Invensys Foxboro I/A Series System

Foxboro I/A system

Invensys Operations Management introduced the next major evolution of its Foxboro I/A Series distributed control system. As the core DCS component of the company’s InFusion Enterprise Control System, the latest I/A Series system includes an Intelligent Marshalling solution and high-performance Foxboro Control Software and Simulation software, which reduce total cost of ownership and expand traditional DCS functionality for superior collaboration, execution and visibility across the enterprise.

With traditional control systems, field wiring must be sorted out in a marshalling cabinet before it is connected to the main I/O module terminal strips of the DCS panel. It’s an inflexible approach that often leads to expensive indirect costs. But because the I/A Series Intelligent Marshalling solution features the Universal Fieldbus Module, a per-channel, configurable I/O module that supports a variety of analog and digital signal types, it eliminates the need for marshalling entirely.

Foxboro I/A system
Foxboro I/A system

Foxboro I/A system

Foxboro Control Software

Designed to simplify engineering efforts and improve the user experience, Foxboro Control Software 3.0 embeds the company’s ArchestrA System Platform and Wonderware InTouch HMI within the Foxboro I/A Series system, applying common object technology from process control up to the business system level and out to any third-party system. This allows users to integrate all of their plant devices, systems, databases and software applications. Additionally, enhanced integration with the latest advanced software applications from Invensys, including its mobile workforce management and workflow offerings, provide more systems flexibility, adaptability and responsiveness, helping to drive lower total cost of ownership. By enabling real-time access to critical plant and business data, users are better able to balance competing strategic objectives related to controls, assets, environment & safety and people to optimize their overall business and achieve operational excellence.

The new Foxboro Control Software Simulation 3.0 offering simulates Foxboro Control Software 3.0 applications for rapid, high-quality systems checkout without the need for control hardware. Simulation capabilities include dynamic control of time, alarms and trends using the same configuration files that are used in a live I/A Series DCS. The software also provides an instant interface to the company’s SimSci-Esscor DYNSIM, Foxboro FSIM and Triconex TRISIM dynamic simulation engines, which are used to simulate plant operations, behavior and responses in conjunction with the DCS or simulated DCS.

New I/A Series system

“The new I/A Series system allows users to begin their journey towards real-time business optimization by taking full advantage of their existing automation systems, while preserving their existing investments and lowering their total cost of ownership,” said Rick Morse, vice president, control and safety, Invensys Operations Management. “These latest offerings– Intelligent Marshalling, which significantly improves the approach to system implementation and design, and Foxboro Control Software 3.0, which allows users to integrate their plant systems, databases and software applications– address major phases of system modernization and allow our customers to upgrade at their own pace with minimal disruption. Together they link business processes with production processes, enabling real-time business optimization and creating a fully empowered workforce.”

product management

“Additional marshalling equipment, field and control side wiring, engineering, documentation and inventory can account for as much as 20 percent of the total project cost,” said Thad Frost, director of fieldbus product management, Invensys Operations Management. “Unlike other control offerings on the market today, with Intelligent Marshalling, each channel is software configurable on a per-point basis, with no extra hardware required. All configurations can be done at the workstation, meaning you can securely configure a point from anywhere in the world. It is a simple, elegant solution that eliminates traditional marshalling panels as we know it.”

“Process manufacturing is facing what could be characterized as a perfect storm. The loss of experience as a result of the shifting demographics, the need to operate proactively rather than reactively, the ability to empower knowledge workers with actionable context and more are all new challenges that require changes in our processes and tools,” said Dave Woll, vice president, consulting services, ARC Advisory Group. “With the Foxboro Control Software 3.0 release, Invensys provides component-object technology throughout the Foxboro I/A Series system up to the operations management level. Its open-technology platform transcends disparate systems, providing the unique ability to collaboratively apply best-of-breed solutions, from Invensys or third parties. This level of enterprise-wide integration makes it significantly easier to access

Foxboro I/A system
Foxboro I/A system

Foxboro I/A Series Introduction

The Foxboro® I/A Series® Burner Management application solution is designed to improve plant operations, provide safe, reliable boiler startup, shutdown, and operation of the burners and associated fuel equipment in the most efficient and logical manner. Based on Foxboro’s extensive knowledge and experience in the power industry, this application solution includes the technology and engineering services necessary to maximize plant operating efficiency, safety, and availability.

FUNCTION

The Burner Management System (BMS) is a safety system, which permits the safe startup, operation,
and shutdown of boilers. It interfaces with field devices that are primarily digital (on/off), executes
sequential control logic utilizing flame monitoring devices, pressure switches, flow switches, limit
switches to determine boiler status. Major system functions include:

1. Boiler Purge
2. Master Fuel Trip (MFT) Condition including first out
3. Fuel Tripping including first out
4. Safety Interlocking
5. Flame Detection
6. Grouped initiation of ignition and shutdown
7. Supervise and control mill and/or burner startup and shutdown sequences
8. Alarm abnormal conditions

SYSTEM DESIGN PHILOSOPHY

Invensys’ Foxboro Burner Management Systems are designed to direct the operators through a
sequential procedure for boiler startup, shutdown and handling of abnormal conditions. The BMS
prevents burner startup if proper conditions have not been met and initiates burner shutdown if unsafe
conditions exist.

The BMS design features energize to trip as well as fail safe logic, which is based on the latest NFPA
guidelines. The BMS logic is executed in an independent fault tolerant control processor. This is true
whether the BMS is a separately supplied, stand-alone system, or integrated within a total plant control
and monitoring system.

Invensys’ Burner Management logic implemented within Foxboro’s I/A Series System is applied
by experienced Engineers who understand burner management system requirements. The overall
system design philosophy incorporates “no single point of failure” that would prevent the boiler
from being shut down, either automatically by BMS (MFT) or manually by the operator, or would
cause an inadvertent shutdown of burner equipment, or prevent the boiler from being tripped either
automatically by the BMS Logic or manually by the operator.

All I/A system failure modes are included within the logic design such that loss of any I/A Module or
power to the system is not only alarmed, but designed to provide safe operation.

IMPLEMENTATION

Foxboro’s BMS is implemented within the Intelligent Automation (I/A) Series System.Foxboro’s BMS is implemented within the Intelligent Automation (I/A) Series System.• I/A is a highly reliable and secure system incorporating Fault Tolerant Control (the highest level ofredundancy)• I/O modules that are distributed for burner segregation and reliable field level signal compatibility(reducing the need for interposing relays)• Redundant power distribution (accepting either AC or DC as source power)• Online diagnostics for complete health monitoring of the entire system• Independent trip equipment to comply with codeFoxboro’s BMS utilizes the same field proven I/A Series system components as those applied tocombustion control, turbine control, plant logic, and data acquisition applications. When integratingthe I/A BMS with the rest of the I/A Series plant controls, users quickly see the benefits of plantintegration including:• Common hardware/software• Integrated CRT graphics• Elimination of new system training• Reduced spare parts inventoryFoxboro’s BMS provides continuous safety monitoring for applications ranging from simple, single fuelto complex, multiple fuel, and multiple burner units. Over tens of thousands Megawatts of power aresafely operated by Foxboro’s burner management applications utilizing the I/A Series System. Ourimplementation includes adherence to published guidelines, selecting the most reliable hardwareplatform, the use of only experienced engineers, and thorough support services required for the safestartup, operation, and shutdown of the fuel system.

BENEFITS

• Continuous startup and operational monitoring with safety tripping• Continuous startup and operational monitoring with safety tripping

• Reliability through consistent operation of major equipment using the same type

• Manpower availability and reductions with fewer operating personnel required

• Better maintenance with minimum abuse and misoperation of major equipment

• Improved status monitoring with field faults immediately identified

STANDARD SOLUTION SERVICES

Foxboro engineers who are knowledgeable in power systems engineering and technology are available to provide services on customer projects from inception to completion. Their services include functional design, detail design, software implementation, staging and testing, user training, and startup.

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