Transcript DCS ROI — The Case for Going Digital

Technology with Purpose
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
It’s a Digital World
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Fieldbus Foundation Market Data
•Today 341 Global Members & Corporate Affiliates,
•257 Registered Devices, 11 Hosts
•5,000+ fieldbus control systems installed or on order around
the world
•400,000+ FOUNDATION™ fieldbus devices in service world
wide
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Growing Membership
350
300
250
200
150
100
50
0
1995
2000
2001
2002
2003
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
2004
Geographic Membership
Asia
Pacific
22%
North &
South
America
45%
Europe
33%
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
North & South
America
Europe
Asia Pacific
Device Registration Trend
FOUNDATION Fieldbus
Total Device Registration Trend
300
Number of Registered Devices
250
200
150
100
50
0
2004Q4
2004Q3
2004Q2
2004Q1
2003Q4
2003Q3
© 2003 Fieldbus Foundation
2003Q2
“...dedicated to a single international fieldbus.”
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2003Q1
2002Q4
2002Q3
2002Q2
2002Q1
2001Q4
2001Q3
2001Q2
2001Q1
2000Q4
2000Q3
2000Q2
2000Q1
1999Q4
1999Q3
1999Q2
1999Q1
1998Q4
1998Q3
1998Q2
Quarter
Fieldbus Technology Expanding Across the Globe
Fieldbus Acceptance Has Been Outstanding
Foundation fieldbus installations include leaders in key industries
 9 of the top 10 oil and gas companies
 24 of the top 25 pharmaceutical companies
 23 of the top 25 chemical companies
 15 of the top 20 pulp and paper companies
 10 of the top 20 food and beverage companies
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Fieldbus Technology Expanding Across the Globe
Global Market Acceptance of Fieldbus
Industry Distribution
Global Distribution
LA
10%
AP
13%
NA
46%
Mining and
Metals
3%
Education
3%
Pulp and
Paper
4%
Other
8%
Chemical
29%
Food &
Beverage
9%
MEA
7%
EUR
24%
Pharmaceutical
9%
Power
13%
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Oil & Gas
22%
Technology with a Purpose
What Does Fieldbus Enable?
A digital plant architecture that uses the
power of field intelligence to improve plant
performance
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Why Change
Benchmark Results Indicate Room for Improvement
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20-40% of control loops in manual control
80% of control loops demonstrate excessive process variability
Many potential Advanced Process Control (APC) benefits are
being missed
Unplanned downtime is the largest single source of lost revenue
86% of maintenance is reactive (too late) or preventative
(unnecessary)
- Best practice is 40% with predictive/proactive
Most Petrochemical companies are not
making returns greater than their cost of capital
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
“Unneeded” Trips To The Field Avoided Through Remote Diagnostics
63%
50%
40%
35%
28%
30%
20%
20%
6%
10%
6%
4%
0%
Routine
Check
No
Problem
Calibration
Shift
Zero
Off
Plugged
Lines
Source: Dow Chemical Company
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Failed
Instrument
The Digital Plant ‘Changes the
Game’ for a Step Change in Results
Value
Digital Plant
Architecture
Hardwired
Panel Boards
Centralized
DCS
Time
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Technology Update
Host Interoperability Support Test (HIST)
Interoperability Testing Kit (ITK)
Power Supply Registration
Standard Transducer Blocks
High Speed Ethernet (HSE)
Safety Instrumented Systems (SIS)
DD Cooperation Project
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Technology with a Purpose
Committed to Continuous Improvement
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
FF Integrated Architecture
H1 – Field Device Integration
Function Blocks Running in Field Devices
Control in the Field - Single Loop Integrity
Power & Signal on a Single, Multi-Drop Wire Pair
Fault Tolerant – Multiple Link Masters
Distances up to 1900 Meters
Supports Intrinsic Safety
Can Add Repeaters
Fiber Optics Option
H1 – Field Device
Integration
P
P
L
P
L
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
P
L
L
HIST Release 1.2
ITK Release 4.6
HIST Release 1.2 – New feature tests:
 HSE Linking Device Configuration
 Flexible Function Blocks
 Multi-Variable Optimization
 Common Device Software Download
 Device Replacement Support
ITK Release 4.6 – Enhanced testing:
 Support for DD Self Re-registration
 Support Capability File Changes for Instantiation
 Library Support for Common Device Software Download
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Standard Transducer
Blocks
- End User Driven Project –
Test and register standard transducer blocks
to enhance interoperability at the transducer level
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Call for Volunteers
Jun 2002
Kick-off Meeting at ISA Chicago
Oct 2002
TEAM: E+H, Fieldbus Inc., Magnetrol, Shell, Siemens Milltronics, Smar,
Syncrude, Yamatake, Yokogawa
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Lab Test Prototype Vendors Identified
May 2003
Lab Validation Tests Completed for Pressure
Dec 2003
Final Specification for Pressure Approved by TSC
Apr 2004
ITK 4.6 support for Pressure Transducer Block beta testing
May 2004
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Power Supply
Registration
- End User Driven Project –
Procedures for self-test of H1 power supplies and
power conditioners to enhance interoperability.
 Project Kickoff
 Draft Specifications Completed
 Run Beta Registration Tests
 Membership review of specification
 TSC Release of Test Specification
 First registered Power Supplies
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May 2003
Jan 2004
Feb 2004
Mar 2004
Apr 2004
May 2004
9 Power Supplies/Conditioners are registered on the FF Web Site
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
FF Integrated Architecture
HSE – Subsystem Integration
High Performance Control Backbone (100 Mbit/s)
Standard Ethernet Equipment and Wiring
Standard Function Blocks PLUS
Flexible Function Blocks for Discrete/Batch/PLC
Redundant HSE Interfaces and Devices
Linking Devices (LD) Integrate H1
HSE Provides the Open Interface for Data Servers
MIS
APPLICATION
PACKAGES
Data Servers
HSE – High Speed Control and
Integration Backbone
LD
P
LD
P
L
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
P
L
P
L
L
High Speed Ethernet
Device Types
HSE Linking Devices
Standard Internet
Network Equipment
H1
H1
P
L
Plant
Host
H1
P
L
8
Linking Devices
Registered
&
on FF Web Site
Plant
HSE Device running
Function Blocks
In Final Beta
Registration
Testing
HSE Device with
Redundant Interface
Final Specification
Released by TSC
HSE Redundant Device
In Final Lab
System Test
“...dedicated to a single international fieldbus.”
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
© 2003 Fieldbus Foundation
Safety Instrumented Systems
- End User Driven Project –
Extends FF Technology to Safety Instrumented Systems (SIS).
IEC 61508 based, TÜV certified concept for application of
FOUNDATION fieldbus to Safety Instrumented Systems.
Example Application Areas:
 Burner Management Systems
 Fire & Gas
 Fuel Engineering
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
SIS Development Team
ABB AS
ABB Instrumentation
E.I. DuPont de Nemours, Inc.
ExxonMobil Research & Engineering
Emerson Process Management
FlowServe
HIMA
Honeywell SMS
ice-PROS
Infraserv Höchst Technik GmbH & Co. KG
Invensys/Triconex
Metso Automation
Rockwell Automation
Rotork Control Systems
Saudi Aramco
Smar
Shell Global Solutions
Softing AG
TÜV
Westlock Controls Corporation
Yokogawa Electric Corporation
Yokogawa - SCE
Norway
Italy
USA
USA
USA
USA
Germany
The Netherlands
Canada
Germany
USA
Finland
USA
UK
Saudi Arabia
Brazil and Singapore
The Netherlands
Germany
Germany
USA
Japan
The Netherlands
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Key SIS End User
Requirements
 Reduced Total Cost of Ownership for FF-SIS applications:
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CAPEX - Hardware, Footprint, Commissioning, Power Consumption
OPEX - Advanced diagnostics, Reduced test interval
Suitable for SIL 2 and 3 applications
Password-protected (e.g. Write Lock) access to SIS field devices
Additional SIS Function Blocks (e.g. logic, 2 out of 3 voting)
Definable actions on diagnosed failures – trip, message
Handle discrete signals (e.g. switches, motor trips, lights, push buttons)
Total system approach
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Total Asset Management – SIS and Non-SIS
Modular Logic Solver –centralized and distributed option
Provide FF diagnostics
Hybrid system architecture – mix SIS & traditional hardware
Provide guidance to manual proof test
Signalling/procedures to enable automatic proof test
Information for opportunity-based proof test
Logging/documentation of results
Provide failure rate information
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
SIS Communication
Extensions
The H1 Communication System (Black Channel) is unchanged.
A new SIS protocol above the Black Channel detects network
faults and appropriate action can be taken without human
intervention.
IEC 61508
New SIS
Communication Diagnostics
Black Channel
IEC 61508
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
SIS User Layer
Extensions
New Function Blocks for SIS Applications – FBAP Part 6
New FBAP diagnostics detect application faults and appropriate
action can be taken without human intervention.
IEC 61508
New SIS Function Blocks
&
Function Block Diagnostics
Black Channel
IEC 61508
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
SIS – Open Fieldbus
Solution
Operation
Engineering
Proprietary Network
Operation
Total Asset
Management
Engineering
HSE
Linking
Device
SIS Logic
H1
Ethernet
Switch
....
Linking
Device
H1
Hardwired
SIS FF Devices
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Non-SIS FF Devices
Example SIS Application
Analog 2 out of 3 Voter
SIS_ SIS_ SIS_
WL RB
AI
SIS_ SIS_ SIS_
WL RB
AI
SIS_
DI
SIS_
AVTR
SIS_ SIS_
WL RB
SIS_ SIS_ SIS_
WL RB
AI
Write Lock (WL)
S
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
SIS_
DO
SIS Development Schedule
2002
 4Q FF Board of Director Approval for SIS Project
2003
 1Q
 2Q
 3Q
 4Q
Project Kickoff Meeting
Architecture Completed
Draft Preliminary Specifications (DPS) Version 0.4
TÜV Concept Approval for SIS
2004
 1Q DPS Version 0.5 External Review
 2Q DPS Version 0.9
 3Q DPS Version 1.0, Develop Lab Test Tools and Lab Prototypes
 4Q Begin Specification Validation Lab Testing @ Infraserv in Frankfurt
2005 – Release Final SIS Specifications and Final TÜV Type Approval
2006 – First Safety-Certified, FF-Registered Devices
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
DD Cooperation Project
The DD Cooperation Project was approved by FF, PNO and HCF in
October 2002 to specify Electronic Device Description (EDD)
visualization and data storage management extensions.
Common EDD extensions for FOUNDATION fieldbus, PROFIBUS
and HART preserves and protects the worldwide investment in
EDD-based devices, tools and training.
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
DD Cooperation
Project Objectives
Develop EDD specification for advanced visualization and data
storage and protect the installed base.
 Built upon the approved IEC 61804-2 International Standard
 Independent of operating system and communication protocol
 Single EDD for all EDD applications (PCs/Handhelds/etc.)
 No changes to existing EDDs
Develop EDD Interoperability Guideline for the extensions.
Independent test and validation of extensions.
Specification extensions available to all consortiums and IEC.
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
DD Cooperation Project Team
ABB
Emerson Process Management
Endress + Hauser
Fieldbus Foundation
FlowServe
HART Communication Foundation
Honeywell
PROFIBUS Nutzerorganisation e.V
Siemens
Yokogawa
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
DD Cooperation Project
Extension Areas
Enhanced User Interface
Parameter organization
Windows, dialogs, group boxes
Images
Applications
Sensor/Actuator
configuration
Motor control
Complex configurations
Graphing System
Visualize complex data
Support for charts and graphs
Multiple plots
Interactive zooming
Direct editing of graphs
Emphasis, key points, notes
Radar level
configuration
Valve signatures
Persistent Data Storage
Store/access device data on the host
Independent of host file system
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Valve diagnostics
Sensor drift
Sensor/Actuator
diagnostics
Archived valve
signatures
DD Cooperation Project
Motor Control Example
Image
MOTOR
SYMMETRY
 Static bit map
 Objective is to provide a
visual representation of the
parameters
Enhanced MENUS and
METHOD are used to build
dialog boxes displaying
motor starts, operating
hours, number of overload
trips, etc.
MOTOR PARAMETERS
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
DD Cooperation Project
Radar Gauge Example
A GRAPH is used to present
the echo WAVEFORM to enable
configuration of thresholds and
false echoes areas in the
device.
DD Cooperation Project
Radar Gauge
Threshold
Calibration
Trigger device to build WAVEFORM data
 Retrieve WAVEFORM data
 Update the GRAPH
Echo Curve
GRAPH
WAVEFORM
(Data from Device)
Filter
AXIS
MENUS & METHODS
(Enhanced UI)
ARRAY(s)
(Device Data)
FILE/LIST
(Persistent Data)
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
DD Cooperation Project
Valve Signature Example
A GRAPH is used to
present the Valve Signature
(Hysteresis) WAVEFORM as
a measure of the air
pressure to stroke the valve
open and close.
Valve Signature
Blue line is a reference retrieved
Open Stroke
via FILE and ARRAY
Trigger device to build
WAVEFORM data
 Retrieve WAVEFORM data
 Update the GRAPH
GRAPH
Close Stroke
WAVEFORM
(Data from Device)
AXIS
MENUS & METHODS
(Enhanced UI)
ARRAY(s)
(Device Data)
FILE/LIST
(Persistent Data)
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
FF Application Coverage
Function Blocks
H1 + HSE
Basic Process Control
Basic Function Blocks
Analog Input
Analog Output
Bias & Gain
Control Selector
Discrete Input
Discrete Output
Manual Loader
PD Control
PID Control
Ratio Control
Advanced Process Control
Advanced Function Blocks
Analog Alarm
Arithmetic
Deadtime
Device Control
Input Selector
Integrator
Lead/Lag
Setpoint Ramp Generator
Signal Characterizer
Splitter
Timer
Safety Instrumented Systems
SIS Function Blocks
Analog Input
Analog Output
Discrete Input
Discrete Output
Analog Voter
Discrete Voter
AND/OR/XOR
Batch/Discrete/Hybrid Control
Flexible Function Blocks - Basic
Multiple Input/Output - 8 Channel I/O
 Discrete and Analog
 Basic I/O Interfacing and Data Acquisition
Flexible Function Blocks -Application Specific
 Batch/Discrete/Hybrid Control
 PLC Sequencing – Startup/Shutdown
 Variable Speed Drive Control
 Gateways to Other Protocols
 Supervisory Data Acquisition
 Advanced I/O Interfacing
 Multivariable Control and Optimization
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Summary of FF Technology
Released Products
H1 Device Development
HSE Device Development
H1/HSE Host Development
H1 Conformance Test Kit
HSE Conformance Test Kit
DD Services Software
DD Registered Library
DD Tokenizer
DD Standard Library
DD Tokenizer
DD Standard Library
H1 Interoperability Test Kit
HSE Interoperability Test Kit
H1 Device Testing
HSE Device Testing
More H1 Tools
More HSE Tools
H1 ITK
Automation Toolkit
HSE Analyzer
Toolkit
H1
Starter Kit
HSE Analyzer
Toolkit Professional
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
Host Interoperability
Support Testing
(HIST)
FF
Specifications &
Application Guides
FF
Training
FF
Consulting
Services
A Different Way of Working
• Need to Handle a new wealth of information - imbedding
and deploying predictive intelligence to the plant
Systems Networked rather than centralized
• Standards used at every level
 - Field: Fieldbus,
 - Platforms: Commercial,
 off-the-shelf software and hardware
 - Network technologies: OPC, .NET
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
FF Standards Summary
USER LAYER SIS
DD – IEC 61804-2
USER LAYER
USER LAYER
DD – IEC 61804-2
OSI Model
7
APPLICATION LAYER
6
PRESENTATION LAYER
5
4
SESSION LAYER
TRANSPORT LAYER
7
IEC 61158 - FMS
USER LAYER
DD – IEC 61804-2
IEC 61508 - SIS
IEC 61158 - FDA
6
COMMUNICATION
STACK
COMMUNICATION
STACK
5
IETF TCP/UDP
4
H1 or HSE
IETF IP
3
NETWORK LAYER
3
2
DATA LINK LAYER
2
IEC 61158 - DLL
1
PHYSICAL LAYER
PHYSICAL LAYER 1
IEC 61158
@ 31.25 kbit/s
IEEE 802.3u
@ 100 Mbit/s
PHYSICAL LAYER
H1
HSE
SIS
IEEE 802.3
MAC
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation
“...dedicated to a single international fieldbus.”
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© 2003 Fieldbus Foundation