2 Wei Hua Installation and Commissioning

基金会现场总线Foundation Fieldbus

魏华WEI HUA

中海石油化学股份有限公司China Blue Chemical Ltd.

—— 安装与调试—Installation and commissioning

概述 /Brief introduction 我不是 Ff 专家，没有高深的理论基础I'm not a Ff expert, and don’t have deep theoretical knowledge

我也不是产品销售人员，虽然讲述的案例中有某些产品有关I am not a sales man, although some products are mentioned in the presentation

工作生涯中使用过气动仪表、电动仪表、 DCS 、 DCS+HART 、 FfI used Pneumatic/ Electrical instrument, DCS 、 DCS+HART 、 Ff in my career

全程参与了 4 套基金会现场总线项目的设计、安装、调试及维护工作Full participation in 4 Ff projects, including design, installation, commissioning and maintenance

安装和调试案例全部来自于工程实践Cases mentioned in the presentation all come from engineering practice

演讲提纲 /AGENDA

1

基金会现场总线的安装Foundation fieldbus installation

2

基金会现场总线调试Foundation Fieldbus commissioning

3安装案例分析Case analysis of on-site installation

基金会现场总线安装指南Foundation Fieldbus Installation Guide

严格区分信号地（ Signal grounding ）和保护地（ Protection grounding ），信号地按照小于 1.5Ω 标准Strict distinction between the Signal grounding and Protection grounding, Grounding resistance of signal grounding should be less than 1.5Ω

对施工单位单独进行基金会现场总线施工和接线培训，培训的内容可以参考PEPPERL+FUCHS 公司的《 Wiring And Installation Guide For Foundation Fieldbus 》和基金会现场总线的文件《 Fieldbus Foundation 31.25kbit/s Wiring and Installation Guide 》Provide workers with specialized training on installation and wiring, the content of the training can refer to <Wiring And Installation Guide For Foundation Fieldbus> from P+F and <Fieldbus Foundation 31.25kbit/s Wiring and Installation Guide>

严格按照基金会现场总线设计文件进行施工和检查，对于现场电缆长度和总线设备的位置变更都必须得到仪表首席工程师（ Instrument Leader Engineer ）的书面批准Construction and inspection must strictly comply with Foundation Fieldbus design file, the modification of cable length or location of Field device must be approved in writing by the Instrument Lead Engineer

对 Ff 施工管理的三点建议：Three suggestions for Ff construction management:

屏蔽与接地（一）Shielding and grounding （ 1 ）

图 1 机柜硬接地、设备硬接地Direct grounding at both sides

机柜Cabinet

接地 /Ground

屏蔽 /Shield

+-

机柜Cabinet

接地 /Ground

屏蔽 /Shield

+-

图 2 机柜电容接地、设备硬接地Field side is earthed directly and cabinet side capacitively

现场设备 /Field device


屏蔽与接地（二）Shielding and grounding （ 2 ）

图 3 机柜硬接地、设备电容接地Cabinet side is earthed directly and field side capacitively

图 4 机柜单点接地Only cabinet side of the shield is earthed

+

-+-

机柜Cabinet

接地 /Ground

屏蔽 /Shield

机柜Cabinet

接地 /Ground

屏蔽 /Shield



屏蔽与接地（三）Shielding and grounding （ 3 ）

北美安装规范（ North America Specification ）：北美绝大部分的工程设计和安装都按照图 4 所示的接地方式进行设计和施工，这种接地安装方式在传统的 DCS 系统中普遍采用。In North America, most of the projects’ grounding systems are designed as shown in Figure 4, this grounding method is commonly used in traditional DCS.

欧洲安装规范（ Europe Specificaiton ）在欧洲的工程设计和安装一般都要求按照图 3 所示的接地方式进行设计和施工， Ff 接地推荐采用图 3 的方式。In Europe, normally the projects’ grounding systems are designed as shown in Figure 3. For Ff project, this grounding method is recommended.

注意： Ff 现场运行中故障的 80%-90% 都是由于接地或者屏蔽原因导致的！！！Note: 80% -90% of the Ff operation failures are due to bad grounding or shielding! ! !

基金会现场总线电缆FOUNDATION fieldbus cable

型号Type

米 Meters /

英尺 Feet

阻抗 /

Impedance （ Ω

）

分布电阻

率 /

Resistivity

（ ohm/

km ）

信号衰减值 /

Attenuation

（ db/km ）说明 /remark

A 1900/6270 100 22 3互相屏蔽对

Individual shielded pairs

B 1200/3960 100 56 5全屏蔽的多线对

Multiple pairs with

overall shield

C 400/1320 未知 /unknown 132 8无屏蔽的多线对

Multiple pairs with no

shield

D 200/660 未知 /unknown 20 8多导线，非线对

Multi-conductor, no

pairing

IEC 61158-2 对现场总线电缆的要求： Specifications of the fieldbus cable according to IEC 61158-2

基金会现场总线电缆FOUNDATION fieldbus cable

IEC 物理层规定标准的 A 型电缆参数如下表：Typical Ff cable characteristics per IEC Physical Layer Standard

线号 /Wire Size

18

AWG （ 0.88mm2

）

16

AWG （ 1.3mm2

）

14

AWG （ 2.1mm2 ）

屏蔽 /Shield90% 覆盖度 /

coverage

90% 覆盖度 /

coverage

90% 覆盖度 /

coverage

衰减值 /

Attenuation39KHZ 时 3db/km

39KHZ 时 2.7db/

km39KHZ 时 2.7db/km

最大电容 /

Maximum

capacitance150pF/m 150pF/m 150pF/m

特性阻抗 /

Characteristic

impedance

31.25kHz 时为 100Ω+/-20%

100Ω+/-20% at 31.25kHz

基金会现场总线电缆Foundation Fieldbus Cable

双绞线屏蔽Twisted pair

金属箔屏蔽Metal Clad shield

金属箔加编织屏蔽Metal Clad plus braid shield

铠装Armored cable

多对铠装Multi-pair, armored

多对 ( 多线 )Multi-pair

电缆桥架的布置Cable tray layout

Lurgi 公司设计的电缆桥架Cable tray design from Lurqi

F3 ：现场总线电缆桥架F3: For FieldbusI3: 本安信号电缆桥架I3: For IS signalsN3 ：非本安电缆桥架N3: For Non-IS signals

电缆桥架布置建议：Some advices of Cable tray:1 、 Ff 和本安、非本安信号分开Separation between Ff, IS and Non-IS.2 、强电信号和弱电信号分开Separation between Power supply system and Control System3 、桥架间距大于 400mmTray spacing greater than 400mm

现场总线安装费用对比（ Ff ）Comparison of Installation Costs （ Ff ）

定额号File NO.

工程名称Items

单位 /Unit

单位价值（人民币 / 元）total cost per unit

单价合计 /Total

cost per unit

其中 /including

人工费Labor cost

材料费Material cost

机械费Machine cost

10-560Ff 压力 / 差压变送器

Press. /diFferential press. transmitter

台 /piece 1133.56 354.05 49.76 729.75

10-561Ff 温度变送器

Temperature transmitter台 /piece 519.06 206.37 44.59 268.1

10-276气动薄膜调节阀

Pneumatic Diaphragm CV台 /piece 119.68 70.81 5.74 43.13

10-563Ff 气动阀门定位器

Pneumatic valve positioner台 /piece 389.57 99.42 21.2 268.95

10-616Ff 总线电缆铺设（米）

Cable installation100M 102.56 78.09 17.65 6.82

10-622 现场总线电缆头安装终端头个 /piece 14.06 5.33 5.95 2.78

10-564现场总线安全栅

Field barrier个 /piece 19.32 15.28 0.84 3.2

2000 年安装工程预算定额海南省基本价（海南省建设厅）》Basis price, By Department of construction of Hainan Province,2000

现场总线安装费用对比（ HART ）Comparison of Installation Costs （ HART ）

定额号File NO.

工程名称Items

单

位 /

Unit

单位价值（人民币 / 元）total cost per unit

单价合计 /Total

cost per unit

其中 /including

人工费Labor

cost

材料费Material

cost

机械费Machine

cost

10-132智能压力 / 差压变送器

Intelligent pressure transmitter台 336.49 130.47 8.92 197.1

10-121温度变送器

Temperature transmitter台 87.52 56.26 5.15 26.11

10-276气动薄膜调节阀

Pneumatic Diaphragm Control Valve台 119.68 70.81 5.74 43.13

10-291气动阀门定位器

Pneumatic valve positioner台 69.46 43.16 3.13 23.17

2-675控制电缆铺设（ 37 芯内）

Cable installation(<37 cores)100M 190.95 152.53 32.25 6.17

10-682接线箱 / 端子排（ 48 点内）

Junction box/TB (<48 points)个 136.52 86.09 11.55 38.88

10-545过程 I/O 卡件调试（模拟）

IO module(Analog)点 47.24 23.04 0.2 24

2-683 电缆头安装终端头（ 37 芯以下）个 103.29 49.78 53.51

2-680 电缆头安装终端头（ 37 芯以下）个 34.69 13.24 22.08


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基金会现场总线调试需要的条件

序号内容标准1 《基金会现场总线现场验收测试指南》合同各方签字同意2 接地系统已经完成并验收合格权威机构防雷中心检测报告3 工厂验收测试整改内容已经完成提交 FAT 整改报告4 主机系统硬件现场安装结束提交主机系统安装调试报告5 主机系统软件已经安装结束主机系统软件正常运行

6控制系统应用软件下装完毕（流程图、基本控制功能、现场总线设备组态）

提交 Ff 系统组态文件

7 现场总线设备安装结束设备安装单项工程验收报告8 现场总线电缆连接并经过了初步检查电缆安装单项工程验收报告9 软件已经下装到现场设备，并调试合格设备调试单项验收报告

10 仪表空气管网提供合格的仪表空气仪表空气管网投用11 AMS 软 / 硬件调试合格提交 AMS 调试报告12 基金会现场总线高级诊断软件调试合格提交诊断系统调试报告

基金会现场总线调试的重点Main focuses of the Foundation Fieldbus commissioning

Ff 调试内容Ff Main focuses

物理层安装调试 Physical layer component installation

& commissioning

控制功能检查Control function

test

诊断功能测试Diagnostic

function test

控制功能和参数优化Control strategy and

parameter optimization

物理层测试工具Test Equipment

FBT 5FBT 3

475

DM-AM

HD2-DM-A

物理层安装调试Physical Layer Installation and Commissioning

现场总线网段电压（ Segment Voltage ）现场总线网段电流（ Segment Current ）信号幅值（ Signal Level ）噪音幅值（ Noise Level ）抖动（ Jitter ） DC 不平衡（ DC Unbalance ）

1 、可以在主控室诊断电脑完成所有的物理层诊断工作The physical layer diagnosis can be done in CCR.2 、诊断结果可以对物理层设备安装进行全面检查，精度提高The diagnosis conducts a comprehensive inspection of the physical layer components installed3 、效率极大提高，使用移动测试工具可以节约 95% 的时间，采用在线先进诊断工具可以节约 99%的时间A very eFficient way, Reduces commissioning time by up to 95%

以 P+F 公司的现场总线先进诊断工具 HD2-DM-A 为例：Take HD2-DM-A(Advanced Diagnostic Tool for Fieldbus, by P+F)for example:

物理层安装调试Physical Layer Installation and Commissioning

控制功能调试Control Function Test

功能测试：功能测试是对基金会现场总线网段设备的全套功能测试，包括系统即插即用互连性测试、功能块的访问确认测试、控制功能块的功能测试、现场总线设备的运行测试。Functionality Test: This test will include, but is not limited to, plug and play interconnectivity to the Host system, verifying access to all Function Blocks being used in the project, actual device operation.


标定测试：标定测试是通过主机系统无障碍的对现场总线网段设备进行标定和设置，标定测试要求在对现场总线设备进行标定和设置时，不影响现场总线网段其它设备的运行。Calibration Test: The test shall include a calibration and setup for each type of device. The calibration and setup procedures for each device shall be done by Host system and available asset management tools, and it does not aFfect the operation of other device of fieldbus network.


冗余切换测试：冗余切换测试是测试 H1 接口卡和现场总线电源调节器的冗余故障报警、切换测试，确保在故障情况下能够实现冗余设备的无扰动切换。Redundancy Switch-over Test: Where redundant FOUNDATION fieldbus interface cards and/ or power supplies are used, the redundant operation of each component shall be tested. The test shall verify that automatic fail over shall not cause an upset. All FOUNDATION fieldbus interface cards and power supplies shall be tested.

控制功能调试案例Control function commissioning case

1 、试验 PT011224A/B/C 的高选功能和 PID控制功能 Test high selection function and PID function of PT011224A/B/C2 、试验 PT011224A/B/C量程修改和 PV011224 自动标定功能 Test scale modification and automatic calibration of PT011224A/B/C3 、测试电源冗余、接口卡冗余、设备的离线和在线功能、短路保护功能、即插即用功能

Test power redundancy, interface card redundancy, equipment oFfline and online features, short circuit protection, plug-and-play functionality

现场总线的诊断功能Fieldbus diagnosis

04/10/2023

- 物理层监测 Physical Layer :- 自诊断 Diagnostics- 物理层监测 Physical Layer Monitoring- 预测性维护 Predictive Maintenance

智能现场设备 Intelligent Field Devices:- 自诊断功能 Diagnostics- 设备管理功能 Asset Management- 预测性维护 Predictive Maintenance

T

智能主机 Intelligent Host:- 自诊断 Diagnostics- 设备管理功能 Asset Management - 冗余功能 Redundancy- 预测性维护 Predictive Maintenance

现场总线的诊断功能Fieldbus diagnosis

主机诊断功能HOST system

diagnosis

物理层诊断功能Physical layer

diagnosis

现场设备诊断功能

Field device diagnosis

控制功能和参数优化Control strategy and parameter optimization

物理层设备优化Physical layer components optimization

控制功能位置优化Control

Functionality Location

optimization

智能设备的自整定优化Self-tuning

optimization of intelligent devices


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屏蔽与接地故障案例Shielding and Grounding Fault Cases

示波器图形Oscilloscope Display

噪音及抖动异常Noise and Jitter is out of spec

故障描述Fault Description ：阀门 PV015708 在运行过程中经常出现 5% 的跳变，设备在网段上经常显示瞬间离线，然后在线！In normal operation , the signal of PV015708 is always unstable( 5% signal skipping). Equipment status is often displayed for an instant oFfline, then online.

整改后的示波器图形Oscilloscope Display

after corresponding improvement

整改后的噪音及抖动Noise and Jitter after

corresponding improvementShielded cable is not grounded

Earthbar is not grounded

屏蔽与接地故障案例Shielding and Grounding Fault Cases

电缆及终端电阻故障案例Cable and Terminator Fault Case

故障描述Fault Description ：现场总线网段 S060.03 调试过程中发现该网段的现场总线设备通讯不稳定，经常出现通讯故障（ CNF ， CONNECTION STATUS FAILURE ALARM ）导致设备离线。

During the commissioning of the fieldbus segment S060.03 ,field device communication is unstable, and it (CNF, CONNECTION STATUS FAILURE ALARM) often results in the device oFfline.



电缆及终端电阻故障案例Cable and Terminator Fault Case

整改后的示波器图形Oscilloscope Display

after corresponding improvement

整改后的噪音及抖动Noise and Jitter after

corresponding improvement

Not specific Ff cable

Not grounded

Terminator is OFf

接线不当故障案例Bad wiring fault case

故障描述Fault Description ：现场总线网段 41-TFN-3018的现场总线变送器 PT3407经常掉线，导致工艺测量参数失真。 Ff transmitter PT3407 on segment 41-TFN-3018 often shows oFfline, and it resulted in distortion of the process value.



动力电缆信号干扰Power Cable Signal Interference

实际接线情况Actual wiring

信号波形Signal waveform

谢谢Thank you!

With

FfWithout

Ff

Documents

2 Wei Hua Installation and Commissioning