Volume 5, Issue 2

Freedom to Choose. Power to Integrate.Freedom to Choose. Power to Integrate.

In This Issue:

z H1: Fit For Process Control

z Justifying Fieldbus Projects

z NAMUR Collaboration Benefits

z Latest End User Results

z Understanding SIL Ratings

z Verifying Host Interoperability

z Segment Design Solutions

z Migrating From HART To Fieldbus

Your Global Source for FOUNDATION Fieldbus™ News

Fieldbus Report Sponsors

The Fieldbus Fouundation would like to thank thefollowing companies for their support of Fieldbus Report.

2

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T hank you for reading the latest issue of Fieldbus Report.As described in the following articles, the FieldbusFoundation’s open, nonproprietary technology, FOUNDATION

fieldbus™, has gained solid acceptance around the world.End users are achieving significant business benefits by implementing fieldbus-based controls in projects of all sizes —and in a wide range of industries.

My travels on behalf of the foundation have taken me tomany areas of the global control and instrumentation market.From Korea, to Australia and Germany, I’ve met end users,suppliers, integrators and A&E firms making the move toFOUNDATION fieldbus.

I’ve seen, firsthand, how FOUNDATION fieldbus enablesincreased plant efficiency, improved product quality and betterregulatory compliance. The technology delivers capital expenseand operational cost savings that are vital in today’s competitiveenvironment.

I’ve also talked to automation vendors realizing new business opportunities by implementing FOUNDATION technologyin their field instrumentation, host systems and componentproducts. The list of registered fieldbus products continues to grow — visit our website at www.fieldbus.org for moreinformation.

Two recent international industry events demonstrated thesuccess of the Fieldbus Foundation, our members, and ourtechnology. The foundation’s exhibits attracted record crowdsat the INTERKAMA+ 2006 Trade Fair in Hanover, Germany; andat ACHEMA 2006 in Frankfurt, Germany.

At INTERKAMA, we presented one of the largest demonstra-tions of fieldbus interoperability to date. Our stand included displays of registered devices, host systems, tools and servicesavailable from leading automation equipment suppliers.

We also conducted a briefing and reception for the Germantrade press. Dr. Gunther Kegel, chairman of our Europe, MiddleEast and Africa (EMEA) Executive Advisory Council (EAC),discussed current fieldbus technology developments. He alsohighlighted some of our EMEA marketing activities and Germanend user initiatives. This event offered the trade press a valuable opportunity to meet key executives involved in field-bus marketing activities within the region.

A panel discussion entitled, “The Trends and Field ServiceConfiguration: EDDL Gains Support of Industrial Consortium,”was held during the INTERKAMA show. Representatives of thefour member organizations that form the EDDL CooperationTeam (Fieldbus Foundation, HART Communication Foundation,PROFIBUS Nutzerorganisation e.V. and OPC Foundation)addressed issues and technical questions posed by moderatorDavid Humphries of the ARC Advisory Group and the panelaudience.

In addition, the EDDL Cooperation Team hosted a series ofend user seminars covering EDDL interoperability. Seminarsconducted in both English and German updated attendees onthe IEC standard harmonization, EDDL technology enhancementsand future developments. Live, multi-vendor and multi-com-munication demonstrations showed how EDDL can be used in different host systems and across multiple fieldbus protocols.

Several weeks later, at the ACHEMA show, the FieldbusFoundation displayed the capabilities of our technology in chemical and petrochemical processing applications.Coordinated by our German Marketing Committee, the ACHEMA stand featured kiosks demonstrating registeredFOUNDATION fieldbus products and compliant solutions availablefrom major control vendors. Experts were on hand to help visitors acquire information and exchange insights with otherfieldbus users.

At both events, I was impressed by the demand forFOUNDATION fieldbus and the commitment of our members fromaround the world. The automation industry is clearly migratingits control strategies — and investments — to fieldbus tech-nology. I’m proud to play a part in this worthwhile effort.

The enthusiasm for FOUNDATION technology is widespreadamong the world’s end users, as demonstrated by several newinitiatives we have launched with that community.

In April of this year, the foundation announced our best practices demonstration program for the use of FOUNDATION

fieldbus in Safety Instrumented Systems (SIS). The demonstra-tion will validate our new specifications for fieldbus productsused in safety systems. The program kick-off meeting was heldat Shell Global Solutions in Amsterdam, The Netherlands,and involved a “who’s who” of end users. The program will culminate in technology demonstrations at four end user sites:Shell, The Netherlands; BP, Germany; Chevron, U.S.; and SaudiAramco, Saudi Arabia.

Also in April, NAMUR, the German Chemical IndustryAssociation, announced an agreement to collaborate on guide-lines for shielding and grounding in a fieldbus architecture, andprofiles for diagnostics available in fieldbus systems.

These new initiatives are examples of end user commitmentto fieldbus technology — and the foundation’s commitment tomeet the needs of our most important served markets.

Thank you for your continued support.

All the best,

Rich TimoneyPresident & CEOFieldbus Foundation

Foundation Growth:Evident Around The World

Rich TimoneyPresident & CEO,Fieldbus Foundation

President’s Letter

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5

Table Of Contents

FeaturesH1: Protocol Fit For Process Control Purposes 6Understanding the differences between the leading buses

Economic Justification For Fieldbus Implementation 9Decisions should be based on the total project lifecycle

NAMUR Collaboration Promises User Benefits 11An interview with Fieldbus Foundation President Rich Timoney

A Closer Look At Common Fieldbus Myths 13Unraveling the misconceptions about FOUNDATION technology

Seminar Program Offers “Fast Track” To Fieldbus 16Educational events provide free instructional opportunity

Fieldbus Projects: Delivering Results Worldwide 17Major end users improve their process performance

Understanding SIL Ratings For Safety Environments 20Why certification is important when choosing SIS products

HIST: Verifying Host System Interoperability 22Working group strengthens rigorous test specifications

Segment Design Solutions Optimize Fieldbus Systems 25Competitive pressure drives physical layer innovation

Advantages Of Professional Consulting Services 27Experts can help ease the transition to digital-based control

Migrating From HART To FOUNDATION Fieldbus 28Helpful tips to assist fieldbus device developers

Reliable Strategy For Cross-limiting Control 31Seattle Steam achieves robust steam boiler operation

Volume 5, Issue 2Your Global Source for FOUNDATION Fieldbus™ News

www.turck.com©2006 TURCK, Inc.

WITH FIELDBUSPRODUCTS FROMTURCK YOU GETMORE...• More Remote I/O products

• More plug-and-play products

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TURCKIS YOURFIELDBUS CONNECTION

FIELDBUS REPORT is published by the Fieldbus Foundation, 9005 Mountain Ridge Drive,Bowie Bldg – Suite 190, Austin, TX 78759. (Phone 512-794-8890, Fax 512-794-8893).Address all correspondence to Editorial at the same address. Printed in the United States. © 2006 Fieldbus Foundation. All rights reserved. The contents of this publication may notbe reproduced in whole or part without consent of the copyright owner.

FIELDBUS REPORT is written and produced by Industrysource – The Industrial MarketingResource (www.indsource.com).

FIELDBUS APPLICATION GUIDESAVAILABLEThe Fieldbus Foundation offers a selection of comprehensive Application Guides that can helpend users get on the “Fast Track to Fieldbus.” These documents provide valuable information

regarding fieldbus installation procedures, wiring guidelines, network isolation techniques, and more.

To download the Application Guides, visit:www.fieldbus.org/About/FoundationTech/Resources

H1: Protocol Fit ForProcess Control Purposes

T oday, many end users face the critical task of selecting a digital communications technology for their process control system. Thischoice can hinge on a number of cost and performance considerations,

so it’s important to understand the differences between bus protocols beforemaking a major investment.

Understanding the differences betweenthe leading buses

End users with traditional DCS-typeapplications found in the oil & gas,refining, petrochemical and chemicalindustries should carefully examinethe standard network protocols when planning for the future.

6

Examining the leading protocols

FOUNDATION fieldbus, HART andProfibus have established them-selves as the three major digitalcommunication standards used inthe process industries today.

According to Al Dewey, principalproduct marketing manager forEmerson Process Management,digital protocols provide the foundation for a plant’s assetmanagement capabilities.

Dewey said, “Selecting theright protocol, whether users aretrying to start up a plant faster orstreamline maintenance tasks,will provide the ability to gainreal-time plant floor informationfrom intelligent devices over theplant network into an asset man-agement application.”

Jonas Berge, Smar Singaporegeneral manager and author ofseveral books on process instru-mentation, offered this advice:“End users with traditional DCS-type applications found in the oil& gas, refining, petrochemical andchemical industries should care-fully examine the standard networkprotocols when planning for thefuture. They should not assume allof these technologies provide thesame level of performance in aprocess plant environment.”

Important factors to consider

End users should keep severalkey issues in mind when evaluatingcontrol network solutions. Theyinclude:

Commissioning

FOUNDATION fieldbus H1 systemmanagement provides auto-detection and addressing thateliminates the need for DIPswitches or manual offlineaddressing. This saves time andmoney during commissioning.

Profibus PA does not have system management, and assuch, is not a “plug-and-play”solution. Profibus devices must be added to the network one at a time. Some devices requireaddresses to be set by DIPswitches.

System Integrity

FOUNDATION fieldbus H1 andProfibus PA are both digital

technologies providing improved control system accuracy andintegrity. FOUNDATION fieldbus H1employs modern communicationrelationships, such as scheduledpublisher-subscriber, whereasProfibus PA relies on a lesssophisticated poll-response tech-nique without scheduling.

HART does not have real-timedigital communications. Instead,device data is delivered via digitalsignaling “superimposed” on topof the traditional 4-20 mA currentloop used to return (or send) the process variable. Althoughaccepted worldwide, the 4-20 mAsignal has inherent weaknesses,such as the inability to detect signal distortion, limiting its effec-tiveness in certain applications.

Loop Performance

FOUNDATION fieldbus H1 commu-nication is scheduled, resulting in response times several timesfaster than systems withoutscheduling using the same busspeed. Scheduling enhances loopperformance by minimizing deadtime and jitter. This, in turn,enables loops to operate closer to setpoint, and setpoints can

subsequently be pushed closer tooptimum.

Because H1 fieldbus is syn-chronous (isochronous), it doesnot need to rely on over-sampling.H1 bandwidth is divided into fixedslots for cyclic (input/output) real-time and acyclic (diagnostics and configuration) non-real-timedata, precisely controlled by aschedule. Thus, non-time-criticaltasks never interfere with criticalcontrol.

Thanks to H1 fieldbus schedul-ing, hand-held tools can be addedto an active bus without affectingprocess applications automaticallyreceiving the highest priority onthe network.

Moreover, FOUNDATION fieldbususes publisher-subscriber com-munication for real-time data,enabling one device to send datato several different devices in asingle communication — reducingoverhead. The improvement inresponse time again translatesinto better performing processloops.

Unlike FOUNDATION fieldbus,Profibus PA does not supportscheduling and has no commonsense of time among devices.

Since its communication is notprecisely controlled by a schedule,the loop cycle is longer and notprecisely periodic.

Fault Detection

HART and Profibus PA requiredevice management software topoll each device for its status in around-robin fashion. With H1technology, however, faults can be communicated to the devicemanagement software instantly,and are time-stamped in thedevice itself. Profibus PA andHART do not provide comparablealert reporting functionality.

Although HART systems supportdevice diagnostics, they may beexecuted less frequently since thefield instruments must conservepower. Plus, scanning HART devices using existing multi-plexers takes several minutes.Devices have to be continually“polled” to see if there is anythingto report. Because the polling isdone at 1200 BPS with HART,there are limitations on how manydevices can be polled for alerts ina specific timeframe.

Upgrades

FOUNDATION fieldbus H1 allowseasy firmware download over thebus, as well as bumpless switch-over without disturbing other communication or the process. H1devices can be easily upgraded tobenefit from the latest features —helping stave off technologyobsolescence.

Firmware download is notavailable with the HART andProfibus PA technologies.

Field Support

Unlike Profibus PA, FOUNDATION

fieldbus H1 supports portable bustesters for troubleshooting in thefield. H1 also supports hand-heldcommunicators for diagnosticsand calibration in the field.

In the end, the goal of selectinga digital protocol should be todeliver business benefits to thecustomer. Whether the user isseeking faster commissioning,better diagnostics, better per-formance, or increased systemintegrity, FOUNDATION fieldbus is anexcellent choice to achieve theseobjectives.

7

FOUNDATION fieldbus H1 technology enables greater system integrity,improved loop performance, faster fault detection, easier

commissioning, simpler upgrades and easier field support.

The Emerson logo is a trademark and service mark of Emerson Electric Co. ©2005 Emerson Electric Co.

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9

Economic Justification ForFieldbus Implementation

Decisions should be based onthe total project lifecycle

On a major process automationproject, FOUNDATION fieldbus cost savings begin at theengineering stage. There is lesseffort to design and engineer a plant.

During construction, most costsavings are achieved becausefieldbus reduces wiring andgreatly reduces the physicalspace needed. These reductions,in turn, mean less labor to install and check out theequipment.

But the benefits don’t stop atconstruction. When the plant is operational, the diagnosticsavailable using FOUNDATION

fieldbus help end users increasethroughput, improve quality,increase uptime, and lowermaintenance and energy costs.

F ew control engineers would argue with the performance advantages of FOUNDATION fieldbus versusconventional analog technology. Fieldbus provides simplified remote I/O networking, real-time data,robust diagnostics, device interoperability and tightly integrated loop control.

Nevertheless, some end users overlook the most important economic benefits of fieldbus when planningprocess automation projects. While the capital cost (CAPEX) savings with fieldbus are well known (lesswiring, fewer cabinets, fewer field devices, etc.), users don’t always consider the operating cost (OPEX) savings delivered by the technology.

FOUNDATION fieldbus users canreduce their control system

footprint and lower associated equipment costs.

Lower equipment costs,faster commissioning

Ask Ian Verhappen about theeconomic justification for installingfieldbus, and he’ll say that usersshould focus on the total projectlifecycle. Verhappen, a fieldbustraining instructor for Tri-StateUniversity in Angola, Indiana,USA (www.tsutechcenter.org/fieldbusinfo.asp), and formerchairman of the FieldbusFoundation’s End User AdvisoryCouncil (EUAC), was an earlyadopter of FOUNDATION fieldbuswhile at Syncrude Canada. Heconsiders the technology to be awise investment for the life of acontrol system project.

“It is not uncommon to seeoverall capital savings of 25-30%on fieldbus projects when com-pared to a traditional 4-20 mAsystem,” said Verhappen. “Field-bus reduces termination counts,and thanks to multivariable

measurements, enables a reduc-tion in remote I/O.”

With FOUNDATION fieldbus, endusers distributing control func-tionality to the field level reduceequipment costs because controlhardware, I/O, and communica-tions hardware are all containedwithin the field transmitters. Thereis no need for air-conditioned rackrooms with raised floors forcabling. There are also no separate control, I/O, or largepower supply cabinets, nor anycontrol, I/O, or communicationsmodules, control and I/O racks, orseparate termination units andassociated cabling. The equiva-lent to these are contained in thefield.

Verhappen commented, “Althoughthe initial cost of fieldbus devicesand materials is a factor for some users, significant savingsare realized when you account for time and labor reductions.

Fieldbus has been proven toreduce installation labor by 50%,commissioning time by 75%, andengineering effort by 50%.”

According to Honeywell FieldbusProduct Manager John Yingst,fieldbus cost savings can have amajor impact on the end user’sbottom line. “One of our cus-tomers credited our FOUNDATION

fieldbus-based solution withreducing their system footprintand the cost of pulling wires,” saidYingst. “A number of reports showconfiguration and commissioningtimes to be greatly reduced withfieldbus. Commissioning timeinvolves getting at a lot of data,and fieldbus’ higher bandwidthreally helps.”

Charlie Piper, product managerfor system fieldbus developmentat Invensys Process Systems,has a similar outlook. “Advancesin electronics and packaging havedramatically decreased control

system footprints independent offieldbus,” Piper said. “Fieldbuscan add further reductions if theaverage number of devices persegment is above around sixdevices, coupled with eliminationof marshalling cabinets.”

Improved operations,better maintenance

Verhappen regards operationaland maintenance efficiencies asthe primary drivers for most newfieldbus projects. He said, “It’sinteresting to look at the implica-tions of maintenance for a typicalindustrial process plant. Studieshave shown that 40% of manu-facturing cost can be attributed to maintenance, and 50% of all maintenance is corrective.Furthermore, 60% of all main-tenance is unnecessary.”

Verhappen noted plants in-stalling FOUNDATION fieldbus havedocumented 10-20% savings inmaintenance as a result of better field diagnostics, increased predictive maintenance data,improved asset management,fewer false alarms, and fastertroubleshooting.

Many end users now maketheir technology decision not ontraditional fieldbus features suchas reduced wiring and commis-sioning times, but rather on thecreation of knowledge-based systems empowering the work-force to implement a system of continuous improvement inoperations. These users recognizethat the true benefits of fieldbusoccur after start-up and commis-sioning.

Piper explained Invensys’approach to fieldbus-enabled assetmanagement: “Smart, digital fieldinstruments enable communica-tion of data which helps predictfuture device performance andmechanical degradation. Newtechnologies, such as FDT andenhancements to Device Descrip-tions, enable graphical user inter-faces through which extensivetesting and analysis of fielddevices is readily accomplished.For example, on valve positioners,it is possible to perform a wealth ofboth on-line and off-line analysisto spot valve problems.”

10

While most end users recognize the capital

cost savings withfieldbus, they don’talways consider theoperational expense

savings delivered by the technology.

11

NAMUR CollaborationPromises User Benefits

R ecently, the Fieldbus Foundationannounced the establishmentof a liaison relationship with the

Working Group 2.6 “Fieldbus” ofNAMUR, the international processindustry end user group based inGermany. This cooperation will focuson grounding & shielding and devicediagnostics profiles — key issuesidentified by both groups as requiringfurther clarification and guidance.

In this issue of Fieldbus Report,Fieldbus Foundation President andCEO Rich Timoney describes his organization’s working relationshipwith NAMUR, and explains its impacton automation end users worldwide.

FR: What is the significance of theFieldbus Foundation’s collaborationwith NAMUR?

Timoney: As one of the cornerstoneactivities to which the FieldbusFoundation’s Europe, Middle East and

Africa (EMEA) Executive AdvisoryCouncil is committed, our cooperationwith end user organizations such asNAMUR, represented by the NAMURWorking Group 2.6 Fieldbus, is a vitalstep allowing for a greater under-standing of end users’ needs andrequirements. This work ensures the continuance of sound technicalcapabilities and functionalities, andenhances the benefits achievable byimplementers of FOUNDATION fieldbus.

FR: At the INTERKAMA+ 2006 trade fair, the Fieldbus Foundationannounced that it will implement theNAMUR Recommendations and Guide-lines of the Fieldbus Working Group.What affect will this move have onindustry adoption of FOUNDATION tech-nology?

Timoney: FOUNDATION fieldbus is thedominant digital communication solution for process control, and is

gaining a strong foothold in Germanyand across the EMEA region. NAMUR,as one of the most influential end userassociations in the process industries,has an obvious stake in the future ofour technology. They want to specifythe protocols listed in the NAMURWork Sheet NE114 as uniformly as possible to enhance operating performance.

FR: When will the NAMUR Guidelinesbe implemented in control systemsand devices employing the FOUNDATION

fieldbus specifications?

Timoney: I believe the grounding &shielding provisions will be adoptedfirst, since they are needed to meetthe NAMUR NE114 requirementsensuring sound installation practices.Diagnostic profiles as described in theNE107 guideline will follow thereafter.

An interview with Fieldbus FoundationPresident Rich Timoney

Fieldbus Foundation President and CEO Rich Timoney described the foundation’s collaborative alliance with NAMUR.

continued on page 14

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A Closer Look AtCommon Fieldbus Myths

T he last issue of Fieldbus Reportdescribed a number of mythssurrounding FOUNDATION fieldbus.

From installation costs, to industryadoption and international standards,the article set the record straight onthe Fieldbus Foundation’s open, non-proprietary technology.

In this continuing series, we take a closer look at the misconceptionsregarding field-level control and instal-lation costs with FOUNDATION fieldbus.

Myth: FOUNDATION fieldbus is impractical for control in the field

Facts: FOUNDATION technology enablesprimary PID and secondary PID (cascade) functions, as well asfeed/forward and lead/lag, to reside in smart control valve positioners/controllers. Fieldbus eliminates theneed to send cyclic control informationto higher levels — only supervisoryand operation-related data must bepassed to the central control system.

Field-centric automation strategieseliminate the complexities of aDCS environment.

Locating regulatory control in fielddevices improves loop reliability andperformance, and increases availability.It also does away with the need forcomplex and costly control room hard-ware, and at the same time, minimizesexternal link requirements.

In addition, fieldbus instrumentswith built-in control functions provideutmost flexibility for configuring controlloops. The devices’ instantiation capa-bility simplifies incorporating and/orchanging control strategies over time.

Field-level control reduces systemoverhead in many applications.

A field-based control scheme reducescosts associated with centralized processing capacity, power supplies,signal conditioning, panel space andredundancy hardware. Installing spareequipment to accommodate futuremodifications is easier — and lessexpensive — since the cost and complexity of hardware is reduced.

End user knowledge is essentialwhen migrating control functionality to the field.

For instrumentation end users,knowledge is the basis of a successfulstrategy of control in the field.

Honeywell Fieldbus Product ManagerJohn Yingst said, “Customers have tobe aware that some devices have limited control libraries, and othershave long block execution times, whichmakes control in the field challenging.So, they have to study their equip-ment, and know their applications,before moving forward. In many cases,it’s best to start with field-level controlon fairly basic loops.”

New supplier solutions addresscommon concerns about buspower and security.

The supplier community has devel-oped solutions to deal with commonconcerns about control in the field,particularly those related to bus powerand communications security. Forexample, some end users believe acable interruption or fault on a fieldbussegment will compel the actuator intofail-safe or shutdown mode.

Unraveling the misconceptionsabout FOUNDATION technology

For instrumentation end users, knowledge is critical toensuring a successful strategy of control in the field.

Physical layer suppliers havedeveloped new fieldbus powerconditioner and device couplersolutions impervious to any singlepoint failure. This means fieldbussegments can now be made trulyredundant for power conditioning,H1 communications and fieldcables.

Myth: FOUNDATION fieldbus increases installation costs

Facts: FOUNDATION fieldbus delivers significant savings intotal installation costs. Fieldbussystems reduce instrumentwiring, which means less termi-nation and fewer screwdriverturns. The technology alsoreduces hardware requirementsand lowers Capital Expenditures(CAPEX).

Fieldbus reduces capitalequipment costs when compared to conventionalcontrol technology.

In a study conducted byRheinhold & Mahla (R&M), field-bus installed costs were found to

be up to 15% less than conven-tional instrumentation systems,and 5% less than conventionaltechnology utilizing remote I/O.

Known as FuRIOS (Fieldbusand Remote I/O System compar-ison), the R&M analysis verifiedfieldbus reduced engineering,wiring and component costs, andenabled faster commissioningthrough standard coding, reducederrors, and improved error diagnosis (read the report athttp://www.fieldbus.org/email/Furiosreport05.pdf).

An ARC Advisory Group studyfound 56.6% of end users rankedthe installed cost of fieldbus to be less than conventional systems, and 81% ranked field-bus costs to be less than conventional systems over afive-year period (read the studyat http://www.fieldbus.org/pdf/ARCInsightReport.pdf).

For additional informationabout FOUNDATION technology,and to download detailedfieldbus technical guides,visit www.fieldbus.org.

14

NAMUR CollaborationPromises User Benefitscontinued from page 11

FR: The grounding & shieldingissue with fieldbus is complex.How will the foundation’s co-operation with NAMUR addressthis matter?

Timoney: Currently, there areseveral different grounding &shielding solutions supported bynumerous guides, standards andindustries. The optimum choiceof solution depends upon severalfactors, including the nature ofthe application and the locationof the installation. The new Fieldbus Foundation guide seeksto comply with the NAMURWorking Group 2.6 FieldbusNE114 guideline, which is currently under development,as well as the international practice and options for ground-ing & shielding of fieldbus systems.

The foundation’s manager of

fieldbus products, StephenMitschke, is leading a collabora-tive working group dedicated tothe compilation of a guide to helpend users make an informeddecision about “best practices”for the grounding & shielding offieldbus networks.

FR: How is the development of a device diagnostic profile standard being handled?

Timoney: Stephen Mitschke isleading a second working groupof manufacturers and end usersto investigate the portfolio ofself-check and diagnostics forfield devices. This initiative will ensure the consistency ofFOUNDATION fieldbus devices withthe NE107 guideline requiringdevices to deliver extensive diagnostics so optimum plantefficiencies can be achieved.

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There are those who promiseadvanced diagnostics for theirfieldbus systems. Problem is,you have to use their devices—and only their devicesto get any benefit. Well forget it. Push performancepast the usual threshold with the I/A Series® system.Our Field Device Manager offers the only managementapplication combining FDT technology for superiordiagnostics with basic Device Description technologyfor configuring and commissioning. It is the first tosupport enhanced EDDL from device vendors nothaving advanced FDT diagnostics. Ultimately providingtruly open, advanced diagnostics for any device, fromany vendor. Combined with ease of engineering andmaintenance, plus the industry’s best fault tolerance—you get the most advanced, most open solutionavailable. More importantly, you get a control systemwith FOUNDATION fieldbus™ that delivers real lifetimeeconomic benefits. More performance. More uptime.Less cost. There’s a reason Foxboro FDT technology isthe leader. It’s called Know-How. To learn more visitfoxboro.com/ff-fdt.

The difference is Know-How.

©2006 Invensys Systems Inc. All rights reserved. Invensys, Foxboro and I/A Series are trademarks ofInvensys plc or its subsidiaries and affiliated companies. All other product names may be the

trademarks of their respective owners.

Seminar Program Offers“Fast Track” To Fieldbus

T he Fieldbus Foundation is offering two seminar tracks tohelp end users and engineers

Get On the Fast Track to Fieldbus.The seminar program was developedin response to growing demands,throughout the process automationindustry, for comprehensive instruc-tion on FOUNDATION fieldbus.

The Fieldbus Educational Seminarsare designed for those looking for an overview of FOUNDATION technologyor planning a fieldbus installation.They explain the basics of the tech-nology, help attendees stay up tospeed on the latest developments andnew products, and provide opportuni-ties to network with other fieldbusprofessionals.

Fieldbus Foundation President andCEO Rich Timoney described the seminar program as “part of our continuing effort to provide compre-hensive, vendor-neutral information to help the industry get on board withFOUNDATION technology.”

Timoney said, “We are pleased to offer an expanded series of freefieldbus educational seminars. Theseminars are intended for those individuals requiring a broad under-standing of fieldbus principles andimplementation strategies. Attendeeshear presentations by leading tech-nology experts, and have an opportu-nity to find answers to their specificquestions.”

Fieldbus Educational Seminar topicsinclude: the integrated H1+HSE fieldbus architecture, physical layercomponents, interoperability, fieldbuseconomics and the “Top Ten” fieldbusmyths. In addition, the seminars feature a hands-on fieldbus inter-operability demonstration performedby connecting user-selected devices

to a pre-selected host system. Thehost is different at each location,with participants building a fieldbusnetwork designed in parallel as part of the seminar exercise.

Numerous controls manufacturersare present at the Fieldbus Edu-cational Seminars displaying their latest FOUNDATION fieldbus solutions.Attendees can browse tabletopdemonstrations of fieldbus-compliantcontrol systems, devices, physical

layer components, and other relatedequipment.

Seminar registration is free andlunch is served as part of the event.All attendees receive a registrationpacket containing a CD with tech-nical guides, the Fieldbus Reportsupplement, and much more.

For additional seminar information,visit the Fieldbus Foundation’s website at www.fieldbus.org.

Educational events provide freeinstructional opportunity

16

Fieldbus Educational Seminars are designed for control professionals lookingfor an overview of FOUNDATION technology or planning a fieldbus installation.

17

Fieldbus Projects:Delivering Results Worldwide

SECCO: World-class example ofcontrol in the field

Shanghai SECCO PetrochemicalCompany Ltd., a joint venture betweenBP, Sinopec and Shanghai Petro-chemical Corporation (SPC), recentlycommissioned a new, $2.7 billion ethylene cracker complex — one ofthe largest integrated petrochemicalplants in the Far East. The SECCOcomplex is among the world’s mosthighly automated petrochemical facil-ities.

At the Shanghai complex, FOUNDATION

fieldbus-based systems manage over48,000 control loops, with about166,000 I/O tags, 40,000 instrumentsand some 13,000 intelligent devicesthroughout the facility. They com-municate with more than 23,000 fielddevices used to control the ethylenecracker and nine downstream derivativeplants.

Over 80% of the fieldbus devices at

the SECCO complex are utilized forcontrol in the field. Around 25,000points are hardwired to the automa-tion system. There are over 70,000cables in the facility.

Emerson Process Management’sPlantWeb digital architecture inte-grates 10 DeltaV process automationsystems with a single global historianand remote operations functions. All10 automation systems are managedfrom a single, centralized control room.

In the FOUNDATION fieldbus segments,SECCO employed the FPS-I typeredundant fieldbus power system fromMTL-Relcom. The FPS-I power supply,equipped with two redundant powersupply modules, provides “hot-plugging”without interrupting power and com-munication on the fieldbus.

MTL-Relcom also supplied Mega-block wiring components certified forZone 2 environments. These devicesare designed to prevent a short circuit

in any of the individual transmitters orspur cable runs from causing a failureon the fieldbus segment.

SECCO’s senior instrument counselor,Wu Guoliang, indicated that the operational status of FOUNDATION field-bus controls has been excellent duringthe first year of installation. He said,“The bus information response speedfully meets the requirements of chemicalprocess control. Basically, all the busdevices operate stably and reliably.”

SECCO specified FOUNDATION tech-nology because of its ability to providepersonnel with robust device, equip-ment and process health information— regardless of their physical locationat the site. The company believedfieldbus’ system self-diagnostic capa-bilities would support its plant optimization strategies and increaseoperational uptime.

CSPC: Real-time diagnosticsenable proactive maintenance

The new CSPC (CNOOC and ShellPetrochemicals Company Limited)petrochemical complex at Nanhai insouthern China is one of the world’slargest FOUNDATION fieldbus projects for

Major end users improve theirprocess performance

The SECCO complex is among the

world’s most highly automated

petrochemical facilities.

Connecting Fieldbus Power & Knowledge

FieldConnex is the industry’s leading fi eldbus installation system.

Our revolutionary high- power trunk method is the most innovativeand flexible solution for installing fieldbus in any application.

Improvement in the overall performance of your fieldbus network is further enhanced with our Advanced Diagnostic Module. ADM is capable of providing the fi eldbus user with information once available to only a small group of experts, but now can be implemented by anyone during start-up & commissioning, standard operation and troubleshooting.

It’s a fact! Pepperl+Fuchs is Connecting Fieldbus Power and Knowledge.

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FIELDCONNEX® IS POWERFULAND INTELLIGENT, AND ITWORKS BOTH NIGHT AND DAY

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•Shanghai Yamatake Automation Co., Ltd.(China) :Tel: 86-21-6448-5981

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generation in automation technologies.

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the process industries. The instal-lation includes 3,000 FOUNDATION

fieldbus segments and 16,000fieldbus devices.

Similar in scale to the SECCO complex in Shanghai, CSPCNanhai is a nine-plant complexcentered on an 800,000 tpa ethylene cracker. World-scaledownstream plants will producelow- and high-density polyethylene,polypropylene, ethylene oxide/ethylene glycol, styrene monomer,and a range of polyols and glycols.

The CSPC site, implementedwith the Yokogawa Vigilant PlantConcept, has nine Yokogawa CENTUM CS3000 systems with200,000 tags. Again, like SECCO,the project is totally FOUNDATION

fieldbus-based. Unlike SECCO,however, with its one, enormouscentral control room, Nanhai features three control centerswith 15 field auxiliary rooms.

Johan Veerman, principalinstrument and process controlengineer at CSPC said,“FOUNDATION fieldbus was the obvious choice for communica-tions. In today’s world, it’s essen-tial to have networks integrate

with each other, and to utilize theinformation flowing through them.Process instrumentation is beingincreasingly field-networked todeal with the huge quantities offield data. Compared to conven-tional 4-20 mA systems, fieldbusnetworks are more flexible interms of wiring, information flow,maintenance, and so on.”

He added, “FOUNDATION fieldbusdoesn’t just reduce the cost ofwiring. It also transmits a lot ofinformation in an intelligent way,making it possible to do remotemonitoring, real-time self-diag-nostics and predictive maintenanceof field devices, as well as plantresource management using fieldcommunication. This will greatlyreduce operating costs of instru-mentation systems.”

Veerman indicated that pro-active maintenance was a keydesign criterion on the CSPC project. “I was looking for a systemto enable proactive maintenance,”he said. “One tool that can do this is Yokogawa’s Plant ResourceManager (PRM), a real-timedevice and advanced diagnosticssoftware package.”

SCA: Fieldbus supports “highperformance” environment

SCA Tissue’s new papermaking,converting, and distribution com-plex in Barton, Alabama, USA, wasthe first “greenfield” project in thecompany’s history. With theopportunity to start with a blanksheet of paper, several innovationsto improve efficiencies were con-ceptualized and brought to life.

One major advantage of agreenfield project is that the enduser does not inherit the ineffi-ciencies or constraints of an existing operation. The Bartonproject allowed SCA Tissue to satisfy market demand for AFHtissue products and evaluate its production and distributionprocesses “from the ground up.”

SCA chose ABB to supply anintegrated, FOUNDATION fieldbus-based automation solution for theBarton facility. Known as thePapermaking Suite 3.0, the solution includes field device integration, on-machine qualitycontrol (QCS), drives systems,machine health/web monitoring,and a Distributed Control System

(DCS). ABB provides on-going main-tenance for all of these systems.

Ron Thiry, SCA’s vice president,manufacturing, stated, “The levelof automation at the Barton facilityis extremely high — from theautomated dewiring of wastepaperbales to the use of AGVs in thewarehouse. Once the rolls leavethe dry end of the paper machine,they are not touched by humanhands.”

The Barton tissue operation isone of the paper industry’s largestFOUNDATION fieldbus installations.PLCs, variable speed drives,transmitters, and other fielddevices are all connected to thebus. This significantly reduced the installation costs of thedevices and provided access tothe embedded intelligence in eachdevice.

All production operations canbe monitored and controlled at any of the online operator stations. Two control rooms (onein the fiber plant and one near the tissue machine) are seam-lessly integrated in terms of whatoperators and technicians canview.

ABB’s fieldbus control platformplayed an important role in SCA’s“High Performance” environment.The Barton complex is a show-case tissue facility due to itsautomation, integration, and infor-mation sharing. The improvementsin performance and efficiencyhave been documented and aresatisfying to owners, customers,and partners.

19

The SCA Barton operationis a showcase tissue

facility due to its automation, integration

and information sharing.

At the CSPC site, FOUNDATIONfieldbus enables remote monitoring,real-time self-diagnostics and predictive maintenance of field devices.

Understanding SIL RatingsFor Safety Environments

R esponding to growing concernsabout industrial safety, theInternational Electrotechnical

Commission (IEC) enacted an industry-neutral standard — IEC 61508 (func-tional safety of electrical/electronic/programmable electronic safety-relatedsystems) — to drive the safety-relatedrequirements of equipment used inSafety Instrumented Systems (SIS).Subsequently, IEC released IEC 61511(functional safety: safety instrumentedsystems for the process industry sector) to help end users determinethe Safety Integrity Level (SIL) neededfor their safety applications.

Why certification is importantwhen choosing SIS products

20

Production processes can be optimizedfor safety system performance by

selecting components rated for usewithin the desired SIL environment.

21

The combination of thesestandards has prompted processindustry end users to seek openand interoperable instrumentationsolutions that will improve theinherent safety of the plant whileproviding increased informationneeded for asset managementand optimization.

What is a Safety IntegrityLevel (SIL)?

A Safety Integrity Level (SIL) is the required safety system performance based on riskassessment of a specific SafetyInstrumented Function (SIF).SILs define the extent to whichend users expect the process inquestion to perform safely, and in the case of a failure, fail in asafe manner.

No individual product within a SIF can carry a SIL rating; rather, individual components of processes, such as field devices, can only be certified as appropriate for use in given SILenvironments. The details of thismeasurement are outlined in IEC61511 (which is also available asANSI/ISA-84.00.01).

Risk Based Safety Analysis(RBSA) is an example of amethod used for associating SILvalues with processes. RBSAinvolves evaluating and quantify-ing the safety risks of a process,and then categorizing them asacceptable or unacceptable.Acceptable risks can be justifiedon the basis of moral, monetaryor other considerations. Con-versely, unacceptable risks haveconsequences too large or toocostly to justify. Whatever thejustification, the goal is to arriveat a safe process.

SIS specifications for fieldbus devices

The Fieldbus Foundation’s SISprotocol specifications, completedin 2005, are in compliance withthe IEC 61508 requirements upto, and including, Safety IntegrityLevel 3 (SIL3). The specificationsenable manufacturers to buildFOUNDATION fieldbus devices meet-ing stringent IEC 61508 guide-lines. Third-party test agencieswill certify that these devices are suitable for use in SIS installations.

For the first time, end userswill be able to choose devicesmeeting the requirements of IEC61511 from multiple suppliers,instead of being restricted todevices designed specifically for a proprietary safety systemplatform.

Choosing components forSIL environments

Processes can be optimizedfor risk by selecting components,such as fieldbus SIS devices andlogic solvers, rated for use withinthe desired SIL environment. Forexample, if the desired SIL valuefor the process is SIL3, the usershould choose devices certifiedto be suitable for that environ-ment.

Simply combining processcomponents appropriate for agiven SIL environment does notguarantee the process will berated at the specified SIL level.The process SIL must still bedetermined by an appropriatemethodology, such as SimplifiedCalculations, Fault Tree Analysis,or Markov Analysis.

Why use a certified SISproduct?

A SIS product certified by a third-party agency for usewithin a particular SIL environ-ment offers several importantcustomer benefits. Reliability calculations for such productsare already performed and available to the end user. Thiscan significantly cut lead times in the implementation of a SIL-rated process. Furthermore, thecustomer has the assurance thatassociated reliability statisticshave been reviewed by a quali-fied, neutral party.

The most important benefit to using certified SIS products is the associated certificationreport. Each certified productcarries with it a report from thecertifying body containing impor-tant information ranging fromrestrictions of use, to diagnosticscoverage within the certifieddevice, to reliability statistics.Additionally, ongoing testingrequirements of the device areclearly outlined. A copy of thecertification report should accom-pany any product certified forfunctional safety.

Worldwide Fieldbus Training SolutionsSAIT is a world leader in FOUNDATION fieldbus™ training.From Alaska to Australia, we provide customized and certifiedsite training for clients around the globe.

Our mobile training units and our leading-edge lab provideyou with flexible, professional Fieldbus training to meet yourbusiness’ every need.

For more information visit: www.sait.ca/fieldbusEmail: fieldbus@sait.ca Phone: 403.284.8967

Real World Expertise | Real World Trainingwww.sait.ca/fieldbus

1

HIST: Verifying Host SystemInteroperability

T he Fieldbus Foundation’s HostInteroperability Support Test(HIST) is the industry’s most

comprehensive testing program forverifying the interoperability of field-bus-compliant host systems.

For end users, the HIST results provide assurance that a supplier’shost system incorporates the robustcapabilities of FOUNDATION fieldbus.The testing also reduces system integration risks, since hosts are independently tested to be able tohandle the characteristics of differentdevices.

Tests confirm FOUNDATIONtechnology features

HIST provides generic test proce-dures performed or witnessed byqualified Fieldbus Foundation staff onFOUNDATION fieldbus systems. Theseprocedures are intended to show ahost system incorporating featuresdefined by the Fieldbus Foundation,such as Device Tag Assignment,Device Description (DD) Services andCapabilities Files (CF), is capable ofsupporting interoperability.

As specified in the HIST documen-tation, each feature contains a set of

test procedures that are run againstthe host or the fieldbus system usingthe host. Many test procedures requirefeatures supported from both thedevice(s) and the host.

A host is able to claim support for aFOUNDATION fieldbus feature if it passesthe test procedures defined by thatfeature. Since the features themselvesare generic, manufacturers derive thetest cases or actual implementationsteps necessary to meet the require-ments of the test procedure.

Working group maintains testspecifications

The Fieldbus Foundation has anactive working team called the SystemIntegration and Maintenance (SIM)team. This group, made up of host

Working group strengthensrigorous test specifications

The Fieldbus Foundation’s System Integrationand Maintenance (SIM) team is made up

of host suppliers, device manufacturers, and end users.

22

23

suppliers, device manufacturersand end users, is responsible forthe maintenance of several specifications, including FF-569“Host Interoperability SupportTest (HIST).”

The SIM team is involved intwo major tasks: defining hostprofiles and defining additionalfunctional testing for host appli-cations. The current HIST profilelist includes several individualfeatures a host may support.The profiles will define whichfeatures are required for a hostapplication to assure interoper-ability between the host applica-tion and field devices. In order for a host to meet a given profile,the supplier must demonstratethat the system complies withthe mandatory features.

It should be noted that differenthost profiles have different setsof required features. For example,a hand-held configuration toolwill have a different set of pro-filed features than a DistributedControl System (DCS).

Additional functional testingstrengthens HIST

The SIM team is in the processof developing additional func-tional testing to be incorporated

into the HIST procedures. Thefirst features that will implementthese tests relate to DD and CFsupport.

The goal of the functional testing is to ensure end users can select a FOUNDATION fieldbusinstrument, and using registeredDDs and CFs, access the fea-tures of the device without anyspecial files or modifications.

As part of the functional test-ing, a series of test DDs and CFs,along with a standardized testdevice, will be used to validatethat a host properly implementsthe requirements of the FF-901“Device Description InteroperabilitySpecification.” For example, testDDs will help verify that the hostcan properly render new DeviceDescription Language (DDL)visualization enhancements suchas windows, images, charts andgraphs.

The test DDs and CFs will be made available to both hostsystem suppliers and devicedevelopers through the FieldbusFoundation’s DL-006 DeviceDescription Library.

For more information about HIST procedures, visitwww.fieldbus.org.

IMPROVE CONSISTENCY AND REDUCE COST WITH ONE SOLUTION.LET’S TALK.

Copyright © 2006 Rockwell Automation, Inc. All Rights Reserved. AD GMS1821-R1P

Improve your process using the one architecture that unifies control disciplines and provides actionable

information. You’ll stay informed and make more effective business decisions. See how Integrated Architecture

can help you achieve operational excellence. RockwellAutomation.com/think/process.

25

Segment Design SolutionsOptimize Fieldbus Systems

W ith FOUNDATION fieldbus tech-nology now widely acceptedaround the world, leading

automation suppliers are offering achoice of innovative solutions helpingend users achieve more power to connect more instruments to fieldbussegments in Class I, Division 1, andClass I, Division 2, hazardous locations.

Some physical layer suppliers utilizethe Fieldbus Intrinsically Safe Concept(FISCO) and Fieldbus NonincendiveConcept (FNICO) techniques to providemore power on bus networks. Otherschoose approaches like the HighPower Trunk (HPT) concept for solvinghazardous area and general-purposefieldbus applications.

Latest advancements increasebus power

Honeywell Fieldbus Product ManagerJohn Yingst sees new developmentson the horizon for the fieldbus physicallayer. “With FOUNDATION fieldbus longpast the ‘critical mass’ stage, wiring

and power conditioningproducts havenot only becomeextremely reliable,but we are seeingsome real com-petitive pressuresand significantdesign improve-ments,” Yingst said.“Suppliers are re-sponding to user demands for more cost- and space-effi-cient products.”

He continued, “While fieldbusinstruments don’t really require morepower than conventional devices,efficiency upgrades in power condi-tioners are a welcome improvement.Host vendors, like Honeywell, areworking closely with manufacturers of power conditioning products tointegrate their solutions into theprocess automation environment.”

Bernd Schuessler, Pepperl+Fuchsbusiness development manager,described similar benefits from innovations in power conditioningtechnology. “With the advent of ‘third-generation’ fieldbus power conditioners, end users can finallyenjoy the same benefits in terms ofpower, cable length, and number ofdevices per segment in hazardouslocation applications as they do ingeneral purpose applications,” saidSchuessler. “Modern segment designconcepts are supported by new field-bus power supplies and condition-ers offering built-inredundancy as wellas online physicallayer diagnostics.These features arenot available withconventional tech-niques.”

Schuessler added,“The HPT conceptdoes not limit theenergy on the field-bus trunk cable toIntrinsically Safe (IS) or nonincendivelevels. Rather, the

energy on the spur connections is limited to the instrument. This allowsend users to get the maximum number of devices on a segment while also being able to perform live maintenance on the instruments and achieve maximum cable length.Depending on the application, the protection happens in the field insidethe junction box.”

New solutions provide systemflexibility

André Fritsch, R. STAHL productmanager, instrumentation, thinksremote I/O networking solutions as a fieldbus add-on for other signalsprovide greater flexibility for thosedesigning FOUNDATION fieldbus systems.“End users can now select Ex e/Ex ifield device couplers, approved forZones 1 and 2, and for Division 2,allowing for the operation of IS fielddevices according to FISCO on a non-IS fieldbus. They have the optionof connecting up to four FISCO fielddevices, or up to eight non-IS fielddevices, per device coupler,” saidFritsch. “These IS circuits also provideshort-circuit protection and are

Competitive pressure drivesphysical layer innovation

Device couplers approved for Zones 1 and 2 allow forthe operation of intrinsically safe field devices

according to FISCO on a non-IS fieldbus.

New fieldbus power supplies and conditioners offer built-inredundancy as well asonline physical layer diagnostics.

galvanically isolated from thenon-IS bus.”

As a unique feature, fielddevice couplers can incorporatean integrated intelligent powermanagement capability reducingstartup current and limiting themaximum short-circuit current toone spur only, even if severalspurs are short-circuited.

According to Mike O’Neill,international sales director forMooreHawke Fieldbus, advance-ments in fieldbus device couplersprovide users with an additionaloption: automatic segment ter-mination. He stated, “It is nowpossible to manually de-energizedevice coupler channels using akey-operated magnetic interlock.This allows individual fieldbusdevices to be disconnected fromthe fieldbus segment without de-powering the entire segment,even in Zone 1 areas.”

Fault-tolerance increasesuser confidence

O’Neill believes increased con-fidence in the FOUNDATION fieldbusphysical layer encourages theuse of control in the field —overcoming previous concernsthat cable problems could lead topower loss at the final actuatorand result in unwarranted planttrips.

“The ability to make fieldbussegments completely fault-toler-ant is the most significant eventfor physical layer designs sincethe introduction of electronicspur short-circuit protection,”O’Neill said. “Today’s segmenttermination solutions can auto-matically bypass a broken orshorted trunk cable. This finalstep in eliminating single pointfailures will have a significanteffect on user confidence,and on the acceptedrules for fieldbus segment design.”

Device developers haveanswers of their own

At TopWorx, designers havetaken a different approach tooptimizing fieldbus networks.They’ve developed new valvecontroller technology requiringonly one function block, thusreducing the number of segmentsneeded in a typical fieldbusinstallation. Traditional valve controllers normally require aminimum of three functionblocks to handle two switchinputs and a solenoid output.The result is quicker device execution time, more devices persegment, fewer segments, andreduced hardware and softwarelicensing costs.

Managing physical layerimproves efficiency

Beyond new segment designinnovations, Tim-Peter Henrichs,TURCK fieldbus marketing manager, believes the fieldbusphysical layer should be managedas part of a modern asset management system. He said,“The exchange of informationbetween the control system andfield devices always occurs viathe physical layer components— regardless of the topology.The availability of a system isalways directly dependent on theavailability of the physical layercomponents.

“Our objective is to continuouslyintroduce more transparencyregarding the physical layer.Managing physical layer com-ponents is key to effective andefficient system operations,and will save time and moneythrough scheduling maintenance

appropriately and more effectively utilizing the

assets that are available.”

26

Advancements in fieldbusdevice couplers provide users with an additional option: automatic segment termination.

27

Advantages Of ProfessionalConsulting Services

T oday, many companies want tospeed their implementation ofFOUNDATION fieldbus. End users

need assistance with applicationtraining, segment design, commis-sioning, troubleshooting and mainte-nance. Device developers need helputilizing fieldbus communicationstacks, Device Descriptions, FunctionBlocks and other tools.

Consultants make digital transition easier

The growth of FOUNDATION fieldbushas given rise to professional consult-ing services addressing both supplier

and end user requirements. IanVerhappen, an expert in the consultingarena, leverages his experience withfieldbus technology to provide servicesranging from system engineering,audits and migration plans, to networkdesign, HAZOP studies and riskassessment.

“Industry is undergoing a stepchange, moving into an integrated digital environment with more dataavailable than ever before,” saidVerhappen. “This is where professionalconsultants can help by offering theirskills to enable end users to make better use of fieldbus data, and todesign more reliable digital controlsystems.”

Services support user implementation

Leading automation vendors offerservices designed to ease customermigration to fieldbus technology. Forexample, ABB has consulting servicesaddressing all phases of fieldbusimplementation. Services includebasic and advanced training/supportfor technology applications, networkdesign, project team development,engineering, commissioning, andmaintenance/troubleshooting.

Emerson Process Management’sFieldbus Consulting Group helps endusers execute fieldbus projects efficiently, climb the learning curvequickly, avoid mistakes, and reducerisks. The Group performs economicanalysis of fieldbus benefits for projectjustification; develops bid specifica-tions, plant engineering standards and

procedures; explains areas of changein engineering; and participates inproject planning.

Community colleges and other edu-cational institutions also recognize the widespread adoption of fieldbusand are offering instructional coursesfor developers and end users. At the Fieldbus Center at Lee College in Baytown, Texas, USA (www.knowthebus.org), users can attend fieldbustraining courses heavily weighted inhands-on applications. The Center’sfacilities closely mirror the actual workenvironment of those involved in plant operation and instrument maintenance.

Likewise, the Southern AlbertaInstitute of Technology (SAIT), which islocated in Calgary, Alberta, Canada(www.sait.ca/fieldbus), offers custom-ized fieldbus training to end userswishing to train large groups of theiremployees. Typically, this type of training is performed at the company’ssite with the aid of SAIT-developedportable fieldbus training units. SAIThas also developed a series of certifiedcourses leading to FOUNDATION fieldbusprofessional certification.

At Tri-State University (TSU),Angola, Indiana, USA (www.tsutechcenter.org/fieldbusinfo.asp), new tech-nologies like FOUNDATION fieldbus aretracked and reviewed by an EmergingTechnologies Focus Team. TSU hasinstituted a comprehensive fieldbusinstructional curriculum and deliverscustomized training solutions toindustries in the U.S. Great Lakesregion.

This group of highly skilled profes-sionals identifies new technologiesmaking an impact on industry today,and develops certification and degreeprograms for launch at the TSUTechnology Center.

Experts can help ease the transitionto digital-based control

The growth of FOUNDATION fieldbus has given rise to professional consultingservices addressing both supplier and end user requirements.

continued on page 29

Migrating From HARTTo FOUNDATION Fieldbus

F or device developers, migrationfrom HART technology to the ad-vanced capabilities of FOUNDATION

fieldbus can be a simple, cost-effectiveprocedure unlocking new sales oppor-tunities in today’s fastest growinginstrumentation market.

However, device manufacturersdeveloping FOUNDATION fieldbus H1 orHSE options for existing HART instru-ments should consider a few detailsnot immediately obvious from thefieldbus standard or specification.

According to Smar SingaporeGeneral Manager Jonas Berge,developers incorporating FOUNDATION

technology into their instrumentationfamily should remember the followinghelpful tips:

• Follow the standard transducerblocks for device profiles such aspressure and temperature transmit-ters. This improves consistency acrossmanufacturer platforms, simplifiesdevice replacement, and enablesfuture field calibrators to work withoutDevice Descriptions (DDs).

• Support sub-schedules to permitsome loops on the bus to executefaster than others. Also, support dualschedules so that a new control strategy can be downloaded andswitching can occur instantaneously.

• Support incremental downloads topermit changes in the control strategyon the fly.

• Support firmware downloads withbumpless switchover so users can

easily upgrade device firmware tobenefit from the latest diagnostics andcontrol enhancements.

• Support fast link settings for H1devices. The standard link is 48 mS,but if more aggressive link settings(e.g., slot time, minimum inter-PDUdelay, maximum response delay) are supported, the time required for eachlink can be reduced. This results inmuch shorter bus cycles than seen forolder devices.

• Support Multi Variable Container(MVC) subscription in output devices,such as valve positioners and actuators, so the central controllerpublishing all output values for the busat the same time can optimize com-munication and controls. Similarly,

multi-channel input devices shouldsupport MVC publishing.

• Carefully review the fieldbus modeand status mechanism. Use DigitalInput (DI) blocks sparingly to indicatedevice status such as local override,hand operation, failsafe interlocks, etc.Instead, internal device status shouldbe indicated to operators using themode parameter and employed in thecontrol strategy using status flags.

• Ensure function blocks execute asfast as possible in order to reduce theoverall bus cycle. This may requireoptimizing code and incorporatingmicrocontrollers, which are sufficientlyfast for most applications. An arith-metic co-processor may be helpful aswell.

Helpful tips to assist fieldbusdevice developers

Increasingly, instrumentation suppliers are packagingsolutions enabling a seamless upgrade from HART

to FOUNDATION fieldbus communications.

28

29

Assistance shortens producttime-to-market

Instrumentation manufacturersentering the digital marketplacecan use consulting services todecrease their time-to-marketfor new fieldbus products. Fromhardware integration and custom-ized templates, to system testingand standards certification,service providers can make sureFOUNDATION technology is integratedinto a supplier’s devices as effectively and economically aspossible.

Companies like Softing AGoffer turnkey hardware and soft-ware development solutions forfieldbus devices, as well as consultancy services helpingwith network interfaces andmigration from analog instru-ment designs to modern fieldbuscommunication.

“Most new fieldbus suppliershave questions about device

registration, host compatibilityand other technology considera-tions,” said Dr. Ernst Flemming of Softing. “We are here to providethe answers they need.”

Softing offers an off-the-shelf“Fieldbus Kit” enabling the rapiddevelopment of FOUNDATION field-bus H1 devices for IntrinsicallySafe (IS) environments. It can beused in conjunction with existingHART devices to create a complete fieldbus product. Thekit is small enough to be inte-grated into most existing devicehousings.

The Fieldbus Foundation itselfoffers various levels of servicesfor the development, testing andregistration of fieldbus devicesand host systems. The founda-tion staff assists manufacturersin executing interoperability andconformance tests for fieldbusdevices, and provides projectmanagement support for thedevelopment of compliant products.

Advantages Of ProfessionalConsulting Servicescontinued from page 27

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How does it work?

System IntegrationMakes it run like clockworkTo ensure that your plant runs smoothly, ouraccredited Fieldbus laboratory exhaustively tests our instruments in several different control systems. Your benefit: optimal fit andno-risk integration.

InteroperabilityIn addition to being certified by the appropriateuser organisation, our instruments are also tested in a multi-vendor environment before market release.

IntegrationWe integrate our instruments into major host systems, e.g. ABB, Emerson, Honeywell, Rockwell, Siemens and Yokogawa.

FunctionalityOptimum device operation is ensured by DDs,EDDs and DTMs. We also take care that our instruments are properly integrated into systems such as AMS and PDM.

SupportOur Fieldbus Laboratory offers customer courses, service and support in all aspectsof fieldbus technology.

www.products.endress.com/system-integration

“For FOUNDATION Fieldbus we not only integrate, we also

test control-in-the-fieldcapability.”

Dominik KobiellaManager Fieldbus Laboratory

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Reliable Strategy ForCross-limiting Control

S eattle Steam is a district heatingcompany located in Seattle,Washington. Founded in the late

1800s, the company maintains 18 milesof pipe buried under the streets ofdowntown Seattle in a one-square-mile area. Customers purchase steamfor heating buildings and water, and in the case of hospitals, for use in sterilization processes.

Seattle Steam’s steam generatingoperation had been modernized severaltimes over its history, and in 1996,the company decided a new boiler

control system was in order. The projectwould involve replacing outdatedpneumatic controls that were increas-ingly difficult for plant personnel tomaintain.

Seattle Steam had no preconceivednotions about process automationtechnology. However, managementviewed reliability as critical and wanted to utilize a PC-based com-puting platform rather a proprietaryDistributed Control System (DCS). Itpreferred an open, interoperable,

standards-based control system providing the freedom to choose “best-in-class” solutions from different vendors.

Demanding combustion controlapplication

Key to Seattle Steam’s automationproject was the need to implementair/fuel cross-limiting control on itsboiler operation — a challengingapplication for most control systems.Cross-limiting combustion controlminimizes the chance of a dangerousratio of air and fuel within a combus-tion process. This is implemented byalways raising the air flow beforeallowing the fuel to increase, or bylowering the fuel flow before allowingthe air flow to drop.

Applying additional dynamic limitsto air and fuel set points can increasefuel savings by maintaining the air/fuelratio within narrow limits during andafter transition. This reduces heat lossby protecting against the demand signal making the air/fuel ratio toolean.

For Seattle Steam, cross-limitingcombustion control would ensure:better optimization of fuel consump-tion; safer operating conditions byreducing the risk of explosion; fastercombustion characterization setup;improved diagnostics and trouble-shooting; and better process visibility.

Control functions handled by field devices

After considering various options,Seattle Steam decided upon a field-bus-based control system provided bySmar International. The project provedto be one of the first commercial field-bus installations in North America, and

one of the initial implementations ofcontrol at the field level.

With the FOUNDATION fieldbus system,cross-limiting control for the boilers is handled entirely by field devices.One differential pressure transmittermeasures fuel flow, while anothertransmitter measures air flow. Eachdevice utilizes standard fieldbus function blocks to implement the control strategy.

The control system employs aunique hardware solution functioningas an interface, linking device, bridge,controller, gateway, fieldbus powersupply, and distributed I/O subsystem.Using open FOUNDATION fieldbus andOPC standards, the device integratesall of the hardware and softwareneeded to monitor, control and main-tain the steam plant boilers, includingintelligent instruments and HumanMachine Interface (HMI) software.

The fieldbus controls restored single-loop integrity to Seattle Steam’soperations and minimized the chanceof introducing errors into the process.Full redundancy and fault isolationalso ensured increased safety anduninterrupted operation. For example,plant operators can turn off their computers, and as long as power ismaintained to the fieldbus system, theboilers remain stable.

In addition, Seattle Steam realizedsignificant hardware and installationcost savings by implementingFOUNDATION fieldbus. Compared to traditional single-loop controllers, thefieldbus system reduced I/O require-ments and the labor involved in wiringfield instruments.

Thanks to FOUNDATION technology,Seattle Steam has a dependable tech-nique for cross-limiting combustioncontrol in its steam plant operation.The fieldbus-based system has performed reliably during many yearsof continuous operation.

Seattle Steam achieves robuststeam boiler operation

FOUNDATION fieldbustechnology is well-suited for demand-ing applicationslike air/fuel cross-limiting control onboiler operations.

For more information on these products, visit promo.us.yokogawa.com and enter key code AD9601.

Yokogawa Corporation of America800-447-9656www.yokogawa.com/us

The clear path to optimum control and asset intelligence:The clear path to optimum control and asset intelligence:

CoriolisFlowmeter

PressureTransmitters

MagneticFlowmeter

TemperatureTransmitters

ValvePositioner

Data AcquisitionSystems

VortexFlowmeter

OxygenAnalyzer

CENTUM CS 3000 R3Distributed Control Systems

Network Control System

Analyzers

Intelligent and Stable Field DevicesYokogawa field devices are FOUNDATION fieldbus™ ready and deliveraccurate process measurement and advanced diagnosticinformation with low installed cost and near zero maintenance.Web-enabled technology allows these devices to continuallyupgrade their capabilities online.

Integrated Plant Resource Manager (PRM)Yokogawa PRM enables you to manage your field assets centrallyand with ease, integrating device information and device diagnosticsinformation across different protocols and multiple suppliers.Maintenance is made easy and cost effective with PRM watchingyour assets on your behalf.

CENTUM CS 3000 R3 Fieldbus Host SystemYokogawa host systems are designed to help you harness the true powerof FOUNDATION fieldbus™. CS 3000 scales easily from single-node systemto a one-million-tag super large system, hosting the wealth of digitalfield information. The 99.99999% availability track record and Vnet/IP1GB Ethernet control network brings you a powerful combination ofsystem reliability and openness.

For every opportunity to renew and/or add field installations, Yokogawa recommends FOUNDATION fieldbus™. Our FOUNDATION

fieldbus™ solutions provide you with the maximum opportunity to improve your asset utilization throughout the plant lifecycle, leveraging reliable instrumentation andpredictive digital intelligence.

For a class schedule call 260.624.2420

or visit tsutechcenter.org/fieldbusinfo.asp

2006 CLASSES:

Introduction to Fieldbus

Hands-on Fieldbus Technology

Fieldbus Diagnostics

Coming Soon ... Online Training Courses

NEW REGIONAL TRAINING CENTERANGOLA, INDIANA USA

NEW REGIONAL TRAINING CENTERANGOLA, INDIANA USA

OFFERING CERTIFIED FOUNDATION FIELDBUS COURSESOFFERING CERTIFIED FOUNDATION FIELDBUS COURSES

33

Fieldbus ProductHighlights

Emerson’s DeltaV ™ System Enhanced forAbnormal Situation PreventionEmerson Process Management’s version 8.4 of DeltaV™ system software extendsPlantWeb® Alerts to HART® devices and improves FOUNDATION fieldbus device alarming and also includes enhancements to help users prevent abnormal situations.

Conditional alarming has been extended to FOUNDATION fieldbus devices, enablingthe devices to deliver critical predictive alarms for immediate attention by

operations staff to avoid unplanneddowntime. Operators need to know when critical field devices require atten-tion and not be bothered when devicesand processes are operating normally.By adding conditional alarming supportfor analog input, discrete input, and PID

function blocks for FOUNDATION fieldbus devices, it is possible to suppress nuisancealarms that interfere with attention to process operations. Configuration of conditional alarms “on” and/or “off” delay times can significantly reduce the numbers of nuisance alarms that are caused by temporary transient conditions.For more on the v8.4 release, visit www.EasyDeltaV.com/version84.

Emerson Process Management • www.EasyDeltaV.com/version84

Fault-Tolerant FOUNDATION Fieldbus Physical Layer Protects Against Single Points of FailuresThe TRUNKSAFE™ Fault-Tolerant Fieldbus System from MooreHawke (a division ofMoore Industries-International, Inc.) provides a cost-effective and simple way tomaintain FOUNDATION fieldbuscommunications between theDCS and field devices withoutinterruption in the event ofeither an open-circuit orshort-circuit cable fault.

Designed for important andplant-critical fieldbus seg-ments (those that if lost, willcause process unit or plantshutdown), TRUNKSAFE is comprised of two redundant fieldbus DC power con-ditioners integrated with a specially-engineered device coupler. Together, theysubstantially increase segment availability since no single point failure will shutdown the network. In addition, more than one critical application can be confi-dently, and economically, implemented on a fieldbus segment. For example, fourcritical spurs can be driven with one failsafe segment, with only a quarter of thetraditional system hardware required.

Other features include auto-resetting short-circuit protection and the company’spatented “Automatic Segment Termination,” which eliminates the most commonfieldbus installation error: segment failure from under- or over-termination.

TRUNKSAFE delivers diagnostic capabilities at every level, including host or fieldcable open- or short-circuit, low DC output voltage, high segment noise, powerstatus on the trunk, on each spur and the status of auto-termination (ON/OFF).

MooreHawke • www.miinet.com/moorehawke

Honeywell Manages Diversity of Fieldbus Project ImplementationsBest-in-class project implementations require an integrated approach.Honeywell fieldbus project methods,templates and tools support con-sistent global project execution,from front-end engineering anddesign through installation and commissioning, acceptance and lifecycle management. With globalskilled resources and best-practicestandards, Honeywell implementsprojects as easily as those for con-ventional instrumentation. Projectsizes range from hundreds to tens of thousands of devices, and appli-cations include refining, off-shoreand on-shore oil & gas, boilers,chemical plants and pharmaceuticals.Honeywell • www.honeywell.com/ps

Invensys’ InFusion Field Device Manager SupportsBoth FDT and Enhanced EDDLA key component of the newInFusion Enterprise Control Systemfrom Invensys is Field DeviceManager — an open toolset to configure, commission, maintain,and diagnose FOUNDATION fieldbusdevices throughout their entire lifecycle. Field Device Manager providesa comprehensive, fully integratedengineering and maintenance envi-ronment and is the first to offer sup-port for both FDT and Enhanced EDDL technologies.Invensys • www.foxboro.com/FF

Yokogawa Introduces Field DeviceManagement ToolThe Yokogawa FieldMate™ Versatile Field Device Management Tool is a newfield device management solution operating in a PC/handheld-based environ-ment. FieldMate provides access to parameter configuration for FOUNDATION

fieldbus intelligent field devices, regardless of the manufacturer, in addition to legacy field communication protocols such as HART and Profibus. It alsoenables easy operation for device configuration, diagnostics, and problem resolution, while automatically storingwork activity in a traceable field maintenance database.By consolidating workflow maintenance,know-how can easilybe shared amongusers.

FieldMate incorporatesa document linkagefeature that allowsinstruction manuals,work orders, and other Windows®-compatible documents to be linked to specific devices for streamlined information access. With its versatility and numerous integrated features, this new Yokogawa PC-based field maintenance solution is a tool that can save time and reduce the complexityof engineering and maintenance tasks — from field technicians to the control systems engineer.

Yokogowa • www.yokogawa.com/iab/vigilantplant/ae/iab-ae-availability-en.htm

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Rockwell Automation Receives HISTApproval for its FOUNDATION FieldbusSolutionRockwell Automation’s FOUNDATION fieldbus solution has successfully completedHost Interoperability Support Test (HIST) testing, providing independent valida-tion of the solution’s capabilities. Rockwell Automation’s FOUNDATION fieldbusLinking Device (1757-FFLD) and RSFieldbus Configuration Software

(9308-RSFBxx) extend the distributed process control capability of Rockwell Automation’s Integrated Architecture. With the 1757-FFLD, users have the flexibility to do process control with any Logix processor while employing the

advanced capabilities of network-based process

instrumentation. The 1757-FFLD includes the unique ability

to bridge both FOUNDATION fieldbus HSE and EtherNet/IP networks to FOUNDATION fieldbus H1 device networks. Bridgingthese networks facilitates information flow between the control layers.Transferred information can include device configuration (such as setup,operation, and diagnostic data) and plant floor process information (such astemperature and flow data).

Rockwell Automation • www.ab.com/networks/fieldbus.html

ABB’s System 800xA FOUNDATION Fieldbus DeviceIntegration Provides Plantwide Process ImprovementsABB’s System 800xA seamlessly integrates fieldbuses and field devices into the

extended automation system environment, enabling system levelengineering, operation, and maintenance of field equip-ment. Its architecture supports process availability requirements with redundancy at all levels and allows

for installation of devices in all plant environments, including hazardous areas.Only ABB delivers the extended function-ality that gives users the visibility and control they need to run plants more efficiently — saving precious time,resources and money.ABB • www.abb.com/controlsystems

Gammapilot M FMG60 Provides Level MeasurementUnder Extreme ConditionsThe Gammapilot M radiometric level transmitter is used for level limit detection, continuous measurement, interface layer and density measurement where extreme or critical conditions necessitate the use of a non-intrusive method, e.g. toxicity,abrasion, high temperatures, high pressures, baffles, etc.It uses the latest FOUNDATION fieldbus technology and offers a wide range of standard function blocks such as Integrator,Input Selector, Signal Characterizer, Arithmetic and PID to support the benefits of field-based control loops.Endress+Hauser • www.endress.com/level

National Instruments Introduces NI-FBUS SoftwareVersion 3.2

The NI-FBUS software version 3.2includes features such as:

- NDDS 5.0 Support - EDDL Features- OPC DA 3.0- Add Interface Wizard- Device Property and Image- .NET Library- Device Live List- NI License Manager

NI-FBUS Communications Manager and Configurator are included. The soft-ware is free for download; no license activation is required for offline mode.National Instruments • www.ni.com/fieldbus

Pepperl+Fuchs Offers New Isolated Fieldbus Power SupplyThe KLD2-FBPS-1.25.360 isolated fieldbus power supply provides 25 V and

360 mA of supply current with minimal heatdissipation, and supports redundant 24 V power.The individual modules can be mounted adjacent to one another without spacing. Thegalvanic isolation and passive design make it a highly reliable power supply and an excellentdesign choice for single segment power needs.The KLD2-FBPS-1.25.360 power supply is part of the FieldConnex® fieldbus installationsystem and supports the innovative High PowerTrunk Concept and Physical Layer diagnostics.

Pepperl+Fuchs • www.fieldconnex.info

Smar Offers “Fourth Generation” Automation SystemSmar SYSTEM302 is a fourth generation Process Automation System thatcombines configuration, operation and maintenance tools with several digitalprotocols used today, such as FOUNDATION fieldbus H1, HART, Modbus, Profibus,DeviceNet and ASI, utilizing theFOUNDATION fieldbus HSE control network technology.

Features include: Multi-user platform;user access control; version controlmanagement; flexible distribution ofcontrol and management tasks; secureintegrity for project configuration data;Windows®-based users and groupsmanagement; integrated database for field device information; smart instru-ment identification; integrated configuration, operation and diagnostic tools;flexible function blocks for integrated regulatory control and logic; FOUNDATION

fieldbus, Modbus, HART, Profibus, DeviceNet and ASI connectivity; HSE host for multiple clients; and asset management.Smar • www.smar.com

Softing Enables Quick Migration from ExistingArchitectures to FOUNDATION FieldbusSofting’s Fieldbus Kit (FBK) provides the quickestsolution to integrate FOUNDATION fieldbus H1and PROFIBUS PA technologies into newor existing process instruments.The FBK hardware contains thefieldbus protocol software, making iteasy to integrate this functionality into existing architectures. In addition, Softing can assistin customizing the software to handle device-specific properties and also canoffer training, creation of Device Description files, pre-certification testing, andapplication support.Softing • www.softing.com/en/pdf/communications/fieldbus/D_IA_21E_0509_FieldbusKit_Z.pdf

Yamatake Delivers Hybrid Smart Positioner,SVP3000 Alphaplus

The SVP3000 Alphaplus Model AVP304 obtains aunique function that is realized by hybrid tech-

nology. The Model AVP304 adopts two signals— analog and FOUNDATION fieldbus.

Users need not worry about positioner selection, since the

Model AVP304 can control a valveboth by analog signal and FOUNDATION

fieldbus signal. The FOUNDATION fieldbus signal isfor diagnostic purposes. Remote-type valve positioner,

Model AVP204, is also available. The SVP3000 Alphaplus and control valvemaintenance support system “Valstaff” provide Stick Slip detection which is adynamic diagnostic.Yamatake • www.yamatake.com

TopWorx DXP Connects On/Off Valves inHazardous AreasThe TopWorx DXP makes it easy to connect automatedon/off valves to FOUNDATION fieldbus. The DXP is UL,CSA, and ATEX certified for use in Class I Division 1 & 2hazardous areas with no seal-off fittings required. Theunique modular design allows customers to mix and match a variety of options in a single model. Besides fieldbus networks, other options include GO Switch, P+F,mechanical limit switches, integral low-power pilot valves,and mounting kits to attach to any valve or actuator.

3300 Fern Valley Road, Louisville, KY 40213 USA Phone (502) 969-8000 – Fax (502) 969-5911TopWorx • www.topworx.com

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F800 Power Supply Gives On-line DiagnosticsOn-line diagnostics assist in troubleshootingand commissioning. The MTL F809F FieldbusDiagnostic Module is a FOUNDATION fieldbusdevice that plugs into the F800 module carrier and continuously monitors the performance of each of the eight fieldbussegments, providing information on the network health. As a functioning fieldbus H1device, the diagnostic information integratesseamlessly into any fieldbus control system.MTL Instruments • www.mtl-fieldbus.com

TURCK Delivers Connectivity,Interfacing and SensingComponentsTURCK offers a complete range of connectivity,interfacing and sensing components that bring consistency and efficiency to fieldbus installations and gets plants online faster. New and notable products include: IM series isolating modules withslim 18 mm housings providing a wide range offunctions necessary for measurement and control

applications; a multi-segment FOUNDATION fieldbus power conditioner that pro-vides up to 500 mA of conditioned power to each segment; and Vprox® 773sensors designed with potted-in cables or quick disconnects for exceptionalversatility in both valve and damper applications in locations classified as hazardous. Users can find these and more products by requesting TURCK’s new Process Brochure B4100 today.

3000 Campus Drive, Minneapolis, MN 55441 USA – Phone (800) 553-0016Application Support (800) 553-0016 – Fax (763) 553-0708 Turck • www.turck.com/process