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F OUNDATION Fieldbus™ -Practical Success Stories Phil Saward, Product Manager. Introduction. Topics What is Fieldbus? Comparison with existing 4-20mA installations Typical field network F OUNDATION TM fieldbus in the Pharmaceutical industry When should Fieldbus be considered?

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F OUNDATION Fieldbus™ -Practical Success Stories Phil Saward, Product Manager

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F oundation fieldbus practical success stories phil saward product manager l.jpg

FOUNDATION Fieldbus™ -Practical Success Stories

Phil Saward, Product Manager


Introduction l.jpg

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 l.jpg

Fieldbus system niches


How is fieldbus different from 4 20ma l.jpg

How is fieldbus different from 4-20mA?

4-20mA

fieldbus

Power

Supply

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 l.jpg

Typical Fieldbus installation

Fieldbus control system (DCS)

Redundant, isolated Fieldbus power conditioner

CONTROL ROOM

FIELD

Field wiring hub with spur short-circuit protection

Safe area

FOUNDATION Fieldbus Devices


Fieldbus today l.jpg

Fieldbus Today


F oundation fieldbus tm in pharmaceuticals l.jpg

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 l.jpg

Market Distribution

Global

Industry


Example ff applications in europe l.jpg

Example FF applications in Europe


When should fieldbus be considered l.jpg

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 f oundation fieldbus tm l.jpg

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 l.jpg

Re-using Installed Cables

Fieldbus devices

J-Box

T

T

Three existing

4-20 mA Pairs

Three existing

pairs, one used

for fieldbus

J-Box


Economic life cycle l.jpg

Economic Life Cycle

Analog

fieldbus

Engineering, Construction,

& Commissioning/Start-up

Operations & Maintenance

Replace

Cash Flow

Time


Engineering construction start up l.jpg

Engineering, Construction & Start-up

Engage in FEED stage

Sooner and faster start-up

Reduce implementation risk and cost

startup

Time

Cash Flow


Termination count l.jpg

Termination count

I.S.

Barrier

I/O

Assembly

Marsh Cab.

Junction Box

FT-100

+

-

1

2

3

4

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

-

+

-

1

2

3

4

5

6

7

8

9

10

11

12

1

2

3

4

5

6

7

8

9

10

11

12

FCV-100

+

-

+

-

+

-

TT-100

PT-101

Conventional analog termination

Fieldbus termination (also included

in conventional termination count)

Field

4 pr

4 pr

4 pr

1 pr

1 pr

1 pr

4

16

Totals:75 Analog

34 Fieldbus

8

2

24

15

20

5

Marshalling done in Junction Box with Fieldbus so Marsh Cab is optional

8


Engineering network loading l.jpg

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

Engineering - Network Loading


Operations maintenance l.jpg

Operations & Maintenance

Longer duration to scheduled outage

Safer operation

Faster time-to

profit

Higher sustained production with

minimize costs

Shorter scheduled outage

Fewer unscheduled

outages

Cash Flow


Measurement accuracy l.jpg

Measurement accuracy

4-20mA

Field JB + marshalling

IS Interface

I/O card

PV = 392.8mb

12.83mA

12.86mA

12.87mA

PV = 393.1mb

Conversion error

Leakage + noise

Conversion error

Fieldbus

Field JB + marshalling

IS Interface

H1 I/O card

PV = 392.8mb

PV = 392.8mb

PV = 392.8mb

PV = 392.8mb

PV = 392.8mb


Diagnostics save wasted maintenance l.jpg

Diagnostics save wasted maintenance

Shell Global Solutions

35%

28%

20%

6%

6%

4%

63% of instrument maintenance labour results in no action taken: waste of resources


Fieldbus project costs l.jpg

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 l.jpg

Questions


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