Design of Safety in communication systems
1. Safe communication over a bus alone does not ensure
that the transferred information is safe
2. No loss / encryption of data
3. Programming Failure
4. Improper installation of networking hardware
5. Data transmission
 Consistency checking
 Confirmation of correct data transmitted & received
 Watch dog for external affect
6. Safe communication
 Risk reduction
 Fault avoidance
 Fault control

35

Reason of Failure in networking:
1. Mis-configured Fire wall
2. Connection of infected laptop for engineering or trouble
shooting
3. Infected remote support
4. Unauthorized connection with unsecured system
5. Connection with Modem, printer
6. Non proven fire wall

36

Use of Robust and Proven Fire wall:
Protection from alien control networks
Protection from external networks
Protection from insecure networks

Protection of safety System
Protection for unpatchable systems
Protection of wireless systems
Protection of OPC traffic
…

37

Operational Excellence (OpX)

Asset Production Safety
Excellence Excellence Excellence

Performance
Availability x rate x Quality rate x HSE compliance rate
OPE
=
Cost
Maintenance cost + Production cost + HSE cost

Maximization of asset Maximization of production Maximization of safety
excellence factor excellence factor excellence factor

OPE: Overall Plant Effectiveness
38

Asset management:
Easy Commissioning and Easy Life

39

Asset management:
Easy Troubleshooting and Easy Life

40

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End User Conf. Mumbai (19.06.09)

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