In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 1

Implementing a FOUNDATION™ Fieldbus Project

Part Seven of Eight

Contents

Introduction User Guide – Implementing a FOUNDATION Fieldbus Project

Chapter 1 Introducing the User Guide

1.1 Executive Summary

1.2 Recommended Technical Resources

Chapter 2 Overview of FOUNDATION Fieldbus

Chapter 3 FOUNDATION Fieldbus Project Management – Minimising Project Risk

3.1 Proven Technology

3.2 Project Evaluation

3.3 Training

3.4 Project Partners

3.5 Procedures, Work Processes and Documentation

3.6 Risk Management

3.7 Testing

Chapter 4 FOUNDATION Fieldbus Project Investment

4.1 Project Planning – CAPEX

4.2 Project Engineering and Installation – CAPEX

4.3 Commissioning – CAPEX

4.4 Project Start-Up – CAPEX

4.5 Operations and Maintenance – OPEX

Chapter 5 FOUNDATION Fieldbus Project Design & Engineering

5.1 Host Selection Considerations

5.2 Field Device Selection Considerations

5.3 Segment Component Selection Considerations

5.4 Network/Segment Topology Design Considerations

5.5 Host/Device Interoperability Testing

Chapter 6 FOUNDATION Fieldbus Project Implementation – Conclusion & Checklist

Appendix References/Sources

In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 2

Implementing a FOUNDATION™ Fieldbus Project

Chapter 5: FOUNDATION Fieldbus Project Design &

Engineering

5.1: Host System Selection Considerations The correct selection of the host system for the project is a key element to the

project’s success. The various hosts on the market reflect different levels of

FOUNDATION fieldbus development but should all support EDDL as well as FDT/DTM

technology. The selection of the host supplier is equally as important as the selection

of the system itself as the project team will need to work very closely with the vendors

and suppliers to ensure a smooth-running project.

Since the functionality of FOUNDATION devices is not directly comparable

with conventional devices, a thorough review and comparison of device

data, functionality and specifications is advised in the context of the

proposed FOUNDATION network and the selection of potential hosts and

asset management packages. Consideration will now need to be given

to input and output, control and diagnostics. The selection of the host,

devices, components and asset management package needs to be done

in parallel and with active input and support from suppliers at the initial

stages to minimise compatibility or commissioning issues further down

the line.

The host system should use a manufacturer’s standard hardware,

systems software and firmware that may be configured to meet the

application requirements but does not require modification to the

system operating software to suit individual applications. Any updates

to the standard system operating software should not affect the

operation of the installed system.

The DCS FOUNDATION fieldbus H1 network topology and settings should comply with

recommended FOUNDATION fieldbus practices to enable communication with all

targeted fieldbus devices. The FOUNDATION fieldbus host should have an integrated

“Since the functionality

of FOUNDATION devices

is not directly

comparable with

conventional devices, a

thorough review and

comparison of device

data, functionality and

specifications is advised

in the context of the

proposed FOUNDATION

network and the

selection of potential

hosts and asset

management packages.”

In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 3

configuration tool that allows easy commissioning, set-up, operation and maintenance

of all FOUNDATION fieldbus devices using consistent methods and a common ‘look and

feel’ with conventional configuration, typically from a single host workstation/control

room. The configuration tool should seamlessly and transparently integrate with, and

maintain the master configuration database. Any separate tools, displays or

procedures that are specific for FOUNDATION fieldbus and are different from the

conventional should be avoided.

The host system should be able to automatically identify new fieldbus devices as they

are connected to the network and offer easy to use ‘drag and drop’ commissioning.

Similarly, complex calculations and bus scheduling can often be automatically

generated through an auto-macrocycle and optimisation function.

Asset Management: To gain the full benefits of FOUNDATION fieldbus functionality

during commissioning and lifecycle activities, an integrated instrument health

monitoring (asset management) package is required. The successful integration and

implementation of asset management requires the early definition and development

of operations and maintenance work processes to utilise the diagnostic tools fully. A

single smart device can potentially provide hundreds of different parameters about

the process or instrument to the operator, technician, inspector, engineer or plant

manager according to the system configuration and established monitoring systems.

Spare Capacity: The FOUNDATION fieldbus host system should include a minimum of

20% spare capacity in terms of hardware capacity; spare performance capacity

(communication idle time); spare H1 interfaces/ports; power supplies and redundant

power supplies; and junction boxes at mechanical completion of the initial project.

This spare capacity allows for an element of future system expansion with minimum

implications on system re-design and additional costs. In the event of incorrect

segment risk assessments in the original project, spare capacity may prevent initial

set-up problems.

Redundancy: Depending on the nature of the process and the consequences of device

failure on production or safety, redundancy may be a critical consideration. Project

designers need to consider the provision of the following redundant parts: power

feeds for the bulk power supplies; bulk power supplies to feed the FOUNDATION power

supplies; system controller power supplies; system controllers; FOUNDATION H1

In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 4

interfaces; and FOUNDATION fieldbus power supplies. Spare standard FOUNDATION

devices may also be kept in stock but the effectiveness of this policy may be limited

unless the devices are always of a consistent specification (e.g. utilising the same

function blocks and having PID control residing consistently in either the DCS or in

the device but not a mixture of the two).

Control Room/Workstations: Consideration should be given to the location of the host

or engineering workstation(s) and maintenance workstation(s). Only one engineering

workstation (control room) is required to perform all control and FOUNDATION fieldbus

configuration, database generation and editing. However, since the automation system

uses a single, global configuration database, it is possible to use additional

workstations to access the configuration, database generation and editing functions.

Any additional maintenance workstation(s) should ideally be integrated with the main

engineering workstation. The location of any asset management packages and tools

will depend on the FOUNDATION host used and the function of the packages.

Data Integrity: In order to maintain the integrity of the FOUNDATION fieldbus device

parameters within the master database in the host, external configuration tools such

as handheld communicators and laptops should not be used. Similarly, diagnostic data

within field devices should only be accessed via a fully integrated asset management

package.

Host System Evaluation: Once the system is up and running, the host system should

be evaluated to determine whether the execution times are as published and whether

the segment loading has adversely affected the host’s performance in any way. The

system diagnostics should be assessed for their usefulness and a check on the

implementation of software revisions and device descriptions should be made.

In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 5

5.2: Field Device Selection Considerations When specifying FOUNDATION registered field devices, it is recommended that project

engineers also ensure that the host supplier can verify that all versions of devices are

fully compatible with the host and integrated asset management packages at the

outset. Additional interoperability testing prior to commissioning is time well spent

and may avoid costly trouble-shooting later on in the project.

Function Blocks: FOUNDATION fieldbus devices contain two types of blocks – device

application blocks and configuration blocks. The resource block and transducer block

(which holds the device diagnostic data) are configuration blocks used to configure

devices whereas user-configurable function blocks are built-in, as required, to

configure the application and define the control strategy or functionality.

The Fieldbus Foundation has defined ten standard function blocks, nineteen advanced

function blocks, four additional function blocks, one flexible function block and two

Safety Instrumented Function (SIF) function blocks in its FOUNDATION technology

specifications. However, not all function blocks are suitable, tested and registered, or

even available for all field device types. It is recommended that function block

availability is checked with the device supplier and that compatibility with, and support

by, the host system is confirmed at the outset to avoid possible redesign at a later

stage of the project.

Since the Fieldbus Foundation testing of function blocks does not address the internal

workings, there is scope for the manufacturers to configure the internal operations to

provide competitive advantages. Users need to compare these carefully to select the

optimum solution in terms of their process and macrocycle efficiency requirements,

particularly in application when Control in the Field is implemented.

Device Configuration: Wherever possible, it is recommended that as much of the

device configuration as is feasible is conducted by the device supplier prior to

shipment – in particular any instantiation of the function blocks. Similarly, if device

identifiers, tag names and FOUNDATION fieldbus addresses are configured by the

manufacturer then on-site configuration and potential confusion can be minimised.

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Power: FOUNDATION fieldbus devices are usually powered from the segment/bus. When

selecting devices, consideration must be given to power consumption requirements to

ensure that the segment can sustain the devices otherwise provision for separate

power is required for the high consumption devices. Allowance must also be made for

short-circuit protection and additional test equipment on the segment.

Safety Instrumented Functions: For FOUNDATION Fieldbus for Safety Instrumented

Functions (FF-SIF) applications, the host and devices must support the FF SIF protocol

which has been approved by TÜV to IEC-61508, including diagnostics, to reduce the

potential for undetected dangerous failures to a level acceptable for SIL 3 applications.

5.3: Segment Component Selection Considerations Additional components required to complete a FOUNDATION fieldbus segment include

bulk power supplies, power supplies, power conditioners, terminators, surge

protection, field device couplers, cables, and on-line diagnostic tools. In certain

circumstances, repeaters may be used to extend the segment distance.

The primary issue is that, wherever relevant, components must be Fieldbus Foundation

tested and registered. This applies to power supplies (excluding bulk power supplies),

field device couplers and spur cabling. The specifying of components for a

FOUNDATION fieldbus segment is contingent upon the fact that host system supplier

verifies that they are compatible with their system. Consideration must also be given

to the recommendations relating to cable specifications, grounding and shielding.

When segments are required to be intrinsically safe, the specific recommendations and

methods for installation in hazardous areas should be followed, for example there is a

significant impact on power consumption, the number of devices permitted on a

segment and permitted cable lengths. Installation therefore may include the use of

barriers, power supplies, terminators, high power trunk cabling, devices and

components approved for IS areas.