proven benefits in projects worldwide - fieldbus … benefits in projects worldwide reduced cost,...
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Proven Benefits in Projects WorldwideReduced cost, faster startup
Dong Manh HoangSEA Service Assistant ManagerEmerson – Fisher
On Behalf of Fieldbus Foundation
Vietnam 20132
Topics CoveredTopics CoveredReduced cable and installationReduced I/O cards, cabinets, and weightSmaller system footprintReduced device countFewer gateways and data mappingSimpler I/O designGreater flexibility to handle I/O changesFaster commissioning
Vietnam 20133
Reduced Hardware RequirementsReduced Hardware RequirementsEliminate physical signal marshalling and cabinets– Signal marshalling edited in software
Robust and reliable by eliminating failure points– Fewer wire connections to go bad
JBCONTROLLERS MARSHALLING
JB
FTA
FTA
FTA
FTA
FTA
FTA
PT
& I/O & POWER
PT
CONTROLLERS& INTERFACESWITH POWER
JB
JBFIELDBUS
FieldbusHardwired
Vietnam 20134
I/O Flexibility through VirtualMarshalling™ I/O Flexibility through VirtualMarshalling™ No custom hardware configurations (traditional I/O card selection) to accomplish marshallingMarshalling edited in software– All signal linking and changes without hardwiring
Fieldbus: 320 DevicesHardwired: 320 Signals
DIAC
AI AO DINA
DICO
DIAC
DORE
DODC
DOAC
AIAO DINA
DICO
DODC
AI
AO
DINA
DICO
DODC
AI
AO
DINA
DICO
AI
AO
DINA
DICO
DODC
DIAC
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DORE
DOAC
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DORE
DOAC
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DIAC
DORE
DOAC
FFH1
FFH1
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FFH1
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Vietnam 20135
The Smallest Hardware Footprint of Any I/O Technology in Process AutomationThe Smallest Hardware Footprint of Any I/O Technology in Process Automation
Significantly reducing the overall amount of hardware needed
Fiel
d Ju
nctio
n B
ox
Mar
shal
ling
Cab
inet
Sys
tem
Cab
inet
FieldbusHardwired
Fiel
d Ju
nctio
n B
ox
Sys
tem
Cab
inet
12 pairs12 signals
12 pairs12 signals
1 pair>24 signals
Mar
shal
ling
Cab
inet
Vietnam 20136
Dramatically Reduced Wiring and I/O Count for Complex DevicesDramatically Reduced Wiring and I/O Count for Complex DevicesHardwired
Multiple wire pairs per MOV
Fieldbus:Multiple MOVs per pair of wires
Cores I/O Description4 3 DO Open/stop/close control
2 1 AODesired valve position control
2 1 DO Emergency shut down
3 2 DIValve position status (limit switches)
2 1 AI Percentage open1 1 DI Available for control1 1 DI Local/remote switch
1 1 DIMotor running open direction
1 1 DIMotor running closed direction
1 1 DI Torque switch tripped2 1 AI Percentage torque
1 1 DIMotor thermostat tripped
1 1 DI Battery condition low22 16 ch TOTAL
With hardwired,
many device features
become too costly to use
Vietnam 20137
Eliminate Proprietary Protocols, Gateways, and SoftwareEliminate Proprietary Protocols, Gateways, and Software
Proprietary– Vendor dependency– Gateways, mapping…
Fieldbus– Standards-based– Simple architecture
MP T M
MP T M
M.O.V.CONFIG.
DEVICEMGMT
FF
MB
MB
FF GATEWAY
FIELDBUS MODBUS
PROPRIETARY
OPERAT.CONSOLE
MP T M
MP T M
DEVICEMGMT
FF
FF
FIELDBUS
OPERAT.CONSOLE
Vietnam 20138
Easy Handling of Late I/O Changes through VirtualMarshalling™Easy Handling of Late I/O Changes through VirtualMarshalling™
Easy late addition of signals:– For feedback and auxiliary
measurement– Without the need for
additional wiringEasy change of device kind without switching I/O cards– On/off valve to control valve– Control valve to MOV– On/off MOV to throttling MOV
More devices can be added without laying more cable
Vietnam 20139
Reduced WiringReduced WiringMultiple devices in parallel on the same pair of wiresA single pair provides both power and communicationLong distance is possibleField junction box hardware is rugged:– Encapsulated for harsh outdoor field conditions– Some passive
S
AIAODI-NAMURDI-ContactDI-ACDO-RelayDO-Transis.DO-Triac
12 pair = 12 signals
S
H1 Fieldbus
1 pair > 30 signals
FieldbusHardwired
Vietnam 201310
Reduced Installation LaborReduced Installation LaborReduces the need for hardware:– Cable, cable trays, and I/O cards etc.
Reduces installation labor:– Laying, cutting, stripping, crimping,
labeling and connecting at every intermediate point
For example;– A bus with 10 instruments– Three signals per device average – Takes the place of 30 pairs of wires
and I/O channelsThe resulting cost is even lower than hardwired remote I/O and local mounting
A 5,000 I/Ohardwired
system becomes a 1,700 fieldbus device system
Device I/OGas Chromatograph 25Electric Actuator (MOV) 16Process Gas Analyzer 5Mass Flow Meter 3On/Off Valve 3Amperometric Analyzer 2Conductivity Analyzer 2Control Valve Positioner 2Density Transmitter 2Flowmeter 2Flue Gas Transmitter 2Interface Level Transmitter 2Oxygen Transmitter 2
Vietnam 201311
Smaller System Footprint – Reduced WeightSmaller System Footprint – Reduced WeightHardwired
Each I/O signal:– One pair of wires– One I/O channel
Many I/O per device
FieldbusDrastic wire reductionFewer cabinets– Reduced I/O cards– No marshalling
Fieldbus: 320 DevicesHardwired: 320 Signals
DIAC
AI AO DINA
DICO
DIAC
DORE
DODC
DOAC
AIAO DINA
DICO
DODC
AI
AO
DINA
DICO
DODC
AI
AO
DINA
DICO
AI
AO
DINA
DICO
DODC
DIAC
DIAC
DORE
DOAC
DIAC
DIAC
DORE
DOAC
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DOAC
FFH1
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Vietnam 201312
Fieldbus Economically Enables Full Device Integration and CapabilityFieldbus Economically Enables Full Device Integration and Capability
Integration of all device signals, not just a subset– Fully utilize device capabilities, not just a partial
Continuous feedback available for all valves
Device Full Function I/O Actual Hardwired I/OGas Chromatograph 25 5Electric Actuator (MOV) 16 6Process Gas Analyzer 5 3Mass Flow Meter 3 1On/Off Valve 3 1Amperometric Analyzer 2 1Conductivity Analyzer 2 1Control Valve Positioner 2 1Density Transmitter 2 1Flowmeter 2 1Flue Gas Transmitter 2 1Interface Level Transmitter 2 1
Vietnam 201313
Simplify I/O DesignSimplify I/O DesignTransmitters, control valves, and two-wire on/off valves share the same busAll devices use the same single type of interface card– No need to select I/O card
All devices use the same single type of safety barrier– No need to select safety barrier
It is not necessary to know the exact type and quantity of signal for each device– Only how many devices
H1
Vietnam 201314
Multi-Channel Devices Reduce Both Device Count and I/O CountMulti-Channel Devices Reduce Both Device Count and I/O Count
Not limited to a single value per deviceMulti-input temperature transmitters– 8 sensor inputs, which are ideal for temperature
profiling applicationsMulti-point indicatorsDual input temperature transmitters
Vietnam 201315
Reduced Device CountReduced Device Count8-channel temperature transmitter takes the place of 8 hardwired transmitters– Reducing the overall device count– Reduced wiring– Reduced I/O card points
AI
8 pair = 8 signals
H1 Fieldbus
1 pair > 100 signals
FieldbusHardwired
Vietnam 201316
Reduced Cost by Shared Network InfrastructureReduced Cost by Shared Network Infrastructure
Eliminate proprietary protocols– Electric actuators/MOVs– Gas chromatographs– Tank gauging systems
No separate bus infrastructure required– Eliminating the need for separate networks, gateways,
and drivers
Vietnam 201317
Many Cost Effective SolutionsMany Cost Effective SolutionsDifferent brand components can share the same network– System, devices, power supplies, etc.
Ability to choose the best available instruments for the application
Vietnam 201318
Faster CommissioningFaster CommissioningNo traditional five-point loop tests– Replaced by a simple plausibility
checkSystem automatically confirms the correct device type has been installed– No need to visually inspect
No ranging required– Measurement in engineering unit
valueAlso for the discrete devices– Intelligent two-wire on/off valves– Electric actuators / motor operated
valves (MOV)
Vietnam 201319
Where Can I Learn More?Where Can I Learn More?What is FOUNDATION fieldbus?Breaking the Limits of Analog TechnologyProven Benefits in Projects Worldwide Enhanced Operations and Maintenance Ease of Use
http://www.fieldbus.org/images/stories/technology/aboutthetechology/overview
/fieldbus_brochure.pdf
Vietnam 201320
Shell Norco, USAShell Norco, USAEthylene Plant 9,000 fieldbus devicesImproved operations through control of key variables to reduce process variability in several major unitsEarly detection of potential device problems Over 340,000 man-hours of operation without a recordable eventZero unscheduled shutdowns or incidentsHigh degree of operator acceptance
Significant operation and maintenance benefits through predictive maintenance provided by FF and asset management technology.
– Improved hydrotreater steam shedding
– Improved heavy-gas stripper reflux flow
– Improvements in aromatics stripper reflux
– Significant improvement in steam usage
– Improved steam condensate drum operations
– Detecting and remedying valve malfunction
– Improvements in flow variability to Shell’s refinery
– Improvements in decoking– Early detection of excessive steam
tracing
Vietnam 201321
Nederlandse Aardolie Maatschappij BV (NAM) , The NetherlandsNederlandse Aardolie Maatschappij BV (NAM) , The Netherlands
Gas wellsJoint venture of Shell and Exxon2,500 fieldbus devicesMake it possible for the engineers to keep track of thousands of valves and instruments– When problems arise, the maintenance engineers can
get a quick picture of what is happening with the equipment.
Vietnam 201322
Qatar Petroleum, PS-2 and PS-3, Qatar Qatar Petroleum, PS-2 and PS-3, Qatar Offshore production platforms1,000 FOUNDATION fieldbus-enabled devicesSpace is very limited on offshore platforms and must be put to optimum use. The FOUNDATION fieldbus-based design enabled drastic reductions in the size and number of marshalling cabinets and in the amount of trunk cable that had to be laid.
Vietnam 201323
Petroleum Development Oman (PDO), Kauther Gas Plant , OmanPetroleum Development Oman (PDO), Kauther Gas Plant , Oman
Gas Plant Through the use of the latest control system and FOUNDATION™ fieldbus technology, process control and the diagnostic monitoring of field instrumentation is done from remote locations.
Vietnam 201324
Shell Expro, Brent Alpha, UKShell Expro, Brent Alpha, UKOffshore platformUsing FOUNDATION Fieldbus technology to reduce operating costsShell has selected FOUNDATION Fieldbus** as its solution because this technology provides the environment for ongoing cost reductions and is able to incorporate future technology advances that will further reduce operational costs
Vietnam 201325
CNOOC / Shell Petrochemicals, Nanhai, ChinaCNOOC / Shell Petrochemicals, Nanhai, China
16,000 FOUNDATION Fieldbus devicesPetrochemicals ComplexEnables a problem to be diagnosed and an alert issued before the instrument actually fails and disrupts a process– Continuously monitors the health of the
instrumentation• Resulting in increased reliability• Fewer suspect measurements
– Preventive maintenance capability• Plant operators can have greater confidence that their facility
will perform as expected.
Vietnam 201326
PTT LNG, Map Ta Phut, ThailandPTT LNG, Map Ta Phut, ThailandLNG import terminal The transmitters, flowmeters, and control valves throughout this terminal are all FOUNDATION fieldbusenabled and can be continually monitored– Alarms are issued before any device fails completely
• Enabling predictive maintenance that reduces maintenance costs throughout the facility lifecycle
Vietnam 201327
Merck Serono Biotech Center, Vevey, SwitzerlandMerck Serono Biotech Center, Vevey, Switzerland
2,000 FOUNDATION™ fieldbus devicesBiopharmaceuticalsAllows for a proactive maintenance approach and the scheduling of field device checksAll device data can be monitored online– The plant can be operated with a smaller field
workforce.
Vietnam 201328
Alcan, Gove, AustraliaAlcan, Gove, AustraliaBauxite to Alumina Refining6,600 FOUNDATION fieldbus devices30% savings in engineering & termination costsSignificant reduction in labour, installation and commissioning costsTime to engineer, wire & test DCS cabinereduced by 35%Time to assemble & pre-commission facility reduced by 25%
Vietnam 201329
BP/SECCO, ChinaBP/SECCO, ChinaPetrochemical processing complex producing ethylene and nine related productsWorld-class, 10-plant complex brought online three months ahead of scheduleSignificant savings on cablingMaintenance costs expected to be cut by one-third
Vietnam 201330
BP Chemicals (now Ashland), Lima, USABP Chemicals (now Ashland), Lima, USABDO plantIncreased process reliabilityConfiguration savingsIncreased process & diagnostics informationIncreased device health information
Vietnam 201331
TotalFinaElf , North Sea, NethernaldsTotalFinaElf , North Sea, NethernaldsOffshore Platform
15% reduced wiring and instrumentation cost20% reduced control system cost80% reduced engineering costsReduced building costsReduced operational cost
Vietnam 201332
Synthomer / Yule Catto, Malaysia Synthomer / Yule Catto, Malaysia Synthetic emulsion polymerReactor output increased to over 30% of design capacityBatch-to-batch repeatability improved by 30%Commissioning time reduced from 30 days to 8 daysNumber of aborted batches reduced by 50%Number of non-conforming batches reduced by 40%
Vietnam 201333
Reliance, Jamnagar, IndiaReliance, Jamnagar, India20,000+ Foundation fieldbus devicesRefineryMigration from a preventive to predictive maintenanceEnhanced diagnosticsStatus and signal-quality messages with every process variable update informs the operator that the signal is valid,– Also used by the control
algorithms to implement control only on valid signals.
Improved planning and scheduling of outagesReduction in maintenance costs.Improved loop operations– Problem loops can be
analyzed remotely and continuously monitored for sticking valves, questionable measurement etc.
Vietnam 201334
Fieldbus Project Business ValueFieldbus Project Business ValueReduced hardware cost– Less Wiring– Lower I/O Count– Reduced Installation Labor– Reduced Weight– The Smallest Hardware Footprint – Reduced Device Count– Fewer gateways
Faster design and changes– Simplified I/O design– Greater I/O flexibility– Easy handling of late I/O changes– Less proprietary protocol data mapping
Faster Commissioning