Transcript FOUNDATION Fieldbus™ -Practical Success Stories

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
fieldbus
Power
Supply
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
Industry
Global
LA
12%
NA
43%
AP
13%
Mining and
Metals
3%
Education
3%
Pulp and
Paper
4%
Other
8%
Chemical
22%
Food &
Beverage
9%
MEA
7%
EUR
25%
Pharmaceutical
9%
Oil & Gas
29%
Power
13%
Example FF applications in Europe
Operator
Location
Control
System
Novo Nordisk
Bagsvaerd, Denmark
Emerson
AstraZeneca
Gartuna, Sweden
Emerson
Novartis
Basel, Switzerland
Emerson
Novartis
Grimsby, UK
Emerson
Sanofi Aventis
Aramon, France
Emerson
Biogal Rt.
Debrecen, Hungary
Yokogawa
Glaxo SmithKline Cork, Eire
Emerson
Genzyme
Emerson
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
Three existing
4-20 mA Pairs
T
Three existing
pairs, one used
for fieldbus
T
Economic Life Cycle
Cash Flow
Engineering, Construction,
& Commissioning/Start-up
Operations & Maintenance
Replace
Time
Analog
fieldbus
Engineering, Construction & Start-up
Engage in FEED stage
Sooner and faster
startup
start-up
Cash Flow
Time
Reduce implementation
risk and cost
Termination count
Field
FT-100
+
1
1
2
3
4
5
6
7
8
+
-
TT-100
2
3
4
5
6
7
8
1 pr
9
10
11
12
+
-
1 pr
Totals:
1 +
+
2
3 +
4 +
-
1 pr
4
+
+
+
+
+
+
-
75 Analog
34 Fieldbus
8
2
Conventional analog termination
PT-101
+
-
8
+
+
+
+
-
16
9
10
11
12
I/O
Assembly
4 pr
4 pr
4 pr
FCV-100
I.S.
Barrier
Marsh Cab.
Junction Box
24
15
20
5
Marshalling done in Junction Box with
Fieldbus so Marsh Cab is optional
Fieldbus termination (also included
in conventional termination count)
Engineering - Network Loading
 Number of devices per
network segment
• 15-20 mA per transmitter
• 20-25 mA per valve
 Segment Length
• Defined by Fieldbus
standard
• function of number of
devices
• Segment topology
 Voltage Calculations
• 9 volt minimum at field
device
• design for 12 volts
 Bus Bandwidth
• Balance cycle time
against number of
devices
• Function of host
control system
 Virtual
Communication
Resources
• Required for
communication
between devices and
host
Operations & Maintenance
Longer duration to
scheduled outage
Safer operation
Cash Flow
Faster time-to
profit
Higher sustained
production with
minimize costs
Shorter scheduled outage
Fewer unscheduled
outages
Measurement accuracy
4-20mA
PV = 392.8mb
Field JB +
marshalling
12.83mA
IS Interface
12.86mA
Fieldbus
12.87mA
Conversion
error
Leakage + noise
Field JB +
marshalling
I/O card
IS Interface
PV = 393.1mb
Conversion
error
H1 I/O card
PV = 392.8mb
PV = 392.8mb
PV = 392.8mb
PV = 392.8mb
PV = 392.8mb
Diagnostics save wasted maintenance
35%
30%
Shell Global Solutions
35%
25%
28%
20%
20%
15%
10%
5%
0%
Routine
check
No
Problem
Calibration
shift
6%
6%
4%
Zero Off
Plugged
lines
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 25–30%
However savings will only be realized if the project
is planned as a fieldbus project.
Questions