FOUNDATION Fieldbus Moving Forward

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1© 2013 Fieldbus Foundation

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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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Thanks to our Sponsors !

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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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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 b y Protocol(Source: ARC Advisory Group)

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FOUNDATION Fieldbus Breaks the Billion Dollar Barrier

• Market for F OUNDATION

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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• Users need to take a lifecycle perspective to understand the benefits of F OUNDATION fieldbus

• Defining the plant lifecycle• The importance of the FEED phase• Installation and Commissioning Benefits are

Considerable• Operations: Managing data for true distributed

control• Transforming maintenance and reducing cost• The importance of training

The Benefits of Fieldbus Throughout the Plant Lifecycle

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• If you are planning on installing fieldbus, it behooves you to take a lifecycle perspective

• Many users focus on the installation and commissioning phase and achieving fast startup, but only then do they consider how to get the most out of the technology in 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 Strate gy Depends on the FEED Phase

• Fieldbus and its impact should be considered in thi s phase, where it can create a more powerful return on inves tment

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Cost Reductions: Engineering & Design

• Significant cost savings can be achieved in the engineering and design phase

• “The Death of the Loop Drawing”: “Some are finding it easier to make their segment diagrams on DCS graphics, and use the DCS database to self-document all the ways a given variable is interconnected.

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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

• We talk a lot about faster time to startup, but 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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Drastic Reduction in Commissioning Times

• Reduce your commissioning time by up to 50 percent.

• 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

PaperPrimaryMetals

Food Processing

Nonmetallic Minerals

Tobacco/Beverages

Furniture

Leather Machinery and Computers

Wood

Transportation

Fabricated Metals

Textiles/Apparel

Plastics/Rubber

Electrical

Printing

Miscellaneous1

10

100

1000

10 100 1000 10000

En

erg

y I

nte

nsit

y

(Th

ou

san

d B

tu/

$ G

DP

) 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™ FieldbusCIF 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 F OUNDATION Fieldbus: from Refineries to Nuclear Plants

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FOUNDATION for ROM Device Consolidates Diagnostic Data from Different Networks….

ConventionalI/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 D iagnostic 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%

Routinecheck

NoProblem

Calibrationshift

Zero Off Pluggedlines

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

• 40% of Mfg. Cost is Maintenance

• 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

• 60% of Preventative Maintenance is Unnecessary

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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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ISA108 Provides Necessary Work Processes for Proactive and Predictive Maintenance

3

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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 proc esses are the keys to success

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Date post:	28-Jan-2015
Category:	Technology
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FOUNDATION Fieldbus Moving Forward

Technology