SPECIFICATIONFOR FOUNDATION Fieldbus (FF) System BI-3751 MAINTAIN GAS COMPRESSION CAPACITY ABQAIQ PLANTS TABLE OF CONTENTS 1.0 INTRODUCTION 1.1 General 1.2 Scope of Work 1.3 Saudi Aramco Standards and this Specification 1.4 Fisher-Rosemount Instrument Use 1.5 Fieldbus Design Process 2.0 DEFINITIONS 3.0 APPLICABLE DOCUMENTS 3.1 Saudi Aramco Materials Systems Specifications 3.2 Saudi Aramco Standard Drawings 3.3 Industry Standards 3.4 Company Standards and manuals 4.0 SEGMENT DESIGN 4.1 Basic Segment Loading Requirements 4.2 Segment Executions Times 4.3 Requirements for PID Control in the Field Device 4.4 Final Element Configured Fail State 4.5 Risk Area and Segment Segregation 5.0 WIRING DESIGN 5.1 Segment Topology 5.2 Distance Constraints 5.3 Spurs 5.4 Cable Types 5.5 Field Junction Boxes 5.6 Wiring Polarity 5.7 Field Wiring Technique 5.8 Fieldbus Power Consumption 5.9 Voltage Drop 5.10 Shielding 5.11 Grounding 6.0 FIELDBUS DEVICES 6.1 Fieldbus Device Minimum Requirements 6.2 The Fisher-Rosemount H1 Smart Carrier shall not be used. 7.0 NON-DEVICE ELEMENT SECTION 7.1 Foundation Fieldbus Power Supplies (FFPS) 7.2 Terminators 7.3 Bulk Power Supplies (BPS) 7.4 Repeater 8.0 CONFIGURATION 8.1 Configuration Guidelines: 8.2 Block Naming 8.3 System Controller and Control Module Naming 9 DOCUMENTATION 9.1 Piping & Instrumentation Diagrams (P&ID’s) 9.2 Instrument Segment Diagrams 9.3 Instrument Specification Sheets (ISS) 10.0 FACTORY ACCEPTANCE TEST (FAT) 11.0 SITE ACCEPTANCE TEST (sat) 12.0 INSTALLATION AND CHECKOUT 13.0 MAINTENANCE SHOP FIELDBUS SYSTEM & TOOLS 14.0 FIELDBUS SPARE PARTS & DELTAV REVISION LEVEL UPDATE PROGRAM 15.0 BENCHMARKING 3 3 3 3 3 3 4 4 4 4 4 4 5 5 5 6 6 7 7 7 9 9 9 10 10 10 11 11 12 12 12 12 12 12 12 13 13 13 13 13 14 14 14 14 15 15 15 16 16 16 17 18 1.0 1.1 INTRODUCTION General This engineering specification covers the minimum requirements for the design TM and installation of an H1 FOUNDATION Fieldbus system based on the 31.25 kbits/s physical layer per ISA S50.02. 1.2 Scope of Work This specification defines the requirement for design, specification, installation, configuration, commissioning and maintenance for a FOUNDATION™ Fieldbus based control systems. As such, this specification is for use by both the LSTK contractor and Control System Vendor. This specification will only discuss the voltage mode (parallel coupling) medium attachment unit, as defined in ISA S50.02, operating at a signal speed of 31.25 kilobits per second (i.e. H1). 1.3 Saudi Aramco Standards and this Specification The FOUNDATION Fieldbus system shall adhere to all existing Saudi Aramco Engineering Standards (SAES) and Specifications (SAMSS), except as defined in this document. The term ‘Saudi Aramco’ within this document shall be defined as “Saudi Aramco PMT, Proponent, and Process Control Systems Division (PCSD)”. 1.4 Fisher-Rosemount Instrument Use Fisher-Rosemount instruments shall be used for all instruments on this project (measurements and final elements), including non-smart conventional 4-20mA, 4-20mA/HART, and Foundation Fieldbus instruments. The Vendor/LSTK shall obtain Saudi Aramco approval for any non-Fisher-Rosemount instrument used for this project. The Fisher-Rosemount H1 Smart Carrier shall not be used. 1.5 Fieldbus Design Process Commentary: The fieldbus system design process will be somewhat different than that for a traditional Distributed Control System (DCS). Tasks associated with DCS implementation; such as instrument selection, instrument placement, junction box design, etc. are commonly completed independently of each other. This is not the case, however, for the design of a fieldbus based system. Since many traditional control functions can reside in fieldbus instruments, design considerations traditionally associated with the DCS must now expand to incorporate field instrumentation. A typical fieldbus segment consists of the following components, reference Figure 1: • • • H1 FFPS BPS Foundation Fieldbus Interface Card Foundation Fieldbus Power Supply Bulk Power Supply (24 Vdc) • • T - Terminator Fieldbus devices, (e.g. transmitters, transducers, etc.) H1 FFPS BPS T T Figure 1 – Fieldbus Segment Components 2.0 DEFINITIONS All definitions of Fieldbus terms and acronyms used in this document can be found at the Foundation website www.fieldbus.org. 3.0 APPLICABLE DOCUMENTS Since this document defines requirements for the complete FOUNDATION Fieldbus system, it includes aspects of control and types of field instrumentation. For this reason, all Saudi Aramco Instrumentation standards and specifications are applicable. The LSTK/Vendor shall comply with the latest issue of these documents. 3.1 Saudi Aramco Materials Systems Specifications All 3.2 All 34-SAMSS Specifications Saudi Aramco Standard Drawings All All SAES-J Standards 3.3 Industry Standards ISA S50.02 Fieldbus Standard for Use in Industrial Control Systems, Part 2: Physical Layer Specification and Service Definition FOUNDATION Layer Profile TM FF-816 Specification 31.25 kbits/s Physical 3.4 Company Standards and manuals Saudi Aramco Drafting Manuals, Volumes I & II 4.0 4.1 SEGMENT DESIGN Basic Segment Loading Requirements Commentary: Prior to defining Fieldbus segments, the process control strategy should be complete, the P&IDs available, and instruments selected with locations determined. 4.1.1 4.1.2 Redundant H1 Interface cards shall be used for all segments. Segments shall contain 8 or fewer devices unless approved in writing by the Saudi Aramco representative. Exception: For segments containing monitor only devices, up to 12 devices may be connected to one (1) segment. Monitor only device does not participate in any control function. 4.1.3 Segments shall contain no more than 2 final elements (e.g. control valve, MOV, AOV, damper actuators,), unless approved in writing by the Saudi Aramco representative. Commentary: While the H1 segment might be able to support six or more control loops, other factors, such as number of function blocks, scan rates, risk assessment, etc. present limitations which dictates fewer. 4.1.4 The ‘primary’ LAS shall reside in the host controller card and the ‘backup’ LAS shall reside in a monitoring only (i.e. not used for control) fieldbus device or a dedicated LAS device. Each segment shall have an enabled backup LAS. Redundant process measurements shall be on separate H1 segments. Segments shall be designed for 25% spare capacity, i.e. FFPS supply current and function block capacity. Calculation of 25% spare current capacity shall include one spur fault condition of 50mA additional load, reference Fieldbus Power Consumption Section. Commentary: One DeltaV H1 interface card (port 1 and 2) is limited to 64 function blocks. 4.1.5 4.1.6 4.2 4.2.1 Segment Executions Times The number of devices per segment, for the following required execution times, shall be as follows: • • • • For segments with monitor only measurements, limit segment to 12 devices. For loops requiring 1-second execution time, limit segment to 8 devices. For loops requiring 0.5-second execution time, limit segment to 4 - 8 devices. For loops requiring 0.25-second execution time, limit segment to ≤ 3 devices with a maximum of one (1) final control element. Commentary: Function block execution frequencies must be compatible with both system loading and process control objectives. The execution frequency of all function blocks contained within a single fieldbus segment is defined by that segment’s macrocycle time. This macrocycle time, which can typically range from 250ms to several seconds (depending on the nature of the device used), is configured for each fieldbus segment. The order of execution is automatically determined based on the connections between function blocks on the fieldbus segment. If a faster control loop is added to a segment containing slower loops, then the macrocycle times of all devices residing on the segment must be adjusted to accommodate it. Some care should be exercised as the segment can become overloaded. The number of function blocks residing on a single H1 card's segment must be taken into account. Each H1 card has two segments (ports) and the card is limited to a total of 64 function blocks. The limitation in the number of function blocks per H1 card is based on the number of function blocks that are actually configured in the devices, not on the number of function blocks that are available in the devices. 4.3 4.3.1 Requirements for PID Control in the Field Device Simple/Single Loop PID Control in the Segment For simple/single PID control in the field device, all function blocks that make up that control loop must reside on the same segment. When all function blocks of a simple/single PID control loop cannot reside on the same segment, the PID control shall reside in the host system. When simple/single loop PID control is implemented in the field device, the PID function block shall be located in the final control element. Commentary: Both the valve and transmitter typically have a PID block available, so locating the PID block in one device over another device is not a trivial issue. There are a number of reasons that the PID block may be located in the valve or in a transmitter. Execution speed, advanced diagnostics, failure mode, and operator access are a few of the factors to be considered when locating where the PID block resides. As with conventional control systems, loop, and device failure modes need to be determined and the proper course of fail action identified for each control loop. 4.3.2 Cascade Control The preferred cascade control configuration is to locate all function blocks and devices on the same segment. For PID control in the field for this case, the primary PID controller may reside in the primary measurement transmitter and secondary PID controllers may reside in the secondary final element. If the primary and secondary loops have devices and function blocks on separate segments, the primary PID control shall reside in the DCS. In this case, the secondary loop PID control may reside in the secondary final element, if all secondary loop function blocks and devices reside on the same segment. 4.4 Final Element Configured Fail State All final control elements shall have a configured fail-state on loss of segment communication. Commentary: The valve has two different fail states depending on failure mode: 1) configured fail state 2) mechanical fail-state. For example, on loss of communication, the valve can be configured to hold last position. Loss of communication can be caused by: • • • H1 card failure, if a backup LAS is not used. Accidental removal of terminator Loss of input signal to the valve (i.e. AI function block). The valve will go to its mechanical fail-state position (i.e. spring return position) on loss of power. Loss of power can be caused by: • • • • 4.5 4.5.1 4.5.2 Broken wire Shorted wire Failed power conditioner Loss of DC supply voltage to power conditioner Risk Area and I/O Grouping Segregation The FOUNDATION Fieldbus segment design shall follow the risk area and I/O grouping philosophy as defined by this project and by BI-3712 and BI-3731. Grouping of instrumentation devices and function blocks on the Fieldbus segments shall be such that a failure of one segment shall not affect more than one I/O group. Risk Area I/O group assignments and the associated segment loading is subject to approval by Saudi Aramco. 4.5.3 5.0 5.1 WIRING DESIGN Segment Topology The fieldbus installation shall use the ‘tree’, ‘spur’, or ‘combination’ topology as shown in Figure 2. Do not use the daisy chain topology. Commentary: Components of fieldbus segments can be connected together in various architectures known as topologies. The topology selected is usually driven by the physical plant location of the devices in order to reduce installation costs. Hence, plot plans are used in addition to P&ID's and instrument indexes in the design of a fieldbus segment. Most often, after the above design considerations are weighed, the following three topologies are used: (See Figure 2) • A tree topology is used when several related instruments are physically located close to each other. A fieldbus junction box is located close to the instruments with spurs extending from it to each instrument. A spur topology is used when several related instruments are located in the same direction from the host device but not necessarily close to each other. In this case, a trunk line is extended from the host to the • farthest instrument and spurs are extended from it as it runs past each instrument. • A spur/tree topology is used when some combination of the above instrument locales exists. Note that spurs are permitted to extend only from trunk lines and not from other spur lines. The daisy chain topology is not used because devices cannot be added or removed from a segment during operation without disrupting service to other devices. To H1 Card Trunk Spur Junction Box (JB) Tree Topology To H1 Card (JB) (JB) (JB) (JB) Spur Topology To H1 Card (JB) Junction Box Combination Topology To H1 Card Daisy-Chain Topology Do Not Use Figure 2 - Fieldbus Topologies 5.2 Distance Constraints The maximum allowed length of a fieldbus segment is 1900 meters (6232 ft.). This total segment length is computed by adding the length of the main trunk line and all the spurs that extend from it. Therefore, Total Segment Length = Trunk + All Spurs Commentary: The maximum length given is from the ISA S50.02 Fieldbus standard. From field experience we have found these lengths to be conservative. As stated in this specification, the length of a segment is limited by voltage drop and signal quality (i.e. attenuation and distortion). As Saudi Aramco gains field experience these length limits will be revised to reflect real world experience. The Saudi Aramco representative must approve, in writing, the use of a different cable type from the cables specified. 5.3 5.3.1 5.3.2 Spurs Only one (1) FF device shall be connected to each spur. A spur is a drop off of the main trunk line. The trunk is considered to be the main cable run and will contain segment terminators at each end. Refer to Table 1 for the maximum spur length based on the total number of devices on the segment. Commentary: Since we are using the spurguarded (short circuit protection) Megablock the segment design is limited to one (1) device per spur. Total Devices on Segment 1-12 13-14 15-18 1 Device per Spur 394 ft. (120 m) 295 ft. (90 m) 197 ft. (60 m) Table 1 - Recommended Spur Lengths per ISA S50.02 5.4 5.4.1 Cable Types Trunk (Homerun) Cabling Either Type ‘A’ cable (i.e. Belden 3076F) or Aramco’s standard 18 AWG multipair, individually shielded cable for analogue signals, per 34-SAMSS-913, shall be used for all trunk wiring. Twenty five percent (25%) spare pairs shall be provided for all Fieldbus segment trunk cables, with a minimum of one spare pair. This requirement includes spares on trunk cable runs between marshalling racks and junction boxes, and between junction boxes. Commentary: The decision to use multi-pair or single pair trunk cabling depends on the number of segments installed in the field junction box. Typically, the trunk cable will be a multi-pair cable if you have more than one segment in the junction box. Note that under all circumstances, there will be at least 2 Fieldbus trunk pairs run together (one active and one spare minimum). 5.4.2 Spur Cables Type ‘A’ cable (#18 AWG), as defined in ISA S50.02, shall be used for all spur cabling. 5.4.3 Color Coding For all FF cables, spur and trunk, the outer jacket color shall be ‘orange’. For all FF cables, spur and trunk, the conductor color code shall be; (+ signal) ............. black (- signal) .............. white drain/shield.......... bare tinned copper conductor 5.5 Field Junction Boxes All trunk and spur connections in the field junction boxes, including pass through trunk pairs without spurs, shall be terminated on Relcom Megablock terminal blocks. All Megablocks shall have the integral short circuit protector for spur TM connections, (i.e. SpurGuard ). Exception: Inactive spare Fieldbus trunk pairs may be terminated on conventional terminal blocks, per Saudi Aramco standards. Only one Fieldbus device may be connected to each spur. Commentary: Megablocks with integral Spurguard short circuit protectors will prevent a fault (short circuit) in the device or spur cable run from bringing the entire FF segment down. On a fault condition, the maximum current delivered to a spur is ~60 mA. Therefore, for worstcase design where a Fieldbus device consumes 10mA quiescent current, and additional 50mA load is added when this spur is shortcircuited. 5.6 Wiring Polarity Wiring polarity shall be maintained throughout the segment design and installation. Commentary: Wiring polarity is critical because some fieldbus devices are polarity sensitive. Wired with the wrong polarity, a device may shortcircuit the segment or simply not operate. 5.7 Field Wiring Technique The termination at the FF device shall be the same as analogue devices, reference SAES-J-902. No modular wiring components shall be used (i.e. passive multiport junctions (bricks), molded connector cordsets, plug in junction connectors, etc.). 5.8 5.8.1 Fieldbus Power Consumption Fieldbus devices may be powered either from the segment (bus) or locally powered depending on the device design. Bus-powered devices typically require 10-30 mA of current at between 9 and 32 volts. The total current draw from devices on the segment must not exceed the rating of the FFBS – ‘Fieldbus power supply’. The segment design must take into account: A) Total device quiescent current draw. B) One spur short circuit fault (i.e. ~50 mA additional current draw). C) 25% additional current load above A and B above. Note: The acronym ‘FFPS’ will be used in lieu of ‘fieldbus power supply’ throughout this document to avoid confusion between the bulk power supply (BPS) and the ‘fieldbus power supply’. 5.8.2 5.8.3 The number of bus powered (two-wire) devices on a segment is limited by the following factors: • • • • • • • Output voltage of the FFPS. Current consumption of each device. Location of device on the segment, (i.e. voltage drop). Location of the FFPS. Resistance of each section of cable, (i.e. cable ‘type’). Minimum operating voltage of each device. Additional current consumption due to one spur short circuit fault, ~50 mA. Commentary: The length of a fieldbus wiring system and the number of devices on a segment are limited by power distribution, attenuation and signal distortion. The ISA S50.02 estimates how long a fieldbus cable can be and still have adequate signal quality, (i.e. acceptable attenuation and distortion). Calculating power distribution for a segment is relatively simple and can be easily performed. 5.9 5.9.1 Voltage Drop Circuit analysis shall be carried out for each fieldbus segment to determine the operating voltage at each device. The calculated voltage at the device shall exceed the devices minimum voltage rating by 4 volts, (e.g. minimum Vdc required by device = 9 volts, therefore the calculated minimum voltage seen at the device shall be 13 Vdc). The calculated voltage at each device shall be shown on the Instrument Segment Diagram (ISD). Commentary: The additional 4-volts at each device has been specified as a spare power margin for future device additions to the segment. Per the FOUNDATION fieldbus specification, field devices must sense a DC voltage between 9 and 32 volts for proper operation. The power used by fieldbus devices varies by device type and manufacturer. Specific minimum voltage and current requirements are contained in the product specifications for each device. The voltage and current requirement for each device shall be taken into consideration while conducting the circuit analysis of the segment. A Fieldbus Foundation certified device is required to be capable of operating at ≥ 9 Vdc. 5.10 Shielding Fieldbus cable shield terminations shall be as per conventional Saudi Aramco requirements. 5.11 Grounding Field instruments and instrument stands shall be grounded as per conventional Saudi Aramco requirements. 6.0 6.1 FIELDBUS DEVICES Fieldbus Device Minimum Requirements The following shall be the minimum ‘features’ available in all Fieldbus devices: • • • • • Foundation Fieldbus Certification as having passed the Interoperability Test Kit (ITK), revision 4.1. The FF Device and all function blocks shall be tested and certified by the vendor of the control system Host DCS. Function blocks shall be downloadable into the devices by the end user. Capable of performing continuous diagnostics, including self-test functions and be able to give specific diagnostic information at the MMI. All Fieldbus instruments shall have automated software ‘wizards’ to allow easy set-up and calibration from the MMI. 6.2 The Fisher-Rosemount H1 Smart Carrier shall not be used. 7.0 7.1 7.1.1 7.1.2 NON-DEVICE ELEMENT SECTION Foundation Fieldbus Power Supplies (FFPS) FFPSs are required for each fieldbus segment. FFPSs shall be redundant and output current limited. Commentary: If an ordinary power supply were to be used to power the Fieldbus, the power supply would absorb signals on the cable because it would try to maintain a constant voltage level. For this reason, an ordinary power supply has to be conditioned for fieldbus. This is done by putting an inductor between the power supply and the fieldbus wiring. The inductor lets the DC power on the wiring but prevents signals from going into the power supply. In practice, a real inductor is not used but an electronic equivalent. The electronic inductor circuit has the added advantage of limiting the current provided to the segment if the cable is shorted. 7.1.3 FFPS units may be ganged together with common BPS feeds, and common alarms, for efficiency. No more than eight (8) FFPS units may be ‘ganged’ together. The primary BPS shall feed one end of the ganged FFPS’s, and the secondary BPS shall feed the other end of the gang. All ganged FFPS’s shall be associated with the same risk area. Commentary: The Relcom redundant power supply (FFPS) can be ordered with pre-made wiring jumpers. These jumpers are used to efficiently distribute power and to series alarms to multiple (ganged) FFPS units. In this way, a gang of Relcom redundant FFPSs may be fed from a one primary and one secondary BPS feed. 7.1.4 7.1.5 7.2 7.2.1 7.2.2 FFPS’s shall be supplied from redundant feeds from the bulk power supplies (BPS). Each feed from the BPS is to be independently fused. Failure or faults in any of the redundant FFPS shall be annunciated in the Host system. A common alarm for all FFPS’s in a single cabinet may be used. Terminators Each fieldbus segment must have exactly two terminators. The wiring between the two terminators is defined as the trunk. The field terminator shall be installed in the field Junction Box (JB). This terminator shall be installed at the farthest end of the trunk. Commentary: When a signal travels on a cable and encounters a discontinuity, such as a wire open or short, it produces a reflection. The portion of the signal that echoes from the discontinuity travels in the opposite direction. The reflection is a form of noise that distorts the signal. A terminator is used to prevent a reflection at the ends of a fieldbus cable. A fieldbus terminator consists of a 1µF capacitor in series with a 100 Ω resistor. Some of the wiring components previously discussed may have terminators built into them, (e.g. FFPS). These terminators may be permanently installed, turned on or off using a dipswitch, or placed into use by a wiring jumper. 7.3 7.3.1 7.3.2 7.4 Bulk Power Supplies (BPS) The bulk power supply feeding the FFPSs shall be from the DCS redundant power distribution panels specified in BE-391623. Overcurrent protection shall be provided for each feed supplying power to an individual or gang of FFPS’s. Repeater Repeater’s shall not be used. 8.0 8.1 8.1.1 CONFIGURATION Configuration Guidelines: The LSTK/Control System Vendor shall create a guideline control philosophy for the DeltaV control system. The guideline shall define all typical control modules, complete with configured function blocks and all parameters defined. This guideline shall set function block and control module philosophy for this and future projects using the DeltaV and Fieldbus control system. The configuration guideline shall be reviewed and approved by Saudi Aramco. 8.1.2 As part of the guideline, a narrative shall be provided for each typical function block and control module, to describe in detail the setting of parameter and the subsequent blocks/module operation. Included shall be narrative discussion on parameter configuration and operation for signal ‘status’, bad value determination, failure mode switching, Initialization feature, anti-reset windup feature, etc. Block Naming Each function block shall use the standard DeltaV naming convention, which is the field device tag name for its main descriptive name and a 'suffix' defining the function or block type for which it is defined, (e.g. FT5010_AI, FT5010_AO, etc.). In the event a device has more than one identical function block, they shall be uniquely identified with a sequential numeral, e.g. FT5010_AI_1 , FT5010_AI_2, etc. System Controller and Control Module Naming Each DeltaV controller and control module will be named based on a reasonable and consistent format developed by the LSTK/Vendor. The naming convention shall be applicable to this and all future projects. Saudi Aramco shall approve the naming convention. 8.2 8.2.1 8.2.2 8.3 8.3.1 9 DOCUMENTATION Foundation Fieldbus system design requires the same documentation as conventional control system designs. The documentation requirements shall be per the DCS specification (BE-391623). However, some documents must be altered for Foundation Fieldbus architecture. Documentation alterations, additions, and deletions required for FF use are defined below. 9.1 9.1.1 Piping & Instrumentation Diagrams (P&ID’s) The fieldbus instrumentation shall be shown on the P&ID per Saudi Aramco standards with the following exceptions: • Fieldbus instrument balloons shall be conventional, with the addition of a Foundation Fieldbus indication on the top right side of the instrument bubble, shown as: FF The line symbology for FF signal wiring shall be shown as a double dash with an open bubble “- - o - - o - - o - -“ The control or logic function balloons shall be shown independent of the hardware in which it is contained. • • 9.1.2 All functions within the same field device shall be tagged with the same number, with individual function lettering appropriate for the application. Commentary: For example using a multi-variable Coriolis meter, the instrument tagging would be FT-1010, DT-1010, and TT-1010 for flow, density and temperature, respectively. 9.1.3 9.2 Multivariable Fieldbus transmitters (e.g. multiple process measurements from the same transmitter) shall be represented with connected instrument balloons. Instrument Segment Diagrams The Instrument Loop Diagram (ILD) shall be replaced with an Instrument Segment Diagram (ISD). The ISD is a hardware-wiring diagram intended to show the physical connections and layout of the segment. Soft data including display, function block, and configuration data shall not be shown. In addition to standard loop drawing information, ISDs shall include the following FF system details: • The title block shall contain the ‘segment name’. The segment name shall consist of the “Controller Name, Card Number and Port Number”. For example if the Controller name is ‘01’, card number is ‘08’ and we are using Port 1, the segment name will be ISD-010801. All segment connections inclusive of the H1 interface card, BPS, FFPS, through the field devices, terminations, junction boxes, and terminators. All segment and field device tagging. All spur cables shall be labelled with the instrument tag number. All cable distances with voltage drop calculation results. Risk area and I/O grouping. The Backup LAS device shall be identified. Terminator locations shall be clearly identified. Refer to Appendix ‘A’ for the required segment-drawing format. • • • • • • • • 9.3 Instrument Specification Sheets (ISS) For FOUNDATION Fieldbus instrumentation the standard Saudi Aramco ISS’s shall be used with the following line item additions: • • • • • • • LAS capable (yes/no) Minimum Operating Voltage (Vdc) Quiescent Current Draw (mA) Polarity Sensitive Termination (yes/no) DD revision level Channel number and Description, (e.g. Channel 1 - Sensor 1, Channel 2 - Body Temperature, Channel 3 - Sensor 2, etc.). Function Blocks Available, (e.g. AI_1, AI_2, PID_1, etc.) 10.0 FACTORY ACCEPTANCE TEST (FAT) 10.1 Vendor shall develop a separate written test plan and test procedure for the FOUNDATION Fieldbus FAT. 10.2 Factory acceptance test shall be per the DCS specification (BE-391623) with the following additions for FOUNDATION Fieldbus: 10.2.1 A complete functional test shall be conducted for one of each FF device used on this project (i.e. third-party and F-R products). This test will include, but is not limited to, plug-and-play interconnectivity to Host system; verify access to all device function blocks, and actual device operation, (e.g. stroke valves/MOV’s, simulate process inputs for transmitters, etc.). 10.2.2 The test shall include a calibration and setup for each type of FF device. Examples are changing RTD sensor types, calibrating transmitter span, zeroing P & DP transmitters, zeroing elevation on DP level transmitters, setup & calibration of new positioner on a control valve, MOV setup, AOV setup, etc. The intent of this requirement is to verify the ease of access to calibration wizards and setup procedures via the Host system. 10.2.3 All calibration and setup procedures, for each device, shall be documented in detail by the Vendor and approved by Saudi Aramco. 10.2.4 Vendor shall develop a redundancy fail-over test procedure for the H1 interface cards and Fieldbus power supplies. The test shall verify that automatic fail over shall not cause an upset, (i.e. I/O signal bumps, loss of operator view, mode changes, etc.). All H1 interface cards and FFPS shall be tested. Saudi Aramco shall approve the test procedures. 10.2.5 Each segment (port), including spares, shall be operationally tested by live connection of at least one Fieldbus device. The Fieldbus device shall be connected to the terminal block designated for the field wiring or system cable. 11.0 SITE ACCEPTANCE TEST (SAT) 11.1 The SAT test shall contain the same scope as covered in the FAT. 12.0 INSTALLATION AND CHECKOUT 12.1 The LSTK/Vendor shall develop a separate installation and checkout procedure for the field FF system. This procedure shall be approved in writing by Saudi Aramco. 13.0 MAINTENANCE SHOP FIELDBUS SYSTEM & TOOLS 13.1 The LSTK/Vendor shall supply and install a complete DeltaV Fieldbus maintenance system in the Abqaiq Plants maintenance shop(s) specified. The intent of this system is to allow Fieldbus instrument troubleshooting, calibration, and setup in the Instrument Maintenance shops. The Maintenance DeltaV Fieldbus system will include all system hardware, software, and auxiliary equipment required to connect and maintain Fieldbus devices in the shop. Equipment shall include but not be limited to a DeltaV control system with dual Operator/Engineering workstations will complete software, control network with appropriate switches, DeltaV chassis with controller & power supply, redundant H1 cards, Bulk and FOUNDATION Fieldbus power supply (FFPS), and Relcom 8 spur Megablocks with Spurguards. The Megablocks shall be externally mounted and easily accessible to maintenance technicians. All workstations will be mounted in appropriate 13.2 ‘shop-proof’ furniture. The DeltaV chassis, power supplies, wiring and terminal blocks will be pre-wired and installed in an easy to access, caster mounted cabinet. 13.3 Vendor shall supply, as required, all standard and special tools, test software, and test and calibration equipment required for the DeltaV Fieldbus system. Vendor shall provide a list of the above tools, test and calibration equipment to Saudi Aramco and LSTK Contractor for review and approval. Standard equipment includes items available from standard catalogs. The list of the standard tools and testing and calibration equipment required shall state the following: • • • 13.5 13.6 Description of its service or simulation application Manufacturer and Catalog No Quantity recommended. 13.4 Vendor shall provide design and performance specifications for all special tools, test software, and test and calibration equipment. The Fieldbus tools provided shall include, but not be limited to, three Fluke 123 industrial scope meters, and three each Relcom FBT3, FBT4, and FBT5 Fieldbus testers. 14.0 FIELDBUS SPARE PARTS & DELTAV REVISION LEVEL UPDATE PROGRAM 14.1 The LSTK/Vendor shall develop a Fieldbus device spare parts management program for Saudi Aramco. This program shall provide management of: • • • 14.2 Stocking a sufficient quantity of Fieldbus spare instruments and associated software. Management, tracking, and update of Fieldbus spare instruments revision levels. Stocking a sufficient number of Fieldbus non-device element hardware. The LSTK/Vendor shall develop and put in place an update program that assures the DeltaV system revision level stays current. Commentary: The DeltaV must be kept current to assure it will work with new Fieldbus instrument revisions. A current revision level DeltaV is also backwards compatible with older Fieldbus instrument revisions. While they look exactly the same, Fieldbus instruments are completely different from, and not replaceable by, conventional instruments. Thus, spare Fieldbus and conventional instruments must be kept segregated and identified differently. In addition, Fieldbus instruments may have associated software that must be stored with it. For these reasons, a complete Fieldbus instrument spare parts management program must be developed. 15.0 BENCHMARKING 15.1 The LSTK/Control System Vendor shall ‘Benchmark’ the project cost implementation differences between PROVOX, DeltaV Classic, and DeltaV FOUNDATION Fieldbus control systems used on this project. The Benchmark will be used to define actual savings attributable to the use of DeltaV ‘Classic’ over PROVOX, and separately, DeltaV Fieldbus over DeltaV Classic. The Benchmarking data provided by the LSTK/Control System Vendor shall quantify the total project costs expended, and where applicable, man-hours expended. In addition, the different technology affects on project schedule shall be recorded. Costs shall be averaged on a per point basis, separated by AI, AO, DI, DO, PID Loop, etc. point types. To obtain representative average costs, all point types for a particular technology (PROVOX, DeltaV Classic, DeltaV Fieldbus) shall be averaged to obtain the per point cost. All data shall be in spreadsheet and graphic format. The data will be provided with a complete descriptive report describing the data and its significance. To provide resolution in where cost differences occur, the benchmarking shall show cost and manpower data in the follow project activities: Design: • • • • • • • • • • • • • • • • Segment diagram versus loop drawing generation. Control configuration man-hours and costs Total documentation man-hours and costs. Total design schedule. Marshalling and DCS footprint. Field Instrument only cost. Complete control system – minus field instrument- cost. Complete control system costs. Shop Instrument calibration check and positioner setup. Wiring + termination manpower costs and schedule. Homerun only costs. OPC to auxiliary system versus conventional Modbus. Loop check. Device configuration download. Instrument example problems & resolution. Manpower and Cost savings in F-R versus 3 Party checkout/commissioning. rd 15.2 15.3 15.4 15.5 Hardware Costs: Installation Costs: Checkout & Commissioning ---- o ------ END ------ o ------