Download 4 (1.25Mb) - Fieldbus Foundation

1 

Fieldbus Foundation – India Marketing Committee 

Fieldbus Foundation 

End Users Council Conference-2009 

The Reliance JERP Project 

Concept to Installation 

Author 

John Eva 

Invensys Operations Management 

2009 FFIEUC-Mumbai Conference 

© 2009 Fieldbus Foundation

2 

A “Fieldbus Foundation” Refinery – Part One 

Concept to Installation 

� Best Practices for a 

successful FF Project 

– To deal with a massive 

number of segments and 

devices 

– To plan for use of technology 

firsts 



3 

Reliance JERP Project 

One of the Largest FF Projects in the World 

� Over 3,600 FF segments 

– Over 2000 redundant FF interface cards 

� More than 18 types of instruments from over 10 vendors 

– Pressure, Temp, pH, Conductivity transmitters 

– Temp Multiplexers 

– Valve Positioner & MOV Actuators 

– Vortex 

– Coriolis 

– Magmeters 

– Radar Level 

– Loop Indicators 

– Diagnostic modules 



4 

Best Practice Principles 

� Choose devices & technology early 

� Establish sizing rules and guidelines 

� Team based interoperability testing of solutions 

software 



5 

Incorporation of Technology Firsts 

� Invensys Field Device Management System 

– First to combine DD, Enhanced DD, and FDT DTM technology 

– Advanced templating of each type of file device 

– Used to commission and diagnose devices on startup 

– Custom DD displays and DTMs for diagnosing devices 

throughout the plant lifecycle 

� New MTL F809F Physical Layer Diagnostic Module 

– Provided 9th H1 channel for diagnostic status 

– Transducer blocks capture data such as average and peak 

noise, failure to respond to pass token 

� Emerson AMS Device Manager with new Router DTM 

– For DVC6000 digital valve controllers 

– Used to provide ValveLink in combination with the Invensys 

Field Device Manager 



6 

The Value of Interoperability Testing 

� Device focused US lab 

– Every device, DD, DTM, physical 

layer diagnostic module, and field 

barrier was validated 

– Early discovery of a few minor 

device issues 

– Created initial templates for device 

usage 

� Application focused Mumbai lab 

– Focused on project specific usage 

of each device type 

– Customized and validated project 

specific templates 



7 

Any Device Interoperability Issues? 

� Very Few 

– Application teams learned how to best apply each device 

through joint cooperation of the development interoperability lab 

and the project specific resources in Mumbai 

– Several devices did not include enumeration of help strings for 

channel selection – a minor inconvenience 

– One device had initialization issues related to fault state and 

power fail recovery – vendor made firmware corrections 

� interoperability testing paid off in few on-site issues 



8 

Interoperability Testing of 

New Technologies 

� MTL 809F Diagnostic Module 

– Joint MTL & Invensys testing in Foxboro Interoperability Lab 

– Validated firmware early - beta level 

– Validated retransmission error tests – introduced simulated 

noise 

– Established best practices on alarm limits and setup of User 

Interface in Field Device Manager 

� Emerson Router DTM Testing 

– Joint Emerson & Invensys testing in Foxboro Interoperability lab 

– Ran complete ValveLink feature tests - valve signatures, partial 

stroke testing 

– Established minimum revision guidelines for all components in 

the solution 



9 

UpFront Training 

� With EPC and Application Engineers 

� Helped establish sizing approaches 

� Increased knowledge of FF principles 

� Got everyone working as a team 



10 

Segment Sizing 

� Project specific guides & typicals saved time and 

increased project efficiency 

– Established simple rules via H1 segment checker for trunk 

lengths, spur lengths, max device quantities 

– Invensys provided a tool to estimate Pub/sub & Client/Server 

H1 loading. Used to establish loop load guidelines 

– Loop criticality rules used to create typical loop patterns for 

device allocation to segments 

� High powered trunk concept made sizing simpler 

– Max of 12 devices on 3 Field Barriers for any segment 

– Short spur lengths kept power sizing simple 



11 

Assigned Loops Based on Analysis of Criticality 



12 

Example Guide for Fast Level 1 Criticality Loops 



13 

Device to Segment Assignments 

� EPC created spreadsheet capture tool for device 

assignments on each segment 

– Loop criticality, Device Tag, Macrocycle, etc. 

� Jointly reviewed and validated by Invensys 



14 

Templates for Field Device Management 

� Typical device applications can be proven up front 

� Custom configuration of device maintenance displays 

– Organize diagnostic data – even with traditional DD files 

� Customize configuration entry screens for ease of use 

� Builds parameter download lists for each device 

– parameters set by host vs. parameters uploaded from devices 



15 

The Value of Inheritance 

� Enter values once in the master 

– each tag instance automatically follows the setting 

� Lock settings 

– unlocked values can be uploaded from the device as manufactured 

– Used to automatically propagate corrections / changes to all 

existing device instances 



16 

A Wizard Can Reduce Commissioning & 

Device Replacement Time 

� Assures device tags and 

system management 

parameters are set correctly 

� Automatically synchronizes 

the device and system 

databases - using download 

rules established in the 

template 

� Used to restore device 

databases after firmware 

upgrade 



17 

Were There Any Problems ? 

� The project had very few problems 

– Preparation and planning paid off 

– Some minor device issues were encountered 

� When minor problems did occur, team cooperation was 

the key to speedy resolution 

– Reliance system engineers 

– System vendor development engineers, service engineers, 

application engineers 

– Device vendor 

– Interoperability lab &Mumbai application lab served to 

reproduce any issues 



18 

Lessons Learned 

� A major project with fieldbus technology goes smoothly 

with upfront planning and teamwork 

� Choose devices early – do adequate device and 

application testing early in the engineering phases 



19 

Questions 

& 

Thank You!

Download 4 (1.25Mb) - Fieldbus Foundation

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?