Foundation Fieldbus, Fourth Edition

Foundation Fieldbus

Fourth Edition

Foundation Fieldbus

Fourth Edition

by Ian Verhappen and Augusto Pereira

Notice

The information presented in this publication is for the general education of the reader. Because neither the author nor the publisher has any control over the use of the information by the reader, both the author and the publisher disclaim any and all liability of any kind arising out of such use. The reader is expected to exercise sound professional judgment in using any of the information presented in a particular application.

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Copyright © 2012

ISA—The International Society of Automation

All rights reserved.

Printed in the United States of America.

10 9 8 7 6 5 4 3 2

ISBN: 978-1-937560-20-1

ebook ISBN: 978-1-937560-40-9

No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publisher.

ISA

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P.O. Box 12277

Research Triangle Park, NC 27709

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Library of Congress Cataloging-in-Publication Data in process.

For my wife Michele, who has supported me throughout my career and through the original development of this book and its revisions, while also raising our daughters Ashley and Madeline. You are the glue that keeps it together.

Thank you also to everyone who has supported me during my Fieldbus development and continued growth, providing opportunities to expand my knowledge and apply what I have learned. You have made it possible to be able to share this knowledge.

—Ian Verhappen

For my wife Margareth and my sons Sergio and Fabio, who gave me the support to write this book and helped me during the revisions.

Thanks to everyone who taught me the Fieldbus concepts since the early years and all the people who, during the several projects that I have been involved in, followed my suggestions for getting their projects working successfully.

—Augusto Pereira

Table of Contents

List of Figures

List of Tables

Ian Verhappen, P. Eng., CAP

Augusto Pereira, Eng

Chapter 1 — Fieldbus Layers

1.1 Topology

1.1.1 Application Layer

1.1.2 User Layer

1.1.3 Testing and Registration

1.1.4 Interoperability Test System

1.1.5 Physical Layer

1.1.6 Topologies

1.2 Communications

1.3 Parameter Classes

1.3.1 EDDL

1.3.2 FDT/DTM

1.3.3 Field Device Interface (FDI)

Chapter 2 — Fieldbus Cabling

2.1 Segment Protection

2.2 High-Speed Ethernet

2.3 Grounding/Earthing

2.4 Surge Protection

2.5 Cable Installation

Chapter 3 — Fieldbus Power Supplies

3.1 Intrinsic Safety

3.2 Fieldbus Intrinsically Safe Concept

3.2.1 Architecture with FISCO installed in the DCS cabinet

3.2.2 Redundant FISCO

3.3 Fieldbus Non-Incendive Concept (FNICO/FISCO Ex ic)

3.4 High Energy Trunk – Fieldbus Barrier

3.5 DART (Dynamic Arc Recognition and Termination)

3.6 Selecting the Right Power Supply

Chapter 4 — Documentation

4.1 Segment Loading Calculation

Chapter 5 —System Integration

5.1 Configuration

5.1.1 Client-Server VCR Type

5.1.2 Report Distribution VCR Type

5.1.3 Publisher–Subscriber VCR Type

5.1.4 Fail Over Strategies and Design Considerations

5.2 Scheduling

Chapter 6 — Commissioning

6.1 Physical Layer Checks

6.1.1 Cable Testing

6.1.2 Electronic Commissioning

6.1.3 Configuration Commissioning

6.1.4 F OUNDATION Fieldbus Digital Communication Certification

6.1.5 Typical Installation Problems

6.2 Device Configuration

6.2.1 Configuration of the Resource Block

6.2.2 Configuration of the Transducer Block

6.2.3 Configuration of the Analog Input Function Block

Chapter 7 — Troubleshooting

7.1 Optimization Tools

7.1.1 Physical Fault Symptoms

7.2 Communications and Configuration

7.3 Tuning

Chapter 8 — Operations & Maintenance

8.1 Operations

8.2 Maintenance

Chapter 9 — New Developments

9.1 Fieldbus Safety

9.2 Wireless & Remote I/O (WIO)

9.3 Wireless

9.4 Host System Interoperability

Appendix A — Nomenclature

Appendix B — Fieldbus Foundation Specification List

Appendix C — Bibliography

Appendix D — Acronyms

Appendix E — FF Segment Design Example Exercise

Index

List of Figures

Figure1-1 Digital control system architecture

Figure1-2a OSI model compared with Fieldbus model

Figure1-2b Fieldbus data transfer packets

Figure1-3 Manchester encoding

Figure1-4 Device description hierarchy

Figure1-4a Analog Input Block (AI)

Figure1-4b Analog Output Block (AO)

Figure1-4c PID Block (PID)

Figure1-5 Fieldbus bridge capability

Figure1-6 Maximum length of Fieldbus network

Figure1-7 Fieldbus network with repeaters

Figure1-8a Physical layouts – Single combined segment

Figure1-8b Wiring practices – Cable efficiency

Figure1-9 F OUNDATION Fieldbus node addresses

Figure1-10a Function block scheduling and macrocycle

Figure1-10b LAS algorithm

Figure1-11 SCADA layer Fieldbus traffic management

Figure1-12 Radar level gauge

Figure1-13 Valve signature with best fit line

Figure1-14 Field device interface communications

Figure1-15 FDI Flow Device and Host

Figure1-16 Device Package showing documents to be updated

Figure2-1 Short circuit protection sizing

Figure2-2 Spur overcurrent failure indication

Figure2-3 Fieldbus connector blocks

Figure2-4 Fieldbus wiring with conventional terminal blocks

Figure2-5 Terminator inside junction box

Figure2-6 Termination guidelines

Figure2-7 HSE profile functional areas

Figure2-8 Ethernet wiring

Figure2-9 Wiring H1 devices to a linking device

Figure2-10 Integrated fieldbus system

Figure2-11 Continuity of ground

Figure2-12 Plant ground and instrument ground

Figure2-13 Cable shield grounding

Figure2-14 Recommended fieldbus grounding

Figure2-15 High frequency capacitive ground

Figure2-16 Equipotential bond

Figure2-17 Segregation of cable classes

Figure2-18 Segregating cables in trays

Figure2-19 General cable installation guideline

Figure3-1 Protective systems incendive limits

Figure3-2 Typical FISCO network

Figure3-3 FISCO calculation for area classification IIC

Figure3-4 FISCO calculation for area classification IIB

Figure3-5 FISCO repeater wiring to field

Figure3-6 Typical fieldbus power conditioner

Figure3-7 Typical fieldbus barrier installation

Figure3-8 High-energy trunk calculation

Figure3-9 Typical spark behavior

Figure3-10 DART extinguished spark

Figure3-11 Power supply selection

Figure4-1 Network diagram with repeater

Figure4-2 Fieldbus data sheet: individual device

Figure4-3 Fieldbus data sheet for multiple devices

Figure4-4 Digital communication signal symbols

Figure4-5 Multivariable Device Representation on P&ID

Figure5-1 Fieldbus VCR communications

Figure5-2 Host configuration screen

Figure5-3 Loop configuration

Figure5-4 Multiple loop function block scheduling

Figure5-5 Segment bandwidth calculation

Figure5-6 Typical fieldbus architecture

Figure5-7 Fieldbus Foundation Network with control in the field

Figure5-8 Macrocycle – control in valve

Figure5-9 Fieldbus Foundation Network with control in the DCS

Figure5-10 Macrocycle – control in host

Figure5-11 Control in output device

Figure5-12 Control in input and output device

Figure5-13 Control in Host

Figure5-14 Control in the DCS – when there are delays

Figure6-1 H1 network analysis tools

Figure6-2 Electrical cable test meters

Figure6-3 Reel of Fieldbus cable

Figure6-4 Correct H1 packet waveform

Figure6-5 Change in base frequency and amplitude

Figure6-6 Effects of inductive components on waveform

Figure6-7 Complete signal distortion

Figure6-8 Check sheet

Figure6-9 Correct transmitter installation

Figure6-10 Correct installation of Fieldbus junction boxes

Figure6-11 Field device grounding error

Figure6-12 Cable cross-section exceeds 40% of conduit area

Figure6-13 Failure to maintain required mechanical separation

Figure6-14 Coiled signal cables

Figure6-15 Corrosion caused by liquid entry

Figure6-16 Corrosion in a junction box

Figure6-17 Excess cable length

Figure6-18 Two installation errors

Figure6-19 Device display on first connection

Figure7-1 MTL diagnostic system

Figure7-2 P+F on-line diagnostics solution

Figure7-3 Turck on-line diagnostic solution

Figure7-4 R. Stahl diagnostic module

Figure7-5 PID Function Block internal functions

Figure8-1 Emerson handheld communicator

Figure8-2 Beamex Fieldbus calibrator

Figure8-3 Fieldbus signal jitter

Figure9-1 SIS (Safety Instrumented System) user layer extensions. .

Figure9-2 Example SIS application analog 2 out of 3 voter

Figure9-3 Device Mapping Diagram (Channel Mapping of other Protocols to FF Flexible Function Block)

Figure9-4 National Instruments USB H1 modem

FigureE-1 Simplified P&ID of a distillation tower

FigureE-2 Fieldbus system design – plot plan

FigureE-3 Instrument location drawing

FigureE-4 Fieldbus system design – area classification

FigureE-5 Junction box location drawing

FigureE-6 Instrument Segment Drawing 01-Seg-1

FigureE-7 Instrument Segment Drawing 01-Seg-2

FigureE-8 Instrument Segment Drawing 01-Seg-3

FigureE-9 Segment 1 macrocycle calculation

List of Tables

Table 1-1 Fieldbus Function Blocks

Table 2-1 Fieldbus cable characteristics

Table 2-2 Cable type specifications

Table 2-3 HSE class summary

Table 3-1 Characteristics of network-energized devices

Table 3-2 Networks’ power supply requirements

Table 3-3 Equipment classification guide

Table 3-4 Default function block information for all designs

Table 3-5 FISCO parameters

Table 3-6 Characteristics of FISCO and FNICL networks

Table 4-1 System decision analysis

Table 4-2 Network decision analysis

Table 4-3 Device criticality decision matrix

Table 4-4 Connector decision analysis

Table 4-5 FISCO installation

Table 4-6 IS/NIS installation

Table 4-7 Configuration worksheet/checklist

Table 5-1 VCR types and their uses

Table 5-2 Configuring a network for safety vs. availability

Table 5-3 Fieldbus operating mode priorities

Table 5-4 Fieldbus alarm levels

Table 5-5 Macrocycle requirements for different configurations . . .

Table 6-1 Examples of identifying signal and block type

Table 7-1 IF communication errors

Table 8-1 Instrument Index

Table 8-2 Device characteristics summary

Ian Verhappen, P. Eng., CAP

B.Sc. Environmental Science and B.Sc. Chemical Engineering

Certificate in Oil Sands Technology

FF Certified Professional and Certified FF Instructor

ISA Certified Specialist in Analytical Technology

ISA Certified Automation Professional

Ian Verhappen is an ISA Fellow and a Professional Engineer, and is Director of Industrial Automation Networks Inc., a global consulting firm focused on Making Industrial Networks Easy. Prior to starting Industrial Automation Networks, Verhappen worked as the Director of Industrial Networks for Measurement Technology Limited (MTL) where he was responsible for their global digital communications product line. He has been working in the automation industry since 1987 and has been actively involved in FOUNDATION Fieldbus technology since 1995, when he led the first Host Interoperability demonstration project at Syncrude Canada Ltd., where he worked for 20 years.

Verhappen is an acknowledged expert in FOUNDATION Fieldbus technology and is an active member of the global standards community. He has authored numerous technical papers on Fieldbus and is a regular columnist for several industry trade journals including Manufacturing Automation, Industrial Networking, Offshore, and Process West. He is co-author with Augusto Pereira of ISA’s popular book Foundation Fieldbus. Verhappen also wrote the chapters on Industrial Networking for the 4th Edition of the Instrument Engineer’s Handbook, published by Taylor and Francis Group, and the Fieldbus chapter for ISA’s book, A Guide to the Automation Body of Knowledge.

He has been the keynote speaker at numerous conferences around the globe, where he has shared his knowledge of industrial networking and field level networks. Verhappen is also an FF Certified instructor and the developer of the FOUNDATION Fieldbus Certified courses at the Southern Alberta (Canada) Institute of Technology (FF Certified Training Center) as well as an instructor in IDC Technology’s on-line diploma program.

In addition to serving as chairman of the Western Canada End User Council, Verhappen was chairman of the Fieldbus Foundation Global End User Advisory Council from 2002 to 2006, reporting directly to the Board of Directors twice per year and in the process helping set the direction of Fieldbus technology. Under his guidance, the End User Advisory Council prepared the Engineering Design Guide, FOUNDATION Fieldbus Document AG-181 for which he was the editor. AG-181, now in Revision 2, has been translated into German, Japanese, Chinese, and Russian and is widely used as the basis for many corporate and project Fieldbus specifications.

Verhappen has been active on a number of Fieldbus specifications committees, including being an outside expert reviewer for the Safety Fieldbus Committee and Program Manager of the HSE Remote I/O development team. Verhappen is a past Vice-President Standards & Practices, a Managing Director on ISA’s Standards & Practices Board, Chair of ISA-103 (FDT), and is past Vice-President Strategic Planning for ISA. He is the 2011–2012 Director of the ISA Communications Division. In addition, he is the Canadian Chair of IEC 65E, 65B and the TC65 Committee as well as a participating member of Canada’s IEC 65A and 65C and ISO TC1 WG7 subcommittees.

In addition to his expertise in industrial network technology, Verhappen is also a trained HAZOP and Risk Assessment facilitator, having conducted such investigations for several billion-dollar projects.

Verhappen has served as project lead, engineer/designer or external review consultant for a number of companies in industries around the world, including pulp and paper, mining, food processing, water and wastewater, oil sands processing, petrochemicals, and refining.

Augusto Pereira, Eng.