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Cooper Industries: Confidential
FOUNDATION Fieldbus™ -Practical Success Stories
Phil Saward, Product Manager
Introduction
Topics• What is Fieldbus?
• Comparison with existing 4-20mA installations
• Typical field network
• FOUNDATIONTM fieldbus in the Pharmaceutical industry• When should Fieldbus be considered?• Why use Foundation Fieldbus?
• Design, installation and commissioning
• Operation and maintenance Economic benefits Technical benefits
How is fieldbus different from 4-20mA?
4-20mA
PowerSupply
fieldbus
PowerSupply
• In 4-20mA circuits, the power supply, field device and input card are connected in series.
• In a Fieldbus system, the power supply, field devices and input card are connected in parallel.
Input card
Safe area
Typical Fieldbus installation
Redundant, isolated Fieldbus power conditioner
Field wiring hub with spur short-circuit protection
FOUNDATION Fieldbus Devices
FIELD
CONTROL ROOM
Fieldbus control system (DCS)
FOUNDATION fieldbusTM in Pharmaceuticals
Installed base worldwide (published by Fieldbus Foundation, 2008):• >10,000 systems• >700,000 field instruments
Diverse adoption:• 9 of the top 10 oil & gas companies• 24 of the top 25 pharmaceutical manufacturers• 23 of the top 25 chemical producers• 15 of the top 20 pulp & paper companies• 10 of the top 20 food & beverage companies
ARC Advisory Group:“…powerful value proposition for fieldbus in the hybrid industries-namely, food & beverage and pharmaceutical, particularly when it comes to easing the process of validation and regulatory compliance and the integration of batch procedural operations with continuous processes. The function block structure of Foundation technology lends itself to these processes very well.”
Market Distribution
Global Global
LA12%
NA43%AP
13%
MEA7%
EUR25%
Other8%
Mining and Metals
3%Education
3%
Pulp and Paper
4%
Food & Beverage
9%
Pharm- aceutical
9%
Power13%
Oil & Gas29%
Chemical22%
Industry Industry
Example FF applications in Europe
Operator Location Control System
Novo Nordisk Bagsvaerd, Denmark Emerson
AstraZeneca Gartuna, Sweden Emerson
Novartis Basel, Switzerland Emerson
Novartis Grimsby, UK Emerson
Sanofi Aventis Aramon, France Emerson
Biogal Rt. Debrecen, Hungary Yokogawa
Glaxo SmithKline Cork, Eire Emerson
Genzyme Belgium Emerson
When should fieldbus be considered?
‘Green Field’ Facility Facility Upgrade
• New unit operation
Process Automation Focus• ≥ 60% of sensors are analogue
Existing cabling infrastructure is overloaded
Why use FOUNDATION fieldbusTM?
Integrated digital architecture “Future proof”
• Sensors can be field upgraded with new features
Economic savings• Different incentives at each stage of a facility life
cycle:• Capital/Construction• Commissioning• Operations, maintenance
• Reduced infrastructure
Re-using Installed Cables
Three existing4-20 mA Pairs
J-Box
TT
Fieldbus devices
Three existingpairs, one usedfor fieldbus
J-Box
ReplaceOperations & MaintenanceEngineering, Construction,& Commissioning/Start-up
Economic Life CycleC
ash
Flo
w
Analogfieldbus
Time
Engineering, Construction & Start-up
Time
startup
Ca
sh F
low
Reduce implementation risk and cost
Reduce implementation risk and cost
Engage in FEED stageSooner and faster
start-upSooner and faster
start-up
Termination count
FT-100
+-
FCV-100
+-
TT-100
+-
Field
PT-101
+-
1
2
3
4
5
6
7
8
9
10
11
12
Junction Box
1
2
3
4
5
6
7
8
9
10
11
12
Marsh Cab.
1
2
3
4
+-+-+-+-
+-+-+-+-
I.S.Barrier
8
24 20 5
16 4
8 2
15
+-+-+-+-+-+-
I/OAssembly
Conventional analog termination
Fieldbus termination (also includedin conventional termination count)Marshalling done in Junction Box with
Fieldbus so Marsh Cab is optional
Totals: 75 Analog34 Fieldbus
4 pr 4 pr 4 pr
1 pr 1 pr 1 pr
Engineering - Network Loading
Number of devices per network segment• 15-20 mA per transmitter
• 20-25 mA per valve
Segment Length• Defined by Fieldbus standard
• function of number of devices• Segment topology
Voltage Calculations• 9 volt minimum at field device
• design for 12 volts
Bus Bandwidth• Balance cycle time
against number of devices
• Function of host control system
Virtual Communication Resources• Required for
communication between devices and host
Operations & MaintenanceC
ash
Flo
w
Higher sustained production with minimize costs
Faster time-toprofit
Safer operation
Fewer unscheduled outages
Shorter scheduled outage
Longer duration to scheduled outage
Measurement accuracy
IS Interface I/O card
PV = 392.8mb12.83mA PV = 393.1mb12.87mA
IS Interface H1 I/O card
PV = 392.8mbPV = 392.8mbPV = 392.8mb
Field JB + marshalling
Field JB + marshalling
12.86mA
PV = 392.8mb PV = 392.8mb
Leakage + noise Conversion error
Conversion error
4-20mA
Fieldbus
Diagnostics save wasted maintenance
0%
5%
10%
15%
20%
25%
30%
35%
Routinecheck
NoProblem
Calibrationshift
Zero Off Pluggedlines
Failed
63% of instrument maintenance labour results in no action taken: waste of resources
63% of instrument maintenance labour results in no action taken: waste of resources
35%35%
28%28%
20%20%
6%6% 6%6% 4%4%
Shell Global Solutions
Fieldbus Project Costs
Estimated Project Savings• Materials and Field Devices
• Some increase
• Installation Labour• Savings up to 50%
• Commissioning:• Significant savings up to 60%
Overall Capital Savings of 25–30%However savings will only be realized if the project is
planned as a fieldbus project.