Fieldbus Presentation

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Training program on Basics of Fieldbus Technology and
FOUNDATION Fieldbus Engineering for Process Automation,
18th and 19th January 2013 at Hotel Regaalis, Bangalore
FOUNDATION Fieldbus Engineering
for Process Automation
By
Sachin Rasane
I&C Consultant & Trainer
OGIC, Pune
rasanesimved@yahoo.co.in +91 94223 59938
ISA Bangalore
Section

Basics of Modern Industrial Automation
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SR/ISATRNG/2013.01.19/SlideNo.2
Academic
- Instrumentation and Industrial Electronics Engineering
- VES Engineering College, Mumbai
- Year 1988
Worked in:
- Domain – Oil and Gas Upstream (Onshore Projects)
- EPC – Jacob’s, Worley Parsons, Kvaerner
- Engineering Consultants – Comprimo, Granherne
- System Vendors – Emerson, Honeywell
- OEM - GE
- Contractors – Al-Hassan, Mannai Engineering
- End Users – PDO-Shell, Occidental, Chevron, ADCO, ARAMCO, PKKR, MRPL, HPCL etc.
Currently working with:
- OGIC– Oil and Gas Instrumentation Club (Conducting Trainings and Workshops for Graduate / Junior
Engineers and Providing Corporate Training). Initiative to reduce Industry-Academia Gap.
Association:
- Member of IEC
- Sr. Member of ISA
- Formed OGIC (Oil and Gas Instrumentation Club) for Global Instrumentation Community

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Agenda
Applying Foundation Fieldbus in Project offers several benefits compare to
Conventional Instrumentation. Fieldbus installation can be relatively quick and
economical if we understand the Technology, Engineering and Design phase.
 Fieldbus Engineering Team & Responsibilities
 Journey to FONDATION Fieldbus
 Why Fieldbus? It’s Benefits to End User!!
 Project Phases
 Vendor Responsibilities
 Process Types
 Fieldbus Selection
 Fieldbus Design for Process application
 Installation/Commissioning
 Operation and Maintenance
This Presentation will highlight some key points from EPC/End Users
perspective for successful implementation of Fieldbus Project.

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Fieldbus Team and Responsibilities
 Fieldbus Development Team
 Vendors
 EPC/Consultant
 End User
Many engineering firms believe that there are no great differences between
4-20 mA analog and Fieldbus installations. Without an engineering partner
with Fieldbus skills, the cost of project will be greater & Project will be mess!!
End User
Fieldbus
Vendors
Fieldbus Development
Team
EPC /
Consultant

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Fieldbus Team and Responsibilities
Fieldbus
Development Team
EPC /
Consultants End UserFieldbus Vendors
1. Tender
2. Evaluation
3. EPC/Vendor
selection
4. Procurement
5. Design and
Engineering
Co-ordination
6. Construction
7. Installation
8. Commissioning
9. Operation and
Maintenance
1. Tender
2. Proposal
3. Evaluation / Proc.
4. Field Instrument
Design
5. ICSS –
DCS/ESD/F&G
Design
6. HAZOP/SIL
7. Procurement
8. Project
Co-ordination
9. Construction
SoW & Assist.
10. As-Built
11. Maintenance
1. R&D
2. Product Design
3. S & M / Proposal
4. Fieldbus Instr.
Selection
5. DCS/ESD/F&G
6. Hardware Design
7. Software Design
8. Networking Design
9. FAT/SAT
10. Install. & Comm.
11. As-Built
12. AMC
1. Develop Fieldbus
Standards
2. Define Fieldbus
Guidelines for
Vendors /
Consultants / End
Users
3. Feedback from End
Users / EPC /
Consultants
/Vendors
4. Continuous
Improvement
They all are I&C Engineers / Experts but the Roles and responsibilities are
different according to the Business need of the company they represent !!

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Fieldbus Team Qualification
 Qualified Engineering Partners
 Project Phase Awareness
 Process and Equipment Knowledge
 Product and Application Knowledge (Fieldbus & Field Instruments)
 Fieldbus & Network Knowledge (Control System)
 Familiar with Enquiry & Design Docs (P&ID, Instrument Index, Data
Sheets, Specs, Layouts …etc.)
End User
Fieldbus
Vendors
Fieldbus Development
Team
EPC /
Consultant

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The Journey to Foundation Fieldbus….
The Process Automation technology developed in each decade was compliment
to next one…!!
Lets have a look at the historical overview and the development trends of
I&C technology, process environments and instrumentation, and the tasks
of end users in different decades.
 50’s – Electro-mechanics / Pneumatic / Hydraulic Systems
 60’s – Combination of Pneumatic & Stand alone Controllers
 70’s – Integrated Circuits and PLC’s
 80’s – DCS with Smart devices / CAD
 90’s – Foundation Fieldbus
All above Technologies played crucial role in development of Fieldbus …!!

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I&C – Technology Trend
50’s – Electro-mechanics / Pneumatic / Hydraulic Systems
 In the 1950s, development trends focused on electro-mechanics,
 Bringing field instruments closer to the process, and reading and monitoring
process data near the process level.
 Pneumatic analogue
instruments were
introduced and also
various
measurement
devices for pressure,
temperature and flow
spread in the
industry. Feedback
control was applied
in hydraulic controls.

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60’s – Combination of Pneumatic & Stand alone Controllers
 In the 1960s technical development took place particularly in the fields of
electronics.
 Pneumatic and electric instrumentation systems relying on analog signals
spread into factories.
 Instrumentation
structures were
standardized, and
centralized control
room solutions were
implemented.
Electronics was first
used in the devices for
automation data
logging and processing
and process control.

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 Digital and
microprocessor
technologies were
applied in electronic
devices and control
stations. Graphic
design curves were
introduced for
Process trends.
70’s – Integrated Circuits and PLC’s
 Trends of the 1970s were integrated circuits and programmable logic
controllers (PLC). The development of analog systems reached its peak,
distributed digital systems (DDS) gained ground, and control rooms became
increasingly complex.
 The centralized control systems incorporated measurement, communication
and information handling.

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 Intelligent Field devices
were supplied by
specialized vendors. End
Users paid more attention
to the selection and
specification of devices.
CAD & Spreadsheet was
introduced for Design and
planning. Development of
International / Local
Company Standards.
80’s – DCS with Smart Devices / CAD
 In the 1980s microprocessor technology was the peak area of development. This
was the start of the era of video cameras, integrated systems and cabling was
replaced by data buses using coaxial or optical cables. Process supervision was
centralized, the operations hierarchically distributed. Management systems were
characterized by control room operation, process stations, and distributed control
functions.

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80’s – International Standards Development

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 The purchase price of a
device is marginal
compared to the total cost
during its lifespan. This
emphasizes the importance
of Safety, reliability and
maintenance..
90’s – Foundation Fieldbus
 The integration of electronic components and microcomputers into process
management has continued to grow, and intelligence has been distributed to
field technology devices. Field instrument and fieldbus development projects
have been initiated, changed, and merged together. Fieldbus and Highway
Addressable Remote Transducer (HART) devices are used for the
measurement of temperature, pressure, DP and level.

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90’s – Foundation Fieldbus
Transmitter Control Valve
Fieldbus Segment
50’s & 60’s Contribution to Fieldbus Concept-
Control in the Field
70s & 80’s Contribution to Fieldbus Concept-
•Function Blocks in the Field
•4-20mA – Two wire system to Digital

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What is Fieldbus???
A digital, bi-directional communication link among intelligent field devices
and Automation systems, allowing control in the field or Automation System.

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Fieldbus Concept
Fieldbus is a local area network (LAN) for process control. The two wires
are a shielded twisted pair similar to the usual 4‐20 mA wiring used for
conventional devices. Because devices share the wires, the devices can send
data to each other without a DCS controller (host).
Fieldbus data transmissions have more information than just a single variable
about temperature, pressure, or valve position. From the data shared
between the devices, the devices can be configured to control the process.
The host then only supervises the operation. This is called “Control-
in‐the‐field”.

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Fieldbus Components
 H1 Interface Card
 Bulk DC Power Supply
 Fieldbus Power Supply
 Fieldbus Cable – Trunk and Spur
 Device Coupler with Junction Box
 Terminators
 Fieldbus Instruments
A Fieldbus segment’s wiring carries power to devices and signals between
devices. The Fieldbus Segment typically consist of following Components;

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Fieldbus Components
H1 Interface Card and Fieldbus Power Supply
A DCS with an H1 interface is usually located in the control room. Its function is
to oversee the operation of the control system, made up of the devices
connected on the Fieldbus segment.
A DC bus voltage (nominally 24V but can be from 9‐32VDC) is supplied to the
devices on the segment by a Fieldbus Power Supply. The Fieldbus Power
Supply is needed to separate the bulk DC power supply from the Fieldbus
wiring so that the signals are not absorbed by the bulk DC power supply. The
Fieldbus Power Supply is normally installed near the control room but could
also be located in the field or in a marshalling panel.

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Fieldbus Components
Fieldbus Power Supply
Fieldbus is required to be isolated from ground (to improve noise immunity).
A DC power supply’s job is to regulate the output voltage (say at 24VDC). A
Power Conditioner allows power to flow to the Fieldbus, but blocks the digital
communication signal from flowing to the Isolator or DC power supply. It’s like a
one way valve. A current limiter is provided in the Fieldbus Power Supply to
prevent damage from a short‐circuit or over‐load condition.
Fieldbus Power Supplies with the Foundation™ Fieldbus checkmark should be
used for Foundation™ Fieldbus as per specification FF‐831.

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Fieldbus Components
Fieldbus Cables - Trunk and Spur
Fieldbus uses shielded, twisted‐pair cable. A twisted‐pair is used, rather than a
pair of parallel wires, to reduce introduction of external noise onto the wires. A
shield over the twisted‐pair further reduces noise. The twisted‐pair wires, the
shield, and their covering jacket are called a cable.
For reliable Fieldbus segment operation, use cable with the Foundation™
Fieldbus Checkmark, which demonstrates compliance with the FF‐844 standard
(also known as Type A Fieldbus cable).

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Fieldbus Components
Device Couplers
Device Couplers are the industry‐standard method of wiring devices to a
Fieldbus segment. Device Couplers provide short circuit protection that
prevents the entire segment from failing if one device or Spur cable is shorted.
Two different types of Device Couplers are available
 Non‐isolated Device Couplers are used in the majority of Fieldbus
installations where isolation is not required. These installations are typically
classified Division 2, Zone 2, or non‐hazardous.
 Isolated Device Couplers are used where Isolation may be required for
Division 1 or Zone 1, 0 hazardous area installations.
The pluggable screw terminal type Fieldbus Device Couplers make wiring
easier and more reliable. Only Device Couplers with the Foundation™ Fieldbus
FF‐846 checkmark should be used.

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Fieldbus Components
Device Couplers
Connection Diagram Actual Connection

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Fieldbus Components
Terminators
Two Terminators are required at each end of the Trunk cable on each Fieldbus
segment. Generally, one Terminator is at the control room end of the cable and
the other Terminator is in the junction box in the field.
The Terminator can be a separate part, or it may be part of a Device Coupler or
a Fieldbus Power Supply. The Terminator should be clearly marked so that it
can be identified in an installed system.
A Fieldbus segment without two Terminators will not have the properly‐shaped
signals. A segment with only one Terminator may appear to function properly,
but will have distorted signals with increased amplitude.
A segment with three or more Terminators will have decreased signal amplitude,
and devices may lose the ability to communicate with one another. An extra
Terminator will typically cause a 300 mV drop in signal level and a missing
Terminator will cause a similar increase.

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Fieldbus Components
Fieldbus Instruments - Field Bus Signal
Devices on a Fieldbus segment transmit digital signals to each other over the
same wires that power the devices. Each transmission on the segment is
received by all devices. Only one device called as Link Master (LM) device on
an H1 fieldbus determines which device may transmit next.
A DC bus voltage (nominally 24V but can be from 9‐32VDC) is supplied to the
devices on the segment by the Fieldbus Power Supply. A Fieldbus device draws
a constant amount of current when not transmitting. To transmit information, the
device varies the amount of current it draws from the segment to create a signal
“riding” on the 24VDC. Digital data is sent on the Fieldbus at a rate of 31.25
Kbits/second.

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Fieldbus Components
Fieldbus Instruments – Process Impulse Hook Up
Close-coupled Hook Ups for mounting Fieldbus pressure instrumentation can
Significantly enhanced measurement accuracy and deliver enormous
advantages;
 Eliminate impulse lines and
connections
 Simpler installation
 Reduced maintenance
 Reducing potential leak paths,
 Process is cleaner as well as safer,
 Making an environmentally
friendly choice.

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Why Fieldbus?
Construction and Installation Benefits for EPC / End User
 Many devices connected to single pair wire.
 Less wire, cables, fewer barriers, fewer panels
 Reduced control equipment, cards, power supplies.
 Powerful software configuration.
 Drag & Drop Technology.
 Plug & Play.
 Control in The Field.
 Less Control Room Equipment.
 Less Space Requirement.
Reduced Installation cost….!

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Why Fieldbus?
Operation Benefits for End User
 Digital Communication.
 High resolution, Distortion free characteristics.
 MORE RELIABLE DATA FOR CONTROL.
 Control Residing in the Field Devices.
 Less chance of performance degradation.
 BETTER LOOP PERFORMANCE
 BETTER CONTROL.
 Easy Accessibility
 Increase monitoring, optimization, management.
 MORE EFFECIENT OPERATION.

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Why Fieldbus?
Maintenance Benefits for End User
 Self Test & Communication Capabilities
 Reduce downtime, Increased plant safety
 Self diagnostics will notify when a problem occurs
 MAINTENANCE CREW WILL HAVE ADVANCED INFO ON PROBLEMS
 Remote Maintenance
 Interchangeability
 Configuration, Calibration and
Reporting from any office with NT computer
 REDUCED MAINTENANCE TIME
 REDUCE INVENTORY

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Why Fieldbus?
Design and Engineering Advantage
 No need of JB ICTD, Marshalling ICTD, Control System ICTD, Loop Diagram
per Tag. They all are replaced with Fieldbus Segment Diagram.- Saving huge
nos. of Deliverables and Activities.
 Cable Schedule Design becomes easy. No need of Various types of Cables,
Cables Nos., Various types Glands and accessories – Saving Huge nos. of
man-hours on Bulk MTO preparation.
 Saves Technical Evaluation of Bulk MTO
 Saves Procurement Time for Bulk Material
Fieldbus Design and Engineering activity is complex compare to Conventional
4-20 mA Design and take almost same manhours.
CTR

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Fieldbus – Business Overview
Why it takes time to adopt Technology in India?
 System & Instrumentation Manufacturers (Vendors)
 EPC Companies / Consultancies
 End Users
In current industrial scenario, the pressure is overwhelming to perform, produce,
deliver faster, better and cheaper. Fieldbus is perfect solution…!!
The main hurdles in promoting Fieldbus are;
 Competitive business
 Low Cost expectation
Vendors should take Lead and Organize Events to promote Technology!
End Users should be Vendor Neutral and provide equal opportunities for
all Vendors to create Healthy Competition!

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Fieldbus – Business Lifecycle
 The Fieldbus Foundation strongly recommends having a knowledgeable and
experienced engineering partner on how to execute Fieldbus project. .!
Fieldbus Business
OEM
Engineering
Consultant
Process &
Power
EPC
Contractor
Manufacturing
Companies
Field Instruments
System Vendors
Integrators

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Fieldbus - Projects Types under EPC Contract and SoW
Process Types
 Continues Process - O&G, Chemical, Petro-Chemical, Water, Power etc.
 Batch Process – Pharma, Food & Beverages, Nylon & Tyrecord etc.
EPC Project Types and SoW
 Greenfield – Totally New plant – Low Risk and low Complex
 Brownfield – Expansion / Demo Mod Scope – Medium / Installed Base Pref.
 Revamping and Upgradation – Online replacement – High & Complex
Nearly over 20,000 FOUNDATION fieldbus systems installed around the world.
Revamping and Upgradation Projects are in Boom!!
Example – ONGC – BPA and BPB Turnaround project!!!

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Typical Project Lifecycle
Its very important to understand Project Lifecycle to promote latest
Technologies like Fieldbus for Process Industries,
Phase I
Feasibility Phase
Phase II
Concept Phase
(Pre-FEED)
Phase III
FEED Phase
The objective
is to
demonstrate
both technical
and economic
viability.
The objective
would be to
select the best
option(s) and
further define to
reduce risk and
improve project
cost estimate
accuracy.
A robust FEED
will deliver the
estimate for
final sanction
together with
the
documentation
for the next
contracting
phases.
Phase IV
Detail
Design
The FEED
output will
enable
procurement
activity to
commence prior
to main EPC
contract award.
Right time to consider Fieldbus

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Fieldbus Selection Criteria's
1. Geographical Location / Local Approval and Vendor Support
2. Process type – Batch OR Continuous / Hydrocarbon OR Water OR Other…
3. Process Operation and Safety… i.e. Hydrocarbon OR Water OR Other…
4. Process and Ambient Conditions
5. Instrument Locations
6. System Integration requirement
7. End User Approval (O&M requirements and Training)
8. I&C - Budget
Operation & Maintenance
Middle
Management
Top
Management
EPC / Consultant
(Design / Evaluation /
Order / Project
Co-ordination)
Fieldbus Vendor
(Training / Proposal /
MAC-MIC Projects /
AMC)
End User

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Fieldbus with Hybrid Network - Selection Strategy
White Paper on ONGC O&G Upstream Revamping Project by Mr. Raut
1. In some process the types of parameters to be monitored are of wide variety.
2. In some cases fluids are not consistent in nature.
3. For some typical applications where special type of instruments have been
necessary and the manufacturers are yet to develop models with FF interface.
4. In some cases (Revamping Projects) existing electronic devices are already
in existence and in operation, the signals have been interfaced either HART
protocol or through RTU and MODBUS link with HOST system.
5. All digital inputs like – Rotating Equipment / Valve Status, Level Switch ,
Pressure Switch , Flow switch etc have been first interfaced with Digital I/O
module and then to HOST controller through Profibus interface.
6. It is essential to select right types of devices to ensure reliable , consistent
and trouble free operation
The Host system has been designed to support a hybrid network to accommodate
devices with 4-20 ma signal , HART signal , Profibus DP and FF signal , most of
the filed devices ( around 90 % ) are with FF interface .

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Fieldbus with Hybrid Network Selection
Serial
no
Parameters &application Instrument device Type of device
01 Well head pressure /temperature Pressure /Temperature transmitters
with Radio telemetry
Radio transmitters
powered with solar cell.
02 Flowing status of wells /flow rate Clamp on Ultrasonic flow meters FF / MODBUS device
03 Gas flow to dispatch header / gas
flow from individual gas wells
Orifice meters (senior orifice
fittings) with multiple sensors
FF device
04 Tank level indicators Guided wave Radar type level
indicators
MODBUS
05 Line temperature of oil & gas line Strip type RTD device with filed
transmitter
FF type
06 Water injection header flow rate Orifice meter /DP transmitters FF type
07 Gas lift header pressure Pressure transmitter FF type
08 Gas lift finger flow rate DP transmitter with P&T
compensation
FF type
09 Test gas flow rate Senior orifice meter FF type
10 Effluent water dispatch meter Magnetic flow meter FF type
11 Mass flow meter for stabilized oil Coriolis meter MODBUS

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Fieldbus Detail Design under EPC Projects
I&C Detail Design Activities and Deliverables divided into Three Categories
Fieldbus
Instruments
Deliverables
Construction SoW
and Deliverables
Control System
Design
(DCS/ESD/F&G)
• P&ID’s – Instr. Inputs
• Instrument Index
• Field Instrument Spec.
• Calculation Sheet
• Instrument Data Sheet
• Hook Ups
• MTO
• etc.
• SoW
• Layouts
• Cable Schedule
• Hook Ups
• Bulk MTO
• JB & System Drawings
• etc.
• SoW
• ICSS System Specification
• System Architecture
• I/O List
• Segment Diagrams
• C&E Diagram
• P&ID’s
• Graphic Specification
• System Drawings
• etc.

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Fieldbus Enquiry from End User / EPC
Fieldbus Enquiry Package should have minimum following Information;
1. Scope of Work
2. PFD’s (check Revision Status)
3. P&ID’s (Check Revision Status)
4. Process Operating Philosophy
5. ICSS Specification / System Architecture / Utilities
6. Field Instrument Specification
7. Instrument Data Sheets
8. I/O List and Alarm & Trip setting List
9. Fieldbus Instrument Location Layouts
10. Instrument Cable Routing Layouts
11. Hazardous Area Classification Layout
12. Control Room Layout
13. Approved Vendor List

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Vendor – Typical I&C Activity Flow Chart
• FEED
• Conceptual Design
• Tender
• Proposal
• Detail Design
• Enquiry Spec
• Order
• DCS / Safety
• System Design
• H/W – S/W Design
Installation, erection,
Calibration and
Commissioning of field
Instruments and
DCS/Safety/F&G
System by EPC /
Instrument Contractor
with System Vendor
• Installation
• Erection
• Calibration
• Commissioning
Detail Engineering
Design for Field
Instrumentation,
Hardware and
Software, Networking,
SCADA etc. by System
Vendor
Engineering documents
are made For Technical
and Commercial Offer
to win project and
further (after getting an
Order) Detail
Engineering Design
activity by EC or EPC
and System Vendor.
Engineering documents
are made For Technical
and Commercial
Analysis
/ study purpose for
Tender Enquiry. This
activity is mainly done
by EC for End User or
directly by End User.

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Fieldbus Proposal & Engineering - Important Tips for Vendors
 Vendor Engineering Team shall have thorough Knowledge of client / Local and
International Codes and Standards.
 Vendor shall know EPC Activities and able to read Deliverables like P&ID,
Process Philosophy, C&E, Layouts (Instrument/Piping/Mechanical) and
Hazardous Area classification etc. to discuss project scope on same level.
 Vendor – S&M team shall have Process Application and Multi-discipline
Engineering knowledge (Only knowing Fieldbus and its Product Technical
Specification is not enough to WIN and execute projects).
 Vendor shall understand Project Phase, Project SoW and Client’s Techno-
Commercial requirements before they submit their Proposal (that helps to WIN
confidence level of Client’s Project/Instrument/ProcurementTeam)
 Vendor shall approach with detail Fieldbus Implementation plan, its benefits,
and after sales Support.
 Vendor shall produce examples of detail Project Pay back period using
Fieldbus with compare to Conventional System and produce Case Studies of
critical process Application.

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Fieldbus Proposal from Vendor
Vendor – S&M shall include minimum following Deliverables in Proposal
after Bid – No Bid decision
Fieldbus Technical Proposal Content
1. Introduction
2. Project Scope and about Proposal
3. Details BoM in given format with Item code-Model / Description / Quantity
4. System Architecture / Segment Design Procedure with sample layout
5. List of Deliverables (Panel & Segment Drgs, Data sheets, Calculations etc.)
6. List of Activities (Meeting, Site Visits, Configuration/FAT/SAT Support etc)
7. ToC (Table of Compliance)
8. Deviation List
9. Assumption List
10. Notes or Remarks if any
11. Project Team Chart and Project Schedule
12. EQC Criteria's (Case Study, Data Sheets, proof of Similar project experience)
13. Fieldbus Instrument / Control System / Components - Product Manuals

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Fieldbus Design & Engineering Flow Chart
Design Strategy
Levels
Facility & Plant
Level Activities
System Level
Activities
Equipment Level
Activities
Prepare Master DDR
And Activity List
Prepare Project
Schedule & Start
Activities
Deliverable Design and
Quality Check
Client Approval and
Release for “AFC”

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Fieldbus Design & Engineering Flow Chart
Design Strategy
Levels
Facility & Plant
Level Activities
System Level
Activities
Equipment Level
Activities
Refer PFD, Study Process and Sub-Process,
respective P&ID’s, It’s connectivity, Main Headers,
Plant Interlocks (ESD / PSD) and main Controls,
Highlight signals by different colors, Compare I/O List
Refer P&ID’s and Equipment List, study Process
Operation, Check Interlocks (ESD / PSD) and
Controls, Check Equipment & Boundary Limits
Highlight signals by different colors, Compare I/O List
Check Overall System Requirement (ICSS). Check
DCS interface with ESD / F&G and Third Party,
Design System Architecture as per End Users
requirement.

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Fieldbus Design Activities
Design Activities by Vendor “Engineering Team” for MAC / MIC Contract
1. Study total Project SoW and Proposal submitted by S&M Team
2. Understand entire Process and Purpose
3. Site Visit / Collect data and prepare site Visit Report
4. Carry out As-Built if necessary (exp. QP Offshore Project)
5. Check Design Deliverables recd. From Client and revision
6. Collect Company Specifications applicable for the project
7. Understand Local/Company Codes and Standards
8. Make List of Activities and Deliverables
9. Prepare TQ list in the beginning and highlight missing part if any
10. Confirm Scope and clarify responsibilities of other parties (OEM Interface /
Contractor Interface / Skid boundary limits).
11. List points to discuss during KoM and highlight extra activities to be done
which is not defined originally in SoW. Clarify & get Client Approval
12. Start Design and Engineering and get it approved from Client

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Fieldbus Design – Reference Drawings for Vendors
1. Scope of Work
2. PFD’s
3. P&ID’s
4. Process Operating Philosophy
5. ICSS Specification / System Architecture
6. Field Instrument Specification
7. Graphic Specification / Alarm Priority Specification
8. Instrument Data Sheets
9. Equipment List
10. I/O List and Alarm & Trip setting List / C&E Diagram
11. Fieldbus Instrument Location Layouts
12. Instrument Cable Routing Layouts
13. Hazardous Area Classification Layout
14. Control Room Layout
15. Approved Vendor List

©ISATRNG-46-20121020
Fieldbus Instruments Design Preparation
PT
001
PICA
001
I/P
PCV
FF
PCV-001
PT
001
PZA
001
HH
H
ESDV-001
Fieldbus Loop SIS Loop
Refer Abbreviation and Symbol List of End User. Not from any other Project.
P&ID Mark up
 Mark up FF-DCS, SIL-ESD Instruments using different color Markers.
 Identify Digital signals to DCS using different color Markers.
 Update Instrument Index with Type of Instrument

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Fieldbus Instrument Design & Selection
Fieldbus Instrument Selection and Data Sheet Preparation
 Refer End User’s Field Instrument Spec. for Process and Utility, Process
Connection, Instrument Application, Type, Selection, Installation etc.
 Refer Instrument Index and identify type of field Instruments (Transmitters,
Control Valves, Switches, MOV’s, ESDV’s etc.)
 Identify Fieldbus Approved Devices and 4-20mA, HART for some typical
applications where special type of instruments have been necessary and
the manufacturers are yet to develop models with FF interface.
 Check Process Data (from Process Dept.)
 Body and Wetted Part MoC
 Power Supply / Signal Type
 IP Rating / Hazardous Area Class / NACE if required
 Process Hook Up
 Electrical Hook Up
 Installation Material
 Select Field Instrument Model No.
• Instrument Data Sheet
• Area Class & IP
• Hook Up

©ISATRNG-48-20121020
Fieldbus Segment Design
03
PT
021
03
PIRCA
021
Area/Sub-Area Code
Instrument Tag Function in System (Pressure, Indication, Recording, Control and Alarm)
Instrument Sequential Tag No.
Instrument Type (Pressure Transmitter, FT, LT, TT, AT, QT)
Area/Sub-Area Code
To 03-PCV-021
(Pressure Control Valve)
PCV
Instrument Sequential Tag. No.
I/P
H
L
FC
FF

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1. Check and Mark Main Process and Sub Process areas on the P&ID
2. Refer Instrument location layout and check Control Room distance from
each Sub Area.
3. Refer Hazardous Area Classification Layout and identify Hazardous and
Non-Hazardous Areas and its classification OR refer Instrument Data
Sheets
4. Check and Club Instruments Segment on Instrument Location Layout.
Verify Process Operation Requirement.
5. Initially club 12 Open loops and max. 4 closed loops per segment
6. Identify Fieldbus JB strategic location and Mark it on Instrument Layout
7. Check Spur and Trunk Routing to-fro JB
8. Refer Piping Isometric / Mechanical Layouts to check spur length
9. Refer PDMS Layouts (if available) for elevations and nozzle orientation to
measure vertical spur length
10. Check and discuss Fieldbus cable routing with Electrical and follow
Company Design guidelines

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1. Check and discuss Field Cable routing with Civil for excavation, road /
Pipeline crossovers, Cable Tray routing and supports
2. Ensure the total Segment length (Trunk + Spur) should not cross
1900mtrs. for type A cable
3. Prepare Segment Diagram with Instrument tag no. / spur no. / Fieldbus JB
no. / Trunk no. and give tag nos. to all components as per company
Tagging Philosophy.
4. Prepare ICTD for each Segment - Fieldbus JB with Polarity, Terminal
nos., wire color code, spur nos., trunk nos. and Components nos.
5. After Self and Discipline check, issue it for AFC
6. Vendor has to refer Segment diagrams with AFC Revision for Fieldbus
Configuration and Verify lengths and Node Voltage is within acceptable
limits. In case of deviation, Vendor to mark addition or deletion of fieldbus
Instrument on Segment Diagram and Consultant has to re-Design and
issue Segment Diagram for AFC with next Revision. This activity to be
done jointly by Vendor and Consultant or End User.

©ISATRNG-51-20121020
Fieldbus Segment Design - Reliability Considerations
Since Fieldbus uses shared wiring, reliability precautions need to be taken for
segments used in critical applications.
The shared wiring and the Fieldbus Power Supply are critical resources,
because all the devices share the same cable and power supply. If these fail,
then the whole segment is inoperative. The main Fieldbus reliability issues are:
Spur short circuits – New Instr. & Spur Install / Instr. Service / Waterlogged
Trunk failures
Power failures
Surges
Segment monitoring

©ISATRNG-52-20121020
Spur short circuits Reasons:
• New Instrument Installation
• New Spur Installation and connection
• Instrument Maintenance
• Instrument get Waterlogged
Design Consideration:
Use Device Coupler with built in Current between the Trunk and the Spur
cable. The current limiter only allows a given amount of current to be used by
each device. If a Spur is shorted, the current will be limited within a few
microseconds. Only the shorted device is affected; the rest of the devices
continue to operate.

©ISATRNG-53-20121020
Trunk Cable failures :
• Trunk get cut during excavation
• Can get damaged due to Overheat
• If bend above bending radius
• Accidentally due to sharp object during
construction
The Trunk cable needs to be protected
in a conduit or a sturdy cable tray with
proper supports. This activity to be done
in co-ordination with Civil for main
Cable Racks and for cable routing along
with the Main pipe racks. Also Keep
sufficient distance from Electrical cables
trays to avoid Electromagnetic
interference.

©ISATRNG-54-20121020
Power Supply failures :
If Fieldbus segment power fails,
the entire Fieldbus segment is
taken down and control is lost.
MTTF of the components of a
Redundant Fieldbus Power Supply.
The Availability for a Fieldbus segment
due to the redundant FPS system can
be 99.9999989% or even higher. This
means that a Fieldbus system could be
down due to redundant power supply
failures on average for 0.3 seconds/year.
The Power Supply failure issue can be
solved by using Redundant Power
Supply with Alarm signal to be connected
to DCS to notify the Operator.

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Lightning Surges:
There is no protection against a direct lightning strike. The energy involved is too
great. The struck device simply disintegrates. Lightning strikes also have effects
at great distances from the strike point.
Since many Fieldbus devices share the same cable, a lightning surge can
adversely affect all of them by breaking down the electrical isolation of Fieldbus
devices.
For further information on Surge Protection, always refer technical data available
from manufacturers of Surge Protection equipment for Fieldbus. Note that it is
important that the Surge Protection devices are specifically designed for Fieldbus..

©ISATRNG-56-20121020
Segment reliability can be improve
by continuously monitoring the
segment to get early warning of
potential issues. Diagnostic
products are available to monitor:
DC voltage
Device signal levels
Noise levels
Shorts to the shield
Communication health
This information can be tracked by
the asset management system for
trend analysis. With this
information, it is possible to reduce
the number of unexpected failures.
Segment Reliability - Design Consideration:

©ISATRNG-57-20121020
Fieldbus Design for Hazardous Areas
Fieldbus Design and Installation in Hazardous areas involves detail study of
company policy, Process Safety and an analysis of the benefits and costs of
each option. Special installation and design practices may need to be followed
for the hazardous area.
Exp. Gas Compressor Hazardous Class. in
• Open Area Installation
• In Building
Design Reference Drawings:
Company Design Standards
Hazardous Area Classification Layout
Hazardous Area Classification Chart
Instrument Location Layout (Scale Drg)
Instrument Data Sheet and P&ID’s

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Fieldbus Design for Hazardous Area – Zone 2
Zone 2, a non‐Arcing method of protection means that the wiring and electrical
apparatus do not generate sparks or hot surfaces that could cause an ignition
under normal operating conditions. In this case, the wiring must be adequately
protected to prevent open, shorts, and grounding. Can not work ONLINE (when
Power is ON). Required HOT permit to ensure no hazardous gases are present.
Zone 2, “High Energy Trunk” method is used when the Trunk carries an
incendive level of power and must be protected as in the non‐Arcing case, but the
Spurs are energy limited by the Device Coupler to limit energy on spure and
Fieldbus device. Due to High Trunk energy it is common to use Redundant PS for
high reliability.
Due to the high power on
the Trunk, the number of
devices and length of the
segment are not limited
being in the hazardous
area. Can work ON Line
without HOT permit.

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Fieldbus Design for Hazardous Area – Zone 2
Zone 2, Fieldbus Power Supply certified as FISCO device (Fieldbus
Intrinsically Safe COncept). Its output is limited in energy such that a short,
open, or grounding of the wiring will not cause an ignition in the presence of
hazardous gases. So, in this case, the entire segment is energy limited. This has
the advantage of being able to live work the entire system. The disadvantage is
that, because of the limited energy, the cable length will be shorter than the
previous methods discussed, and the number of Fieldbus devices on the
segment will be less.

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Fieldbus Design for Hazardous Area – Zone 0 / 1
Increased Safety method is a non‐Arcing technique for Zone 1. Since gases
are more likely to be present in Zone 1 than in Zone 2, the requirements on the
equipment certified and installed under Increased Safety are higher to reduce
the Probability of an ignition. If the Zone 1 certification requirements are met, the
Fieldbus segment is installed as if it were non‐hazardous.
High Energy Trunk for Zone 1 has an incendive‐level trunk which is installed
using Increased Safety techniques. The segment contains an Isolated Device
Coupler, as Fieldbus Barrier, in the field to separate the Trunk from the Spurs
(Galvanic Isolation). The Spurs are then Intrinsically Safe (entity or FISCO).
The Trunk cable, however,
cannot be live worked, and
requires HOT permit before any
work is done. The Fieldbus
devices and the Spur cables may
be worked without permit (subject
to Company Safety Policy).

©ISATRNG-61-20121020
Fieldbus Design for Hazardous Area – Zone 0 / 1
Using FISCO (Fieldbus Intrinsically Safe COncept) method both the Trunk and
Spurs are protected by a FISCO Fieldbus Power Supply that limits the energy to
meet the Zone 1 requirements. the advantage is that the entire segment (beyond
the FISCO supply) may be live worked. A Redundant FISCO Supply is available
to improve system availability.

©ISATRNG-62-20121020
Fieldbus Installation Check List
1. Strictly follow Company Installation Guidelines, if not available follow
Fieldbus Foundation Guidelines.
2. Check inside the field device against sour, corrosion, water, etc. before
Installation also check Instrument Tag plate for Range and model no. against
Data Sheet. Check firmware has any bug or malfunction during callibration.
3. Use “Company’s” Process Hook Up Standard – Project Drawing for Process
Connection against each Tag no. carefully.
4. Check Direct / remote Installation on 2” pipe.
5. Use Type A Fieldbus cable. Check Fieldbus Checkmark. Use proper gland.
Check termination, Ferrules with Polarity, Shield.
6. Refer Segment Drawing and check all Fieldbus devices, Spures, Trunks, JB,
Fieldbus Components with Tag nos.
7. Check Fieldbus Trunk and Spure cable route. Keep distance from Electrical
cables as per Company Standard.
8. Check Function Blocks sheet for each loop; Once device is correctly
configured information must be stable and consistent to process current;
check online parameters and also quality (good, bad) directly at FB´s.

©ISATRNG-63-20121020
Fieldbus Installation Check List
1. Strictly follow Company Installation Guidelines, if not available follow
Fieldbus Foundation Guidelines.
2. Check inside the field device against sour, corrosion, water, etc. before
Installation also check Instrument Tag plate for Range and model no. against
Data Sheet. Check firmware has any bug or malfunction during callibration.
3. Use “Company’s” Process Hook Up Standard – Project Drawing for Process
Connection against each Tag no. carefully.
4. Check Direct / remote Installation on 2” pipe.
5. Use Type A Fieldbus cable. Check Fieldbus Checkmark. Use proper gland.
Check termination, Ferrules with Polarity, Shield.
6. Refer Segment Drawing and check all Fieldbus devices, Spures, Trunks, JB,
Fieldbus Components with Tag nos.
7. Check Fieldbus Trunk and Spure cable route. Keep distance from Electrical
cables as per Company Standard.
8. Check Function Blocks sheet for each loop; Once device is correctly
configured information must be stable and consistent to process current;
check online parameters and also quality (good, bad) directly at FB´s.

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