FOUNDATION Fieldbus

Factory Acceptance Test and Device Commissioning

Taipei, Taiwan
27th July 2010

System Consultant Honeywell Taiwan

2010 Roadshow Workshop Taipei, Mailiao

Agenda
Factory Acceptance Test. Brief Introduction
Scope of Test. Hardware Commissioning. Functionality Test. Redundancy Host Test. Segment Check Test. Cable Check and Test.

Device Commissioning. Prior to Field Device Commissioning.

Preparation. Field Device Commissioning.

1999 2005 Fieldbus Foundation

Factory Acceptance Test

2008 Roadshow Workshop Singapore, Vietnam

1999 2005 Fieldbus Foundation

Introduction
1. Traditionally, Factory Acceptance Test (FAT) is testing the factory acceptance level of the host system, field devices and subsystems. 2. FAT procedure includes staging test plan, guidelines, specifications and methodology prepared by DCS vendor and client as defined in the project conceptual design and detail engineering documentation. 3. Some of these includes and not limiting to the following: - Fieldbus power requirements. - Fieldbus networks/segments. - Fieldbus communication. - Host (hardware and software) integration. - Loop checks and database verification. - HMI graphics checks. - Fieldbus device inspection (data sheets). - Etc, etc.

1999 2005 Fieldbus Foundation

Scope of Test
1. Appropriate test equipment (calibrated to international standards) for simulation of process variables or to measure output values. 2. In certain cases software simulation is also used for soft loop integrity checks. 3. Other tests includes and not limiting to the following: - Hardware commissioning. - Functionality test. - Calibration check. - Redundancy host switch-over test. - Segment check. - Cable check and test.

1999 2005 Fieldbus Foundation

Hardware Commissioning
1. System hardware audit physical, cable dressing, point to point terminations, fieldbus terminators, tagging, name plates, identification labels, etc. 2. System grounding Host cabinet safety and isolation grounding. 3. System power supply UPS power, 24Vdc. Fieldbus power conditioner. Fieldbus power supply test specification.

FF-831

1999 2005 Fieldbus Foundation

Functionality Test
1. Fieldbus devices plug and play interconnectivity to host systems. Fieldbus device should be self discover on the segment to which it is connected. 2. Commissioning and matching of field devices, download configuration. 3. Verification and testing of device function blocks, actual device operation from the controller or on the wire. 4. Simulation of process inputs using test equipment OR through use of software simulation at the input or output function block.
Trunk
Spur SIM ACT

AI PID
SIM

AO

1999 2005 Fieldbus Foundation

Redundancy Host Test

1. As defined in Project documentation. 2. Test procedure develop by host vendor: Module configuration test, power up and observed diagnostics. Switching test - H1 interface card, alarms and diagnostics. Fieldbus power conditioners hardware failure is communicated to host. Host system alarms in operator stations.

3. Disconnect host, alarms will alert. Fieldbus devices remains visible in segments. No loss of information, signal bumps, etc as per specifications. 4. Repeat for other host. 5. Integration test of host with Controller as defined in project documentation.

FB Power Conditioner

FF-831

1999 2005 Fieldbus Foundation

Segment Check and Test

1. Test procedure develop by host vendor: Matching host and devices DD, EDDL, DTM file revision. Communication check, macro-cycle duration. Noise check, signal Level, voltage level, resistance and capacitance check, no shield short-circuit, backup LAS as per vendor specifications and Foundation recommendation.
Configuration System
FFBUS

FIM4

2. Spare capacity for expansion, observe specification on hosting devices per segment and check bandwidth using Link active scheduler or equivalent.

H1 Network

3. Scope waveform analysis.

Instruments described with DDL, EDDL, DTM

1999 2005 Fieldbus Foundation

Cable Check and Test

1. Test procedure develop jointly by host and cable vendor: Cable insulation test. Cable capacitance test. Cable current limiting test.

2. Before trunk and spur cables are connected to any Fieldbus devices or termination block, cable insulation and capacitance test are required. 3. Follow FF engineering guide AG-181 for installation, commissioning of fieldbus segments, measurements of resistance, capacitance of fieldbus cables.

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1999 2005 Fieldbus Foundation

Fieldbus Devices Commissioning

2008 Roadshow Workshop Singapore, Vietnam

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1999 2005 Fieldbus Foundation

Prior to Field device commissioning

1. Cable continuity, grounding and insulation tests. 2. Segment test, prior to trunk cable and devices connection to spurs. 3. Field devices inspection (cable, physical installation, etc). 4. Field Device coupler. 5. Fieldbus power supply. 6. Field device connection and signal analysis. 7. Device configuration checks.

8. Optional bus monitor capture and scope wave form capture for segment analysis.

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1999 2005 Fieldbus Foundation

Preparation
1. Prior to start with device commissioning, all FF devices shall be loaded with minimum (pre-tagged devices), each device is uniquely identified: 1. Device ID.
- Device vendor identification, model type, etc.

2. Device Name (tag name).

- Set by the user.

3. Device Address
- Unique numeric address on the segment.

2. All devices arrive on site pre-configured, pass the inter-operability test at host testing and qualification center using device vendor DD, EDDL or DTM files. 3. Completed the FAT testing.

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1999 2005 Fieldbus Foundation

Field Device Commissioning.

1. When a new device is added to a Fieldbus segment, its presence is shown in both the host display and the control builder as un-commissioned device. Information default such as tag name, address, model and revision are available. 2. During device commissioning, parameter help information for the device will be added to the system knowledge builder. 3. Device definition file will be read directly into the system library for off-line or on-line configuration.

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1999 2005 Fieldbus Foundation

Field Device Commissioning.

4. Two methods to commission a device. - Match from uncommissioned device to project device. - Match from project device to uncommissioned device. 5. If uncommissioned device were configured using a HH communicator or Manual configuration with the correct tag name and address data, select Match from uncommissioned device to project device. 6. If uncommissioned device contains factory defaults data, select Match from project device to uncommissioned device button to preserve the project device data and change the uncommissioned device data to match it. 7. Bring the device to a commissioned state takes a few minutes.

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1999 2005 Fieldbus Foundation

Thank You

www.fieldbus.org

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1999 2005 Fieldbus Foundation