1. Optimized Hazard Protection
StoneL
Optimized Hazard Protection

2. StoneL’s Overall Focus
Enabling you to cut installation costs and improve operating performance by effectively implementing bus networking and optimized hazard protection

3. New Field Wiring Architecture
Bus Networking
Save up to 40% using bus networking vs conventional
Optimized Hazard Protection
Save Up to an Additional 25% Using Tray Cabling Concepts
Stress the value proposition of “flex wiring” concept that will enhance installation cost savings of an additional 15% over fieldbus installation savings. This is to “wet the whistle” for our role out in May-June and training in Aug & Oct.
I look at it in 3 stages:
VCT – build the best mouse trap – eventually our competitors have similar product to offer
FL – move “up stream” with StoneL manufacturered product – we begin to separate ourselves from some switch companies but now have other competitors
Conceptual selling – moving into a consultant type role and explain how to further take advantage of digital technology beyond hardwire (I.e. flew wiring). Still requires some hardware, but this type of selling is more difficult to copy then equipment selling.

4. Bus Network Savings Reduced Installation Cost Less Space Required
Easier Commissioning
Greater Flexibility

5. Hazard Protection Savings
Further Reduce Installation Costs
Safer System
Easier Maintenance
Increased Flexibility

6. Total Savings Up to 65%

7. FieldLink “Enables” You to Realize Savings
Full Array of Process Networking Products
Compliance to Tray Cabling & Traditional Hazard Protection
Certified Integrator Network

8. Optimized Hazard Protection for Process Networking

9. What We’ll Cover Process Area Classifications & NEMA Ratings
Protection Concepts for Bus Networking in Hazardous areas
StoneL Component Compatibility with each Protection Concept
Other Wiring Considerations
Optimal Implementation of Protection Concepts can Dramatically Cut Costs and Improve Operating Safety!

10. NEMA Ratings; (National Electrical Manufacturers Association)
Most Significant Ratings
NEMA 4 - Waterproof
NEMA 4X - Waterproof & Corrosion Proof
NEMA 6 - Temporary Submersibility
NEMA 7 – Class I (Obsolete)
NEMA 9 – Class II (Obsolete)

11. Hazardous Area Ratings

12. Other Hazardous Area Considerations
Temperature Classes
Define maximum surface temperature of Field Device; Gases may ignite due to thermal conditions
Gas Ignition Temperature
T Classes
700
Ammonia 630
Methane 595
Hydrogen 560
Propane 470
Ethylene 425
Butane 365
600
500
T ºC
400
300
T ºC
Cyclohexane 259
Diethyl Ether 170
Carbon Disulphide 100
200
T ºC
Note: T ambient = 40 ºC
T ºC
100
T ºC
T ºC

13. Area Classification Example
Tank Vents
Area Classification for a fixed-roof tank venting a heavier than air vapor
Div 1
Div 2
Bund wall

14. Hazardous Area Ratings

15. Wiring Systems Used in North America
Typically Greater Use of Hazard Protection To Assure Greater Safety
All Areas
Hazardous Areas

16. Hazardous Area Approvals
Manufacturers May Use Ratings on Labels Even Though Non Third Party Approved
Third Party Approval Agencies; Equipment must be Tested by Third Party to NEC Standard to have Logo on Label:
- FM (Factory Mutual, US Market)
- UL (Underwriters Labs, US Market)
- ULc (UL for Canada & US Markets)
- CSA (Canadian Standards Association)

17. Protection Concept Considerations
Explosion Proof
Explosion Proof w Nonincendive Equipment
Tray Cable w Nonincendive Equipment
Tray Cable w Nonincendive Field Wiring
Intrinsically Safe

18. Area Classification Compatibility

19. Explosion Proofing Basic Concept
Contain ignition inside Conduit System and Enclosures
Cool Gases to Prevent Ignition Outside of Containment Vessels
Advantages
Well Understood in North America
Unlimited Power for Instrumentation/Bus Circuits
Disadvantages
Deterioration in Conduit and/or Housing can Degrade Protection
Enclosures May not be Opened with Circuits Energized
Bulky Conduit and Enclosures are Expensive, Space Consuming and Inflexible

20. Bus Network (Division 1 and 2)
Field Enclosures
Explosion Proof
Seal Fittings
Purging an Alternative
Connections
Explosion Proof Approved Fittings Only (No quick connectors)
Field Wiring
Rigid Conduit with 5 full threads of engagement
Metal Clad or Mineral Insulated Metal Sheathed Where Flexibility Needed
Field Instrument Components
Seal offs May be Needed

21. Bus Network (Division 1 and 2)
Hazardous Area

22. Seal Offs
Must be sealed with potting after wires are pulled through seal off and conduits
Wadding is stuffed on each side and a compound poured in top conduit opening
Can be difficult to make a good seal in the field

23. Network Economic Analysis
Conventional AS-I FF *
Computer I/O; Master/Gateway $ $ $
Conduit, Cable Tray, Wiring & Fittings $ 1,600 $ $
Valve Monitor/VCT with Pneumatic Valve $ $ $
Switched Protected Drop Connector NA $ $
Installation & Commissioning Labor $ $ $
Power Supply $ $ $
Total Installed Cost $ 2,940 $ 1, $ 2,020
* FOUNDATION Fieldbus is not directly comparable. Analog instruments may require less adder over conventional 4 to 20 Ma instruments making this system cost effective when combining analog and discrete field instruments on the same segment. Functionality for FOUNDATION Fieldbus devices is also significantly greater, offering increased diagnostic and operational capabilities.

24. StoneL Components
Junction Module (JM)
Quartz VCTs
Wire (In Conduit)

25. with Nonincendive Equipment
Basic Concept
Used as part of an Explosion Proof System in Division 2 Areas
Enclosures must be rated at least NEMA 4 or 4X and Contain Electrical Apparatus which has no Arcs or Sparks (solid state) or Arcs are Contained within an Hermetically Sealed Chamber
Surface Temperatures of Components will not exceed T ratings
Advantages
Lower Cost Enclosures
Less Space Consumed
Enclosures May be Opened with Circuits Energized
No Seal Offs are Required
Non-Metallic Enclosures Acceptable
Substantial Electric Power for Instrumentation
Disadvantages
Circuits have Electric Shock Hazard (May not be manipulated while energized)
Division 2 Areas Only

26. Network (Division 2 Only)
Field Enclosures
- General Purpose with Nonincendive Components
- No Seal Offs Required
- May Open Enclosure with Circuits Energized
Field Wiring
Threaded Rigid Metal Conduit
MI and MC cable with Ex Termination Fittings
Liquidtight where Flexibility Required
Flexible Cord listed for Extra Hard Usage with listed Bushed Fittings
Connections
- Approved Ex Fittings
Quick Connectors with Special Provisions 1. Power is removed before plugging & unplugging and 2. Current does not exceed 3 120VAC and 3. Cord is listed for hard usage with locking and grounding plug type and Label is attached to receptacle warning against plugging and unplugging while circuit energized
Field Instrument Components
Current Interrupting Contacts must Be Hermetically Sealed
Nonarcing (solid state) Components Must Limit Temperature to Less than 80% of Gas Ignition Temperature

27. Network (Division 2 Only)
Hazardous Area

28. Network Economic Analysis
Conventional AS-I FF *
Computer I/O; Master/Gateway $ $ $
Conduit, Cable Tray, Wiring & Fittings $ 1,400 $ $
Valve Monitor/VCT with Pneumatic Valve $ $ $ 1,025
Switched Protected Drop Connector NA $ $
Installation & Commissioning Labor $ $ $
Power Supply $ $ $
Total Installed Cost $ 2,435 $ 1, $ 1,915
* FOUNDATION Fieldbus is not directly comparable. Analog instruments may require less adder over conventional 4 to 20 Ma instruments making this system cost effective when combining analog and discrete field instruments on the same segment. Functionality for FOUNDATION Fieldbus devices is also significantly greater, offering increased diagnostic and operational capabilities.

29. StoneL Components FieldRack PowerSupplies
JM, FieldBlock, Quartz, Onyx, Eclipse ECN, VCTs
Hawkeye with I/O VCTs Wire (In Conduit)

30. & Special Considerations
Unlimited Power Ideal for Large Strings of On/Off Devices Using Conventional Low Power Solenoids
Use Any “Fieldbus” Protocol
Use Heavy Enough Wire (18 Gage or Less) to Pull Through Conduit

31. Tray Cable Wiring with Nonincendive Equipment
Basic Concept
Limited Power to Circuit of less than 100 Watts to Minimize Ignition & Shock Hazard (PLTC) or Current Limited from 3 to 5 Amps with maximum of 150 VAC (ITC)
Utilize Special Cabling (PLTC or ITC) in Cable trays or with General Support Structures
Advantages
Significant Power for Bus Networks
Low Cost Wiring and Instrumentation Enclosures
Limited Shock and Ignition Hazard (Class 2 Circuits)
Suitable for all Fieldbus Protocols
Disadvantages
Little Knowledge of PLTC or ITC Wiring Concepts
Suitable for Division 2 Only

32. Network (Division 2 Only)
Hazardous Area

33. Network (Division 2 Only)
Field Enclosures
Same as NIE
Field Wiring
ITC (Instrument Tray Cable) Used with Power limited to 150 Volts and 5 Amps
PLTC (Power Limited Tray Cable) Used with Max of 100 watts & 60 Volts (Class 2 Approved Power Supply)
Used in cable tray systems
Must have 2in. Separation or Mechanical Barrier from Higher Power Circuits
Both may be Used as Open Wiring Mechanically Protected by Angles, Struts or other Mechanical Means or Supported by Messenger Wire
Both may be Used as Open Wiring where Cable Complies with Metal Clad or Follows Div 2 Ex Wiring Rules (Liquidtight etc.)
Connections
Approved Ex Fittings
Quick Connectors with Special Provisions
Compression Fittings Installed to Avoid Stress at the Cable Terminations
Field Instrument Components

34. Network Economic Analysis
Conventional AS-I FF *
Computer I/O; Master/Gateway $ $ $
Conduit, Cable Tray, Wiring & Fittings $ $ $
Valve Monitor/VCT with Pneumatic Valve $ $ $ 1,025
Switched Protected Drop Connector NA $ $
Installation & Commissioning Labor $ $ $
Power Supply $ $ $
Total Installed Cost $ 1,685 $ $ 1,625
* FOUNDATION Fieldbus is not directly comparable. Analog instruments may require less adder over conventional 4 to 20 Ma instruments making this system cost effective when combining analog and discrete field instruments on the same segment. Functionality for FOUNDATION Fieldbus devices is also significantly greater, offering increased diagnostic and operational capabilities.

35. StoneL Components FieldRack Power Supplies (Class 2 approved) JM
FieldBlock
Quartz, Onyx, Eclipse ECN
Hawkeye with I/O VCTs
Wire (ITC and PLTC rated)

36. Special Network Considerations
Any Protocol may be Used with Tray Cable Concepts in Hazardous Areas
Restrict Wire Gage to Larger than 20 AWG

37. Tray Cable with Nonincendive Field Wiring Drops & Associated Apparatus
Basic Concept
Utilize Tray Cable for Trunk
Utilize NIW for Drop Leg and Field Instruments
NIW is not Capable Under Normal Operation of Igniting Gas or Dusts (Normal operation includes opening, shorting or grounding the field wiring)
Advantages
Significant Power to Bus Trunk & Adequate Power to Each Device 30 VDC)
Low Cost Wiring and Instrumentation Enclosures (General Purpose Wiring from Protected Drop Connector)
Very Limited Shock and Ignition Hazard (No shock hazard at field instrument)
May work on Field Instruments with Circuits Energized
Disadvantages
Little Knowledge of Tray Cabling and NIW Concepts
Limited Availability of Appropriate Protected Drop Connectors and Field Instruments (May use IS approved instruments)
Suitable for Division 2 Only

38. Network (Division 2 Only)
Field Enclosures
Trunk: Same as NIE
Drop Leg: General Purpose Equipment
Field Wiring
Trunk: Use Tray Cabling Wiring Concepts
Drop Leg: Use nonincendive field wiring concepts which allow general purpose wiring (Cable capacitance and inductance is negligible for 20 gauge and larger up to 300 meters)
Connections
Trunk: -Approved Ex Fittings
- Quick Connectors with Special Provision
-Compression Fittings Installed to Avoid Stress at the Cable Terminations Field Instruments
Drop Leg: - Protected Drop Connector Limits Power to Field Instrument (Associated Apparatus)
(Max voltage & current determined by ignition parameters for atmosphere; Short circuit
current at max possible operating voltage may not cause ignition)
- Quick Connectors may be used without limitation
Field Instrument Components
Trunk Components rated as nonincendive equipment
Drop Connectors rated as nonincendive equipment with drop leg current and voltage limiting
Drop Connector and Field Instrument Parameters must coordinate as follows:
Drop Connector Field Instrument
Voc < Vmax
Isc < I max
Field Instrument (Associated Apparatus) limited Capacitance & Inductance (IS devices may
be used as nonincendive field wiring associated apparatus.

39. Network (Division 2 Only)
Hazardous Area

40. Network Economic Analysis
Conventional AS-I FF *
Computer I/O; Master/Gateway $ $ $
Barriers $ $ $
Conduit, Cable Tray, Wiring & Fittings $ $ $
Valve Monitor/VCT with Pneumatic Valve $ $ $
Voltage & Current Limiting Drop Connector** $ 0 $ $
Installation & Commissioning Labor $ $ $
Power Supply $ $ $
Total Installed Cost $ 1,545 $ $ 1,320
*FOUNDATION Fieldbus is not directly comparable. Analog instruments may require less adder over conventional 4 to 20 Ma instruments making this system cost effective when combining analog and discrete field instruments on the same segment. Functionality for FOUNDATION Fieldbus devices is also significantly greater, offering increased diagnostic and operational capabilities.
** Drop connector acts as a barrier for nonincendive drops

41. StoneL Components May use IS Field Devices Hazardous Area Trunk
- FieldRack
- Power Supplies (Class 2 Approved)
- Wire ( ITC and PLTC rated)
Drop Connectors Being Submitted as NIW Power limiting
Field Instruments Currently Being Approved

42. Special Network Considerations
AS-interface, Foundation Fieldbus H1 and Profibus PA are compatible
Concept should be applied rigorously (Components should be approved for IS or Nonincendive field wiring apparatus and protected drop connectors coordinated properly)

43. Intrinsically Safe Circuits
Basic Concept
Prevents Ignition of Gases
No Ignition Under Normal or Abnormal Circumstances
Limit Electrical Energy Input and Energy Storage
Provide Over Voltage and Short Circuit Protection
Advantages
Low Cost Wiring and Instrumentation Enclosures
No Shock Hazard
Instruments May be Serviced While Hot
Disadvantages
Limited Power Delivery Holding Maximum Number of Devices per String to 4 or 5
Use of Barriers Drops Available Voltage to Instruments
Communication Protocols Limited to Those with Physical Layer (FF H1 and Profibus PA)
Ignition Source
Explosion
Triangle
Oxidizer
Flammable Mixture

44. Devices Simple Devices Do not Require Approvals
Must not generate nor store more than 1.2V, 0.1A, .25mW (Examples: RTDs, TCs, LEDs, Diodes)
IS Apparatus
- Require Approvals
- Given “Entity Parameters” ( Examples: Transmitters, Positioners, Solenoid Valves)

45. Bus Network (Divisions 1 & 2)
Field Enclosures
NEMA 4 or 4X
General Purpose
Field Wiring
General Purpose Cabling
IS Barriers to Limit Voltage & Current under Fault Conditions
Cable Capacitance Must be Evaluated
Connections
General Purpose Connections Apply (Quick Connectors may be used without Limitation)
Field Instrument Components
Must be IS Approved or Simple
Hazardous Area

46. Bus Network (Divisions 1 & 2)
Utilize Entity Concept
- Entity Parameters of Barrier and Field Devices Must Match
- Cable Inductance & Capacitance Considered Concentrated and Must Be Considered
Barriers Typically Limited to 60mA & 1.2W for Hydrogen; Restricting Number of Field Device OR
Utilize FISCO Model (Fieldbus Intrinsically Safe Concept)
- Device Entity Parameters for Inductance & Capacitance Minimize
- Cable Inductance & Capacitance not Considered Concentrated so not Added to Calculations
- Barriers Typically Limited to 100mA & 1.8W; Hydrogen Enabling Use of More Field Devices

47. Entity Concept Example
Tag Vmax Imax Pmax Ci Li Inom
V mA W µF mH mA T T T
Cable
Voc Isc Pm Ca La Inom
Barrier
Required
Selected
Barrier T1 T2 T3
Hazardous Area

48. Entity Concept Example
Repeater/Barrier Selected Delivers 11 Volts Nominal
Cabling 2  /100m meters X 2  /100m =10
Voltage Drop (Worst Case) A X 10  = 0.58Volts
Minimum Voltage Available V – 0.6V =10.4 V > 9V OK!

49. FISCO Model Example Tag Vmax Imax Pmax Inom V mA W mA T1 24 250 2 16
Voc Isc Po Inom
Barrier
Required
Barrier (Repeater)
Selected
Barrier T1 T2 T3 T4
Hazardous Area

50. FISCO Model Example
Field Devices & Barrier must be Approved per FISCO (Can use FISCO approved with Entity Concept; Entity Approvals not Used with FISCO)
FISCO Field Devices: Ci < .005µF Li < .01mH
FISCO Cable Parameters: R loop  to 150 /km L to 1mH/km C to .2 µF/km
Overall Length Max of 1km with Max Spur Length 30m
Min, Voltage Available: 13V – (10X.078) = 12.2V > 9V

51. Multiple Barrier/Repeater on Same H1 Segment
Single Host and LAS controls several spurs
Single Power Supply
Barrier/Repeaters Enhance Signal and Provide IS Protection
Field Devices Matched to Individual Barrier/Repeaters
Hazardous Area

52. Bus Network Protocols
Use Physical Layer (FF H1 or Profibus PA)
May use FISCO devices with Entity Concept but not Entity Approved Devices with FISCO

53. Network Economic Analysis
Conventional FF
Computer I/O; Master/Gateway $ $ 50
Barriers $ $ 190
Conduit, Cable Tray, Wiring & Fittings $ $ 220
Valve Monitor/VCT with Pneumatic Valve $ 415* $ 850*
Protected Drop Connector $ $ 70
Installaton & Commissioning Labor $ $ 150
Power Supply $ $ 30
Total Installed Cost $1,545 $1,670
* Analog instruments may require less adder over conventional 4 to 20 Ma instruments making this system cost effective when combining analog and discrete field instruments on the same segment. Functionality for FOUNDATION Fieldbus devices is also significantly greater, offering increased diagnostic and operational capabilities.

54. StoneL Components Passive Drop Connectors
Protected Drop Connectors Approvals in Process (FieldBlock & JM)
FF Eclipse & Dual Module Approvals in Process (Quartz, Onyx, SolaR)
FF I/O Modules Approvals in Process
Hawkeye with I/O Module Approvals in Process

55. Other Considerations (All Areas)
AS-Interface and DeviceNet flat cabling not desirable for Use in Process Areas
When Using Auxiliary Power Cables with Communication Cabling, Care must be Taken to Prevent Mutual Inductance
DeviceNet Transmission (Layer 0) Specifies the Exact Cabling to be Used with this Protocol.
Use Different Cable with Protocols Using Different Physical Layers!!

56. Protocol Length Limitations
Length of Network Determined by
- Signal Attenuation and/or Reflections (Given by Protocol Spec.)
and Voltage Drop
Protocol Standard Length Voltage Levels
AS-Interface 100m to 31.6VDC
DeviceNet 500m 11 to 25VDC
Foundation Fieldbus 1900m 9 to 32VDC
Modbus Voltage Supplied Separately and May be Device Specific

57. Networks – Voltage Drop Issues
Voltage at Field Device: Power Supply Voltage
less Cable Voltage Drop less Drop Connectors
Example: V (Supply) x V (Trunk Cable) - 1V (Protected Drop Connector) x V (Drop) = 28.1V at Device VCT8
Acceptable Voltage Range 26.5 to 31.6V
Voltage = Current x Resistance

58. Product Reference/Protocols

59. Product Reference/Protocols

60. Enclosure Guide

61. Enclosure Guide

62. Optimized Hazard Protection
StoneL
Optimized Hazard Protection