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DeltaV Power and Grounding.pdf
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About this manual
This manual explains how to design and prepare control-system electrical power and ground networks before installing a DeltaV system. This manual also explains how to protect the DeltaV system from harsh environments before and after system installation. Applying the information in this manual can save you much time and expense by significantly increasing the reliability and availability of the control system and by making the system easier to start up and maintain.The power and grounding practices described in this manual are based on best engineering practices, gleaned from years of experience, and on industry standards. In addition to this manual, you may need other DeltaV and
industry publications to obtain complete information for preparing your site. References to related industry standards appear throughout the manual.
This manual supersedes all previous Emerson manuals with respect to power, grounding, and surge suppression, including the following manuals:
• D800053, Quick Start Guide for DeltaV Power, Grounding, and Surge Suppression
• D800015, Site Preparation and Design for DeltaV Digital Automation Systems
Each edition of this manual is applicable to all DeltaV versions. Therefore, information in previous editions is carried forward to this edition.
This edition includes the following updates to earlier editions:
• Added clarification on the use of Notes, Cautions, and Warnings in this manual.
• Added clarification on the required sizing of DC reference wire to the DCG.
• Added clarification on the use of color in wiring diagrams in this manual.
• Revised Figure 3-28 to add fused terminal blocks.
• Corrected errors in Table 4-1.
• Added Appendix F about wire-color conventions.
Contents
Preface: Read this section first. ..................................................................................... 1
About this manual ............................................................................................................................................................1
Important .........................................................................................................................................................................1
Conventions for wire colors in wiring diagrams.................................................................................................................2
Using this manual.............................................................................................................................................................3
CE statement....................................................................................................................................................................3
Conventions used in this manual ......................................................................................................................................3
Definitions used in this manual ........................................................................................................................................3
General definitions ...................................................................................................................................................3
Power and grounding definitions ..............................................................................................................................4
Introduction................................................................................................ 7
A solid foundation ............................................................................................................................................................7
Best engineering practices .................................................................................................................................................7
Principles of proper site preparation..................................................................................................................................7
DeltaV power and power quality ................................................................. 9
Connecting plant power to DeltaV ...................................................................................................................................9
AC power from a grid.............................................................................................................................................10
DeltaV AC distribution and grounding system .......................................................................................................13
DC distribution system ..........................................................................................................................................14
Floating AC and high-resistance grounded systems typically with marine applications.............................................16
Protection from surges and lightning ..............................................................................................................................19
Power quality..................................................................................................................................................................23
Why clean power? ..................................................................................................................................................23
How to establish and maintain clean power ............................................................................................................27
Isolation to protect from power quality issues .........................................................................................................31
Isolation transformers .....................................................................................................................................................32
Protection from other equipment on AC power grid.......................................................................................................33
Backup/redundancy for higher availability ......................................................................................................................34
Backup power recommendations ............................................................................................................................34
Types of redundancy ..............................................................................................................................................34
DeltaV system cabinets and enclosures ...................................................... 36
Environmental considerations.........................................................................................................................................36
Environmental areas ...............................................................................................................................................36
Dust and corrosive vapor control ............................................................................................................................37
Temperature control...............................................................................................................................................37
Humidity control ...................................................................................................................................................37
Environmental control during transport and storage ...............................................................................................37
Using protective enclosures.....................................................................................................................................37
Industry standards for environmental conditions.....................................................................................................38
DeltaV power quality......................................................................................................................................................39
Filtering and surge suppression ...............................................................................................................................39
AC/DC bulk power supplies...................................................................................................................................39
DeltaV power and grounding schema options and examples ...........................................................................................40
Bulk power supply example designs ........................................................................................................................41
DC/DC bulk power supplies ..................................................................................................................................49
DeltaV DC system power supply (SPS) ..................................................................................................................52
DC power wire size ................................................................................................................................................52
Adjusting system power supply input voltage ..........................................................................................................52
Equalizing supply output voltage with redundancy modules....................................................................................52
DeltaV cabinet and enclosure grounding.........................................................................................................................52
Chassis ground (CG)..............................................................................................................................................56
DC ground (DCG) ................................................................................................................................................56
Shield termination and grounding ..........................................................................................................................57
Supplying additional power to extended I/O carriers...............................................................................................57
Power and grounding for DeltaV CHARMs ...........................................................................................................59
Warning labels................................................................................................................................................................65
Hazardous area design and installation............................................................................................................................65
Qualifications of personnel .....................................................................................................................................66
Control drawings and installation instructions ........................................................................................................66
Zone 1 carrier power and grounding.......................................................................................................................66
Intrinsic safety considerations .................................................................................................................................66
IS CHARMs shield bars .........................................................................................................................................68
Power and grounding for DeltaV Safety Instrumented Systems (SIS)..............................................................................71
Safety Critical SIS component power......................................................................................................................71
Using bulk power supplies in DeltaV SIS systems ...................................................................................................72
Signal wiring.............................................................................................. 82
Selecting cables ...............................................................................................................................................................82
Best signal wiring practices..............................................................................................................................................82
Protecting I/O signals from AC line noise...............................................................................................................83
I/O signal cable runs...............................................................................................................................................86
Low-level I/O signal cable runs through junction boxes ..........................................................................................89
Resistor-capacitor snubbers.....................................................................................................................................89
I/O bus signal wiring ......................................................................................................................................................89
HART wiring.........................................................................................................................................................89
AS-interface wiring.................................................................................................................................................90
DeviceNet wiring ...................................................................................................................................................91
FOUNDATION fieldbus wiring............................................................................................................................93
Profibus DP wiring.................................................................................................................................................93
Ground design for DeltaV......................................................................... 95
Grounding purposes and functions .................................................................................................................................95
Control system ground considerations ............................................................................................................................96
Maintaining ground integrity..........................................................................................................................................96
Grounding a control system effectively............................................................................................................................96
Using existing ground networks......................................................................................................................................98
Types of ground systems.................................................................................................................................................98
Star or single-point ground .....................................................................................................................................98
Mesh star ground network......................................................................................................................................99
Organizing the ground network....................................................................................................................................102
Notes ...................................................................................................................................................................102
Improving the earthing sub-system ...............................................................................................................................103
Resistance, reactance, and impedance....................................................................................................................103
Soil resistivity .......................................................................................................................................................103
Design and installation practices that ensure low impedance .................................................................................105
Ground conductor sizing......................................................................................................................................106
Ground bus construction......................................................................................................................................107
Recommended method of connecting ground cable to a ground bar .....................................................................109
Marking ground components ...............................................................................................................................110
Enclosure grounding.....................................................................................................................................................110
Grounding for CHARMs and remote enclosures ..................................................................................................110
Multi-story Buildings....................................................................................................................................................110
Appendix A Interference and transients............................................................. 114
Static coupling..............................................................................................................................................................114
Voltage differentials ......................................................................................................................................................114
Inductive coupling........................................................................................................................................................115
Appendix B Shield earthing for high-integrity ground systems.......................... 117
Appendix C Earthing and grounding ................................................................ 118
Designing an earth ground system ................................................................................................................................118
Appendix D Earth grounds in water and ice...................................................... 124
Testing an earth ground................................................................................................................................................124
Three-point testing method ..................................................................................................................................124
Two-point testing method....................................................................................................................................126
Slope testing method ............................................................................................................................................126
Annually inspecting an earth ground system .................................................................................................................126
Appendix E Effects of heat and air flow inside an enclosure.............................. 127
General.........................................................................................................................................................................127
Heat impact on mean time between failure (MTBF).....................................................................................................127
Airflow considerations ..................................................................................................................................................128
Heat-related issues ........................................................................................................................................................128
Solutions ......................................................................................................................................................................129
Measuring enclosure hot spots ......................................................................................................................................130
Maintenance considerations..........................................................................................................................................130
Controlling humidity....................................................................................................................................................130
Heating and cooling calculations ..................................................................................................................................131
Cooling calculations to control heat generated within enclosures...........................................................................131
Cooling calculations to control heat transferred into enclosures.............................................................................132
Calculating the effects of a pressurization system...................................................................................................133
Conclusions..................................................................................................................................................................133
Appendix F Wire-color conventions ................................................................. 134
Appendix G Emerson DeltaV control and installation drawings....................... 135
Appendix H Warning labels .............................................................................. 137
Appendix I Power and Grounding Audit Worksheets..................................... 139
Introduction .................................................................................................................................................................139
Purpose.........................................................................................................................................................................139
Intended audience ........................................................................................................................................................139
System audit during fault conditions.............................................................................................................................139
Product data sheets .......................................................................................................................................................139
Required equipment .....................................................................................................................................................139
Definitions ...................................................................................................................................................................140
Comments....................................................................................................................................................................141
Building installation worksheet .....................................................................................................................................141
Cabinet installation worksheet ......................................................................................................................................146
Earthing installation worksheet .....................................................................................................................................156
Appendix J Environmental considerations ....................................................... 161
Electrostatic protection .................................................................................................................................................161
Material sensitivity to static electricity...................................................................................................................161
Electrostatic sources..............................................................................................................................................161
Preventing static electricity buildup ......................................................................................................................162
Using grounding devices.......................................................................................................................................162
Flooding the air with ions.....................................................................................................................................163
Using static shielding containers ...........................................................................................................................163
Handling static-sensitive devices ...........................................................................................................................163
Airborne contaminants size chart ..................................................................................................................................164
Atmospheric dust size chart...........................................................................................................................................165
Mechanical influences on the control environment .......................................................................................................166
Proper installation ................................................................................................................................................167
External protection methods.................................................................................................................................167
Product specifications ...........................................................................................................................................167
Electromagnetic effects .................................................................................................................................................167
Electromagnetic measurement ..............................................................................................................................167
Radio operation in a near field area.......................................................................................................................168
Applicable electromagnetic signal standards ..........................................................................................................168
Reducing EMI levels.............................................................................................................................................168
Determining EMI levels .......................................................................................................................................169
EMI effects on magnetic media.............................................................................................................................169
Corrosive Environments ...............................................................................................................................................170
Corrosion effects on the control system environment ............................................................................................170
Classifying corrosive environments in the presence of sulfides ...............................................................................170
Classifying corrosive environments in the presence of sulfides and chlorides ..........................................................171
General method for identifying the environment ..................................................................................................171
Humidity effects on reactivity results ....................................................................................................................171
Designing to environmental classifications ............................................................................................................172
Dusty environments......................................................................................................................................................173
Minimizing the effects of dust ..............................................................................................................................173
Protecting against dust..........................................................................................................................................173
Modifying the environment..........................................................................................................................................173
Modifying the control system environment...........................................................................................................173
Control room installations....................................................................................................................................174
Production floor and remote installations .............................................................................................................174
Enclosure and room air pressure calculations.........................................................................................................175
Maintaining environmental control systems..........................................................................................................175
Appendix K References ..................................................................................... 177
General reference..........................................................................................................................................................177
Power transmission reference ........................................................................................................................................177
Reference books for personnel and property safety ........................................................................................................177
American standards.......................................................................................................................................................177
The Institute of Electrical and Electronics Engineers Inc. IEEE standards .....................................................................178
Canadian Standards Association standards ....................................................................................................................178
European international standards..................................................................................................................................178
Lightning references......................................................................................................................................................179
US Military Handbook.................................................................................................................................................180Illustrations
Figure 0-1 Using this manual ............................................................................................................................. 3
Figure 2-1 Typical power generation and distribution ...................................................................................... 11
Figure 2-2 Isolated 3-phase system with redundant power................................................................................ 13
Figure 2-3 Isolated single-phase system with redundant power ......................................................................... 14
Figure 2-4 Bussed DC power ........................................................................................................................... 16
Figure 2-5 Three-phase floating power for marine applications ........................................................................ 17
Figure 2-6 EMC immunity zones..................................................................................................................... 20
Figure 2-7 Lightning protection zones.............................................................................................................. 20
Figure 2-8 SPD Grounding for DeltaV ............................................................................................................ 22
Figure 2-9 Isolated CHARM enclosure with SPDs........................................................................................... 23
Figure 2-10 Power distribution decision flowchart ........................................................................................... 28
Figure 3-1Simplex DeltaV bulk power supply .................................................................................................. 42
Figure 3-2 Redundant bulk power for simplex controllers ................................................................................ 44
Figure 3-3 Redundant bulk power simplex controller with surge protection ..................................................... 45
Figure 3-4 Redundant independent bulk power supplies for redundant controllers .......................................... 46
Figure 3-5 Highest integrity and highest availability......................................................................................... 48
Figure 3-6 Simplex plant DC power................................................................................................................. 50
Figure 3-7 Redundant 24 VDC plant power .................................................................................................... 51
Figure 3-8 Simplex S series controller............................................................................................................... 53
Figure 3-9 Redundant S Series Controller ........................................................................................................ 54
Figure 3-10 m-Series with extended carrier power ............................................................................................ 55
Figure 3-11 s-series redundant extended power to left extender ........................................................................ 58
Figure 3-12 S-Series redundant extended power between extender and carriers................................................. 59
Figure 3-13 High-integrity power and grounding for a CHARM enclosure...................................................... 61
Figure 3-14 Highest-integrity power and grounding for a CHARM enclosure.................................................. 62
Figure 3-15 High-integrity CHARM with added shield bus............................................................................. 63
Figure 3-16 CHARMs with DC supply ........................................................................................................... 64
Figure 3-17 IS CHARMs enclosure.................................................................................................................. 68
Figure 3-18 IS with non-IS CHARMs enclosure .............................................................................................. 69
Figure 3-19 IS CHARMs with separate IS shield bus ....................................................................................... 70
Figure 3-20 IS Carrier based IO cards .............................................................................................................. 71
Figure 3-21 SLS redundant power - high integrity with good availability ......................................................... 73
Figure 3-22 SLS redundant power with isolation transformers and surge suppression....................................... 74
Figure 3-23 SLS redundant power - highest integrity with highest availability.................................................. 75
Figure 3-24 SLS Highest integrity and highest availability - surge protection and isolation transformers .......... 76
Figure 3-25 SLS with single feed ...................................................................................................................... 77
Figure 3-26 SLS with redundant independent feeds ......................................................................................... 78
Figure 3-27 CSLS Highest integrity power and grounding with injected power................................................ 79
Figure 3-28 CSLS CHARMs with redundant field power injection.................................................................. 80
Figure 4-1 Proper shield management .............................................................................................................. 85
Figure 4-2 Instrument shielding details ............................................................................................................ 86
Figure 4-3 Three- and four-wire instrument shielding details ........................................................................... 87
Figure 4-4 I.S. instrument shielding details ...................................................................................................... 88
Figure 4-5 AS-i bus grounding and power........................................................................................................ 91
Figure 4-6 DeviceNet power and grounding..................................................................................................... 92
Figure 4-7 Profibus DP power and grounding.................................................................................................. 94
Figure 5-1 Single-point star grounding system.................................................................................................. 99
Figure 5-2 Mesh star ground network ............................................................................................................ 100
Figure 5-3 Hybrid star mesh ground network................................................................................................. 101
Figure 5-4 Separate DeltaV ground ................................................................................................................ 102
Figure 5-5 Local area ground bus ................................................................................................................... 108
Figure 5-6 Ground-bar isolating standoffs...................................................................................................... 109
Figure 5-7 Modified PANI method................................................................................................................ 110
Figure 5-8 Multi story building with one power source .................................................................................. 112
Figure 5-9 Multi-story building with multiple power sources ......................................................................... 113
Figure A-1 Return paths for static coupled interference .......................................................................... 114
Figure A-2 Static coupling caused by voltage differential ........................................................................ 115
Figure A-3 Inductive coupling from down-conductor into signal cable................................................... 116
Figure A-4 Example design for plant ground grid................................................................................... 119
Figure A-5 Typical Ufer ground system below grade .............................................................................. 120
Figure A-6 Example connecting to existing ground rods......................................................................... 120
Figure A-7 Example connecting to existing counterpoise........................................................................ 121
Figure A-8 Example connecting to an existing ground grid..................................................................... 121
Figure A-9 Example connecting to Ufer ground ..................................................................................... 122
Figure A-10 Example connecting to existing buried steel plate.................................................................. 123
Figure A-11 Three-point method for testing earth ground........................................................................ 125
Figure A-12 Two-point method for testing earth ground.......................................................................... 126
Figure A-13 Relative sizes of common air contaminants ........................................................................... 165
Figure A-14 Size distribution of a typical atmospheric dust sample........................................................... 166
Table 0-1 Wire colors in DC wiring diagrams.................................................................................................... 2
Table 0-2 Wire colors in AC wiring diagrams..................................................................................................... 2
Table 2-1 Standardized global power.................................................................................................................. 9
Table 2-2 Causes of power disruptions............................................................................................................. 12
Table 2-3 Solutions for power interference: UPS or CVT? ............................................................................... 25
Table 2-4 Additional solutions for power interference ...................................................................................... 26
Table 2-5 Typical transfomer attenuation......................................................................................................... 32
Table 3-1 Hazardous materials Classes, Divisions, and Zones........................................................................... 65
Table 4-1 Minimum cable separation distances ................................................................................................ 84
Table 5-1 Resistivity of soils and resistance of single rods ............................................................................... 104
Table 5-2 Ground wire sizing......................................................................................................................... 106
Table 5-3 Braided cable construction types (as an alternative) ........................................................................ 107
Table A-1 Depths and measuring points for three-point testing method................................................ 125
Table A-2 Correlation between temperature and MTBF ....................................................................... 128
Table A-3 DeltaV Control and Installation Drawings ........................................................................... 135
Table A-4 Common sources of static electricity..................................................................................... 162
Table A-5 Copper reactivity rates .......................................................................................................... 170
Table A-6 Classification of chemically active contaminants in cm3/m3 (ppm)........................................ 170
Table A-7 Environmental characterization by visual changes in copper ................................................. 171
Table A-8 Interpreting humidity effects ................................................................................................ 172
Table A-9 Constant percentage ............................................................................................................. 175
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