9.00-foundation fieldbus saward mtl

8/3/2019 9.00-Foundation Fieldbus Saward MTL

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Cooper Industries: Confidential

FOUNDATION Fieldbus -

Practical Success Stories

Phil Saward, Product Manager


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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


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Fieldbus system niches


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How is fieldbus different from 4-20mA?

4-20mA

Power

Supply

fieldbus

PowerSupply

In 4-20mA circuits, the power supply, fielddevice and input card are connected in series.

In a Fieldbus system, the power supply, fielddevices and input card are connected in

parallel.

Input card


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Safe area

Typical Fieldbus installation

Redundant,

isolated Fieldbus

power conditioner

Field wiring hub with

spur short-circuit

protection

FOUNDATION Fieldbus Devices

FIELDCONTROL ROOM

Fieldbus control

system (DCS)


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Fieldbus Today


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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 ofvalidation and regulatory compliance and the integrationof batch procedural operations with continuousprocesses. The function block structure of Foundationtechnology lends itself to these processes very well.


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Market Distribution

GlobalGlobal

LA

12%

NA

43%AP

13%

MEA

7%

EUR

25%

Other

8%

Mining and

Metals

3%Education

3%

Pulp and

Paper

4%

Food &

Beverage

9%

Pharm-

aceutical

9%

Power

13%

Oil & Gas29%

Chemical

22%

IndustryIndustry


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Example FF applications in Europe

Operator Location ControlSystem

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 Belgium Emerson


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When should fieldbus be considered?

Green Field FacilityFacility Upgrade

New unit operation

Process Automation Focus

60% of sensors are analogue

Existing cabling infrastructure is

overloaded


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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


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Re-using Installed Cables

Three existing4-20 mA Pairs

J-Box

TT

Fieldbus devices

Three existingpairs, one usedfor fieldbus

J-Box


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ReplaceOperations & MaintenanceEngineering, Construction,

& Commissioning/Start-up

Economic Life Cycle

CashFlow

Analog

fieldbus

Time


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Engineering, Construction & Start-up

Time

startup

CashFlow

Reduce implementation

risk and cost

Engage in FEED stageSooner and faster

start-up


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Termination count

FT-100

+

-

FCV-100

+

-

TT-100

+

-

Field

PT-101

+

-

1

2

3

4

5

6

7

8

9

10

11

12

Junction Box

1

2

3

4

5

6

7

8

9

10

11

12

Marsh Cab.

1

2

3

4

+-

+-

+-

+-

+-

+-

+-

+-

I.S.Barrier

8

24 20 5

16 4

8 2

15

+-

+-

+-

+-

+-

+-

I/OAssembly

Conventional analog termination

Fieldbus termination (also included

in conventional termination count)Marshalling done in Junction Box with

Fieldbus so Marsh Cab is optional

Totals: 75 Analog

34 Fieldbus

4 pr 4 pr4 pr

1 pr 1 pr 1 pr


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Operations & Maintenance

CashFlow

Higher sustained

production with

minimize costs

Faster time-to

profit

Safer operation

Fewer unscheduled

outages

Shorter scheduled outage

Longer duration to

scheduled outage


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Measurement accuracy

IS Interface I/O card

PV = 392.8mb12.83mA PV = 393.1mb12.87mA

IS Interface H1 I/O card

PV = 392.8mbPV = 392.8mbPV = 392.8mb

Field JB +

marshalling

Field JB +

marshalling

12.86mA

PV = 392.8mb PV = 392.8mb

Leakage + noise Conversionerror

Conversionerror

4-20mA

Fieldbus


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Diagnostics save wasted maintenance

0%

5%

10%

15%

20%

25%

30%

35%

Routine

check

No

Problem

Calibration

shift

Zero Off Plugged

lines

Failed

63% of instrument maintenance labour results in no action

taken: waste of resources

35%

28%

20%

6% 6%

4%

Shell Global Solutions


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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 projectis planned as a fieldbus project.


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Foundation System Architecture

Sch

eduled Determinism Highly Reliable PerformanceAutomatic 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


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Questions

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