FOUNDATION Fieldbus Practical Success Stories

Phil Saward, Product Manager

Cooper Industries: Confidential

Introduction

 Topics
What is Fieldbus?
Comparison with existing 4-20mA installations Typical field network

FOUNDATIONTM fieldbus in the Pharmaceutical industry When should Fieldbus be considered? Why use Foundation Fieldbus?
Design, installation and commissioning Operation and maintenance
 Economic benefits  Technical benefits

Fieldbus system niches

How is fieldbus different from 4-20mA?

4-20mA
Power Supply Power Supply

fieldbus

Input card

In 4-20mA circuits, the power supply, field device and input card are connected in series. In a Fieldbus system, the power supply, field devices and input card are connected in parallel.

Typical Fieldbus installation

Fieldbus control system (DCS)

Redundant, isolated Fieldbus power conditioner CONTROL ROOM FIELD Field wiring hub with spur short-circuit protection

FOUNDATION Fieldbus Devices

Safe area

Fieldbus Today

FOUNDATION fieldbusTM in Pharmaceuticals  Installed base worldwide (published by Fieldbus Foundation, 2008):
>10,000 systems >700,000 field instruments

 Diverse adoption:
9 of the top 10 oil & gas companies 24 of the top 25 pharmaceutical manufacturers 23 of the top 25 chemical producers 15 of the top 20 pulp & paper companies 10 of the top 20 food & beverage companies

 ARC Advisory Group: powerful value proposition for fieldbus in the hybrid industries-namely, food & beverage and pharmaceutical, particularly when it comes to easing the process of validation and regulatory compliance and the integration of batch procedural operations with continuous processes. The function block structure of Foundation technology lends itself to these processes very well.

Market Distribution
Global
LA 12%

Industry
Mining and Metals 3% Education 3% Pulp and Paper 4% Food & Beverage 9% Other 8% Chemical 22%

AP 13%

NA 43%

MEA 7%

EUR 25%

Pharmaceutical 9% Power 13%

Oil & Gas 29%

Example FF applications in Europe

Operator Novo Nordisk AstraZeneca Novartis Novartis Sanofi Aventis Biogal Rt. Location Bagsvaerd, Denmark Gartuna, Sweden Basel, Switzerland Grimsby, UK Aramon, France Debrecen, Hungary Control System Emerson Emerson Emerson Emerson Emerson Yokogawa Emerson Emerson

Glaxo SmithKline Cork, Eire Genzyme Belgium

When should fieldbus be considered?

 Green Field Facility  Facility Upgrade

New unit operation

 Process Automation Focus

60% of sensors are analogue

 Existing cabling infrastructure is overloaded

Why use FOUNDATION fieldbusTM?

 Integrated digital architecture  Future proof

Sensors can be field upgraded with new features

 Economic savings
Different incentives at each stage of a facility life cycle:
Capital/Construction Commissioning Operations, maintenance

Reduced infrastructure

Re-using Installed Cables

J-Box

Fieldbus devices
J-Box
T T

Three existing 4-20 mA Pairs Three existing pairs, one used for fieldbus

Economic Life Cycle

Engineering, Construction, & Commissioning/Start-up

Operations & Maintenance

Replace

Cash Flow

Time

Analog fieldbus

Engineering, Construction & Start-up

Engage in FEED stage Sooner and faster startup start-up

Time Cash Flow

Reduce implementation risk and cost

Termination count
Field
FT-100 + 1 2 3 4 5 6 7 8 9 10 11 12

Junction Box

Marsh Cab.

I.S. Barrier
4 pr 4 pr + + + + 1 + 2 + 3 + 4 + 1 pr

I/O Assembly

4 pr 1 pr 1 2 3 4 5 6 7 8 9 10 11 12

1 pr

FCV-100 + -

16

+ + + + + + -

TT-100 + -

Totals:

75 Analog 34 Fieldbus
8 2

PT-101 + -

Conventional analog termination 24 15 20 5 Fieldbus termination (also included in conventional termination count)

Marshalling done in Junction Box with Fieldbus so Marsh Cab is optional

Engineering - Network Loading

 Number of devices per network segment
15-20 mA per transmitter 20-25 mA per valve

 Bus Bandwidth
Balance cycle time against number of devices Function of host control system

 Segment Length
Defined by Fieldbus standard
function of number of devices Segment topology

 Virtual Communication Resources

Required for communication between devices and host

 Voltage Calculations
9 volt minimum at field device design for 12 volts

Operations & Maintenance

Longer duration to scheduled outage Faster time-to profit Safer operation

Cash Flow

Higher sustained production with minimize costs Shorter scheduled outage Fewer unscheduled outages

Measurement accuracy

4-20mA
PV = 392.8mb

Field JB + marshalling 12.83mA 12.86mA

IS Interface

I/O card

12.87mA

PV = 393.1mb

Leakage + noise

Conversion error

Conversion error

Fieldbus
PV = 392.8mb

Field JB + marshalling

IS Interface

H1 I/O card

PV = 392.8mb

PV = 392.8mb

PV = 392.8mb

PV = 392.8mb

Diagnostics save wasted maintenance

35% 30% 25% 20%
20% 35% 28%

Shell Global Solutions

15% 10% 5% 0%
Routine check No Problem Calibration shift

6%
Zero Off

6%
Plugged lines

4%
Failed

63% of instrument maintenance labour results in no action taken: waste of resources

Fieldbus Project Costs

 Estimated Project Savings

Materials and Field Devices
Some increase

Installation Labour
Savings up to 50%

Commissioning:
Significant savings up to 60%

 Overall Capital Savings of 2530%

However savings will only be realized if the project is planned as a fieldbus project.

Foundation System Architecture

 Scheduled Determinism
Highly Reliable Performance

 Automatic Addressing
Plug and Play

 Functional Communication
Peer to Peer More Powerful Publisher/Subscriber Higher Performance

 Alarms and Events

Time Stamped, Auditable Records

 Firmware Download
Reduced Risk of Obsolescence

 Rigorous Testing Host & Device

Questions