2013 Fieldbus Update

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© 2013 Fieldbus Foundation
Seminar Outline
• We have some of the most knowledgeable fieldbus
people here today, both presenting and in our
audience. Use the opportunity to network and learn!
• We have designed this seminar to provide a hands on
perspective
• Fieldbus doesn’t need to be difficult
• Fieldbus can provide significant benefits throughout
the plant lifecycle

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Agenda

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Thanks to our Sponsors!

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Three Demonstrations with a Common
Thread
• Three demonstration units with
three different host systems:
Emerson, Invensys Yokogawa
• Devices from Beka, Emerson,
Invensys, Westlock, MTL/Cooper,
Pepperl+Fuchs, Siemens,
Yokogawa, Smar, Topworx, Stahl,
and Phoenix Contact and more.
• Each unit shares a common
segment to highlight the fact that
FOUNDATION fieldbus is an
interoperable standard that
provides ease of use.
• Demonstrations follow the plant
lifecycle from FEED to operations
and maintenance

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Why FOUNDATION Fieldbus?
• Largest Installed Base
• Fit for Purpose
• End User Designed and
Supported
• More than a Network: A
Managed Infrastructure
• OPEN and Continuously
Evolving
• Wide Range of Tested and
Registered Product
• Training and Resources

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We Have Already Reached the Digital
Age: Will Process Industries Catch Up?
• The rest of the world went digital a long time ago; from the telephone
networks to your TV, it is universally acknowledged that digital networks give
you better access to data, better data manageability, and more bandwidth.
• Yes, digital networks need to be managed somewhat differently from
conventional analog technology, but in most cases, the initial investment in
training is minimal.
• NEW GENERATION of workers are more familiar and comfortable with digital
technology.

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The Analog Hall of Fame
How Many Still Use These?
They’re all Cheaper than Digital, and they all Work!

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More Than a Network:
a Managed Infrastructure
• Function blocks enable control in the field, object oriented data
management

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Number One in Digital Communications
for Process Automation!
Market for Digital Fieldbus Products and Services by Protocol
(Source: ARC Advisory Group)

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FOUNDATION Fieldbus Breaks the Billion
Dollar Barrier
• Market for FOUNDATION
fieldbus products (excluding
EPC and system integrator
services) exceed $1 billion in
2012.
• The installed base of
FOUNDATION fieldbus systems
and devices is over $6 billion
• Celebrating 20 years in 2014!
Market for Digital Fieldbus Products and Services
(Source: ARC Advisory Group)

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Fit for Purpose, User Supported
• FOUNDATION Fieldbus was Built
from the Ground Up for
Process Automation
• We have the strongest end
user council of any
communication protocol in
process automation
• Users continue to drive
evolution in the standard
• More users are adding
FOUNDATION fieldbus to their
purchase requirements

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Open and Continuously Evolving
o We are a truly open standard
o We continue to add to our
specification
o NAMUR NE 107 Diagnostics,
advanced alarm handling
capabilities
o FOUNDATION for ROM
Specification integrates
wireless devices and remote
applications
o We can adapt to new
technologies as they come
along
NAMUR NE107 Diagnostic Categories

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We Test & Register Everything from Cable
to Host

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Registered Devices

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• Take a lifecycle perspective
• Many users focus on the installation and
commissioning phase and achieving fast
startup
• Don’t ignore operations and maintenance
domain
• One phase of the lifecycle affects the next.
Adopting a Lifecycle Perspective Helps
you Realize the Benefits

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Defining the Plant Lifecycle

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Automation is a Small Percentage of
Total Project Costs, But a Big Influence

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The Importance of Early Involvement in
the FEED Phase
• The Success of Your Operations & Maintenance Strategy
Depends on the FEED Phase
• Fieldbus and its impact should be considered in this phase,
where it can create a more powerful return on investment

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Cost Reductions: Engineering & Design

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Cost Reductions in Engineering and
Design can be Significant
Source: Alcan
Source: TotalFina Elf

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Reduced Engineering Means Faster
Time to Startup

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Installation and Commissioning
Benefits are Considerable
• FOUNDATION fieldbus also allows you to deal with project
changes more effectively, and manage delays in preceding
phases of the project better
• Avoid shutdowns during performance runs
• Faster time to startup can provide a return on the
automation investment

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An Example of Installation Cost
Reductions
Source: Tecnimont 2009

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An Example of Commissioning Cost
Reductions
Source: Tecnimont 2009

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Eliminate Steps in the Commissioning
Process
What used to take 2
hours per device for
two technicians can
be done in 25 minutes
with one technician.

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Operations: Functional
Expansion
NEW!

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How FOUNDATION Fieldbus can Help Reduce
Energy Costs
• An Ideal Solution for Predictive
Maintenance on Key Energy
Related Assets Like Heat
Exchangers, Burner
Management Systems
• Clean Heat Exchangers Before
they Choke Beyond Limit
• Tighter Control of Fan/Damper
Actuators
• Unparalleled Efficiency
Monitoring
• Monitor & Define Optimal Zone
of Operation for Equipment
Energy Consumption (Trillion Btu)
Petroleum
Chemicals
PaperPrimary
Metals
Food Processing
Nonmetallic
Minerals
Tobacco/Beverages
Furniture
Leather Machinery and Computers
Wood
Transportation
Fabricated Metals
Textiles/Apparel
Plastics/
Rubber
Electrical
Printing
Miscellaneous
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10
100
1000
10 100 1000 10000
EnergyIntensity
(ThousandBtu/$GDP)
Energy-Intensive
Industries
Industrial Energy Intensity vs. Energy Consumption
Mining
Source: US Department of Energy

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Reduce Unplanned Shutdowns
• Unplanned Shutdown Accounts for 5 Percent of Production in
the Process Industries
• One Unplanned Shutdown can Wipe Out your Entire Plant Profit
for the Year
• Field Diagnostics Provide Advance Knowledge of Impending
Problems
• FOUNDATION technology enables truly distributed and
deterministic controls which are designed to function
regardless of host issues

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Customer Experience: CIF Reduces
Unplanned Shutdown
FOUNDATION™ Fieldbus
CIF with inherent backup capability
prevented 2 incorrect plant
shutdowns, which would have
resulted from communication
interruptions.

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Fieldbus for New Projects and Modernization
• According to ARC, the
installed base of process
automation systems reaching
the end of their useful life is
$65 billion. Most of these are
20 years old or older.
• FOUNDATION Fieldbus is being
chosen by more major end
users as they begin to
modernize their installed
base.
• Users want to avoid a
functional replacement.
Nobody Wants to Replace this with
“More of the Same”

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Modernizing with FOUNDATION Fieldbus:
from Refineries to Nuclear Plants

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Reduced Footprint
Fieldbus has the Smallest Footprint in Process Automation

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FOUNDATION for ROM Device Consolidates Diagnostic
Data from Different Networks….
Conventional
I/O
WirelessHART
H1 HART
I/O
ISA100.11a
Diagnostic
&
Instrument
Data
Diagnostic
&
Instrument
Data
Diagnostic
&
Instrument
Data
Diagnostic
&
Instrument
Data
Diagnostic
&
I/O Data
FOUNDATION Infrastructure for Data Management and Diagnostic Information
FOUNDATION for ROM Device
Transducer
Blocks
Transducer
Blocks
Transducer
Blocks
Transducer
Blocks

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Managing Diagnostic Data from Multiple Networks in
a Single Infrastructure
• Easier audit trail and reporting
• Data is time-stamped
• FOUNDATION Fieldbus devices can
indicate data quality -- whether signals
communicating setpoints, PVs, etc.
have good, bad or uncertain quality.
• Structured data and data quality
means improved handling of failures
when one does happen.
• Failure is alarmed, handled by control
algorithm

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Reduced Maintenance Costs
0%
5%
10%
15%
20%
25%
30%
35%
Routine
check
No
Problem
Calibration
shift
Zero Off Plugged
lines
Failed
35%
28%
20%
6% 6%
4%
Source: Shell Global Solutions
63% of maintenance labor
results in no action!!

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Reduced Maintenance Costs
• 50% of Maintenance Is Corrective
• Corrective is 10 times More Costly
Than Preventative Maintenance
• Preventative Maintenance is Done
25% of Time and is 5 Times More
costly Than Predictive Maintenance

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The Benefits of Predictive Maintenance are
Documented

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Think all Networks Offer the Same
Diagnostics? Think again.
• More Diagnostics, with
better granularity
• Better Management of
Diagnostic Data
• Data Quality and reliability
• Severity of Diagnostic
Conditions per NE 107

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New Developments: Project Gemstone
• “Project Gemstone” To Make Fieldbus Experience Easier, More
Application-Centered
• Encompassing a wide range of FOUNDATION™ fieldbus development
efforts, Project Gemstone covers many of the initiatives the Fieldbus
Foundation is already working on today.
• Includes FOUNDATION for Remote Operations Management (ROM),
Field Device Integration (FDI) Cooperation, and ISA108 intelligent
device management.
• The foundation’s new usability team is also focusing on how to make
fieldbus device replacement easier and faster than ever.

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ISA 108: The Installed Base Isn’t Living
Up to its Potential
Source: ARC Advisory Group
• Minority of Intelligent
devices integrated with
DCS or PAM
• Intelligent devices
installed with no PAM
system at all
• Large amount of stranded
diagnostics exists

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New ISA 108 Standard
ISA108 Standards Committee: Intelligent Device Management:
Deployment and Work Process Standards
Purpose: To define standard templates of best practices and work
processes for implementation and use use of diagnostic and
other information provided by intelligent field devices in the
process industries.
Scope: Committee work products will include recommended work
processes and implementation practices for systems that
utilize information from intelligent field devices and the people
that use them. Work process templates by worker roles
(maintenance, operations, etc.) will be one area of research.
Best practices for implementation will be developed. Models
will be developed for the flow of information from devices
through the various systems that use the information.

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FDI Rationalizes EDDL and FDT
Technologies
The Device Package:
The Heart of FDI
EDDL
Device
Definition
Business
Logic
User
Interface
Description
UIP
User Interface
Plug-in,
Device
Applications
(Optional)
Attachments
Manuals
Certificates
Protocol Specific
Files
(GSD/ML/etc.)
FDI Device Package
Authenticity
Integrity
http://www.fdi-cooperation.com/

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Resources: System Engineering Guide
AG-181

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DesignMate Segment Design Tool
• Complete software tool
for planning, validation,
and documentation of
H1 segments
• Automatically audits
segment layouts
against physical layer
specifications
• Available for free
download from the
Foundation

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End User Advisory Council
Regions Areas Covered
Americas
americas_euc@fieldbus.org
South America
United States
Western Canada
Europe/Middle East/Africa
emea_euc@fieldbus.org
Europe
Middle East
Africa
Asia/Pacific
asia_euc@fieldbus.org China
Japan
Singapore
India
Oceania
oceania_euc@fieldbus.org
Australia
New Zealand
We Need Volunteers for the Canadian EUC!

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Fieldbus Forums
http://forums.fieldbus.org/

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Fieldbus Forums LinkedIn

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Blog: Foundationfieldbus.blogspot.com

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YouTube

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Summary
• You can realize significant lifecycle cost benefits with FOUNDATION
fieldbus
• Fieldbus is different, not difficult
• Remember, the right partner, training and work processes are the
keys to success
• Take advantage of the many resources available!

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