Implementing a F OUNDATION ™ Fieldbus Project a F OUNDATION ™ Fieldbus Project Part Six of Eight ... ARC Advisory Group/Emerson Process ... Eames & Jörg Kempf); Vogel Business

In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 1

Implementing a FOUNDATION™ Fieldbus Project

Part Six of Eight

Contents

1.0

Introducing the User Guide

1.1 Executive Summary

1.2 Recommended Technical Resources

2.0 Overview of FOUNDATION Fieldbus

3.0 FOUNDATION Fieldbus Project Management – Minimising Project Risk

3.1 Proven Technology

3.2 Project Evaluation

3.3 Training

3.4 Project Partners

3.5 Procedures, Work Processes and Documentation

3.6 Risk Management

3.7 Testing

4.0 FOUNDATION Fieldbus Project Investment

4.1 Project Planning – CAPEX

4.2 Project Engineering and Installation – CAPEX

4.3 Commissioning – CAPEX

4.4 Project Start-Up – CAPEX

4.5 Operations and Maintenance – OPEX

5.0 FOUNDATION Fieldbus Project Design & Engineering

5.1 FOUNDATION Fieldbus Project Design & Engineering

5.2 Field Device Selection Considerations

5.3 Segment Component Selection Considerations

5.4 Network/Segment Topology Design Considerations

5.5 Host/Device Interoperability Testing

6.0 FOUNDATION Fieldbus Project Implementation – Conclusion and Checklist

Appendix: References/Sources


Implementing a FOUNDATION™ Fieldbus Project

Chapter 4: FOUNDATION Fieldbus Project Investment

4.5: Operations and Maintenance - OPEX Total OPEX savings are hard to estimate before a project is

implemented. There is growing evidence of huge returns on investment

of FOUNDATION projects – as soon as production is started or resumed.

Tangible benefits, for example the reduction in commissioning and

maintenance times, are enhanced by intangible benefits, for example

the ease of commissioning or data management, to offer the

FOUNDATION fieldbus end user a high level of plant optimisation through

production efficiencies and an effective maintenance strategy.

The level of achievable benefits from a more streamlined and efficient

operations and maintenance function will be enhanced if appropriate

work processes are developed at the beginning of the project in

conjunction with input from operators and technicians. Consistent

employment of the established work processes and maintenance

methods will help keep the operations and maintenance overheads low.

With the costs of traditional maintenance representing approx 40% of

manufacturing costs14, and the prospect of maintenance savings of

between 10-20%, end users are driven to targeting the operations and

maintenance functions to reduce production costs significantly through

improved asset management and maintenance strategies.

Diagnostics: Field diagnostics benefit a wide range of automation stakeholders

including process engineers, maintenance technicians and plant operators. The use of

diagnostics can dramatically change how process and asset data, alerts and messages

are viewed and used at a facility. Ultimately, plant management will realise improved

process performance, greater reliability, increased uptime and lower operating costs.

“Tangible benefits, for

example the reduction

in commissioning and

maintenance times, are

enhanced by intangible

benefits, for example

the ease of

commissioning or data

management, to offer

the FOUNDATION fieldbus

end user a high level of

plant optimisation

through production

efficiencies and an

effective maintenance

strategy.”


According to the NAMUR NE107 recommendation, “Self Monitoring and Diagnosis of

Field Devices”, field diagnostic results should be reliable and viewed in the context of

a given application. The document recommends categorising diagnostics into just four

standard status signals – maintenance required; failure; function check; and out of

specification (Fig 3).

It also recommends that the categorisation of a diagnostic event should be

configurable by the user, as reactions to a fault in a device may be very different

depending on the user’s requirements and the role of the recipient of the alert.

According to NE107, plant operators should only see status signals, with detailed

information viewable by devices viewable by device specialists.

Using the existing power of FOUNDATION fieldbus, and considering the NE107

recommendations, the Fieldbus Foundation developed its FOUNDATION Fieldbus

Diagnostic Profiles Specification to enhance the organisation and integration of device

diagnostics within fieldbus systems.

Fig 3 : NAMUR NE107 Diagnostics Categories & Symbols

Advanced Diagnostics in Operations: A wealth of device information is available

through FOUNDATION systems including: instrument ID and location; status of process

variables; ambient conditions; diagnostic information; configuration data; device

characteristics; calibration information etc. FOUNDATION fieldbus makes it possible to

manage and prioritise system, device and process information more effectively to

deliver robust and relevant information to the right person at the right time without a

flood of nuisance alarms. Required information is targeted and displayed instantly.

This knowledge-based system empowers operators, technicians and process engineers


“End users in the

petrochemical industry

have reduced their

operating costs by

approx 30% by

utilising advanced

diagnostics.”

and makes plant operation easier, faster and more efficient.

Alarms and alerts are supported by diagnostic data and all information is time-

stamped and can be archived and retrieved as required. Information about whether

data is good, bad or uncertain helps operators differentiate between a process

problem and device problem, which avoids costly and inconvenient unplanned plant

shutdowns. In the event of a shutdown, the location and resolution of the problem is

faster and the outage time reduced.

Utilising advanced diagnostics and an asset management system allows the user to

reap the benefits from FOUNDATION technology:

• Increased plant efficiency (e.g. 20%)15

• Increased operating efficiency (e.g. 2-3%)16

• Increased availability of plant

• Increased throughput and productivity (e.g. 6 - 10% improvement in

throughput)17, 18

• Reduced process downtime

• Greater manufacturing flexibility

• Increased production consistencies (e.g. 40% increase in production

performance measures)19

• Reduced process variability (e.g. 75% reduction in speed variability)20

• Improved asset utilisation

• Improved safety, health and environmental compliance

It is estimated that typical process plants could be underperforming

by approx 20% in terms of plant availability, asset reliability and

production throughput.21

End users in the petrochemical industry have reduced their

operating costs by approx 30% by utilising advanced diagnostics.

Advanced Diagnostics in Maintenance: Globally, process industries lose an estimated

$20 billion (approx 5%) of annual production through unscheduled downtime. Of

these losses, approx 80% could have been avoided with the implementation of

preventive or predictive maintenance strategies instead of reactive strategies.22


Preventive maintenance is undertaken 25% of the time23, and of this, end users have

estimated that over 60% of preventive maintenance activities (labour hours) result in

no action and are ultimately unnecessary24. A move towards a proactive maintenance

strategy will cut maintenance costs dramatically.

Fig 4: Predictive Diagnostics Help Users Develop A Proactive Maintenance Strategy

The enhanced device diagnostics capabilities of FOUNDATION technology support asset

management systems that allow automation end users to advance beyond reactive,

preventive and predictive maintenance techniques and implement proactive strategies

where equipment maintenance schedules are based on built-in asset diagnostics.

Users can also achieve opportunity-based maintenance that combines proactive

maintenance with special events such as a planned shutdown.

Diagnostics-driven maintenance strategies reduce fixed and variable maintenance

costs and extend useful asset life by reducing the interval between maintenance

events, reducing call-outs, reducing the cost of failures, reducing downtime, and

making it easier to plan maintenance and service work. End users have reported a

wide range of maintenance cost reductions including:

• 50% reduction in overall maintenance labour 25

• 78% reduction in on-going maintenance time for instrumentation 26

• 25% reduction of maintenance time eliminated 27


• 20% reduction of annual total maintenance costs 28

• 100% reduction in maintenance call-outs in one area of plant 29

Ease of Commissioning: The benefits of quick and easy device configuration and

commissioning are not just limited to the original project implementation but also

ongoing maintenance. The operator-friendly, common ‘look and feel’ of the host

commissioning software and the ‘drag and drop’ menus allow for faster device

replacement with negligible or minimal impact on the control system and plant

availability. When downtime is scheduled, process start-up will be faster.

The topology of the recommended FOUNDATION system designs allows for minimal

disruption to the segment – ensuring negligible or minimal disruption to the process.

A well-documented and considered spares policy and software revision controls will

ensure that the correct replacements devices are available with the correct function

block configurations and correct DDs.

Future proof: Installing a FOUNDATION system or integrating the technology into an

automation infrastructure is a sound investment with an infinite lifetime. With

technology development initiatives responding to market demands, the technology

will continue to evolve to meet the requirements of end users today and in the future.

The list of FOUNDATION registered hosts and devices is constantly growing with an

increasing number of suppliers developing and launching new FOUNDATION products

to the list.

The system will continue to be easy to maintain and adapt to new demands if the

maintenance function continues to follow its established procedures and work

processes that relate to software revision control and device replacement / spares.

Similarly, new segments are easier to integrate if the documentation has been

properly managed.

The maintenance function will have more flexibility if a level of redundancy and spare

capacity was built into the system at the outset.


References:

14. ARC Advisory Group, Dedham, MA: ARC independent research. Quoted in Ian

Verhappen Lifecycle Economics presentation available from www.fieldbus.org

15. Richard Lemaire, chemical industry

16. Rich Hatton, pulp & paper industry

17. Craig Herbert, power, medical

18. Dewey Ertell, food & beverage

19. Matthew Anderson, food & beverage

20. Carl Holte, pulp & paper – reduction in speed variability of paper machine to

give better quality product

21. ARC Advisory Group/Emerson Process Management article (Innovative Asset

Management Tools Increase Plant Reliability, Throughput and Availability, Justin

Eames & Jörg Kempf); Vogel Business Media. http://www.process-

worldwide.com/engineering_construction/operating_technology/maintenance/articles/365744/

22. ARC Advisory Group/Emerson Process Management article (Innovative Asset

Management Tools Increase Plant Reliability, Throughput and Availability, Justin

Eames & Jörg Kempf); Vogel Business Media. http://www.process-

worldwide.com/engineering_construction/operating_technology/maintenance/articles/365744/

23. ARC Advisory Group, Dedham, MA: ARC independent research. Quoted in Ian

Verhappen Lifecycle Economics presentation available from www.fieldbus.org

24. Shell Global Solutions

25. Jeff Milligan, oil & gas – re-instrument – manual/pneumatics

26. Mike Chlapowski, oil & gas – re-instrument – manual/pneumatics

27. Tim Durham, food & beverage – new project

28. Martin Flatley, oil & gas – re-instrument – DCS/PLC

29. Rich Hatton, pulp & paper (dry end of machine) – re-instrument –

manual/pneumatics

Documents

Implementing a F OUNDATION ™ Fieldbus Project a F OUNDATION ™ Fieldbus Project Part Six of Eight ... ARC Advisory Group/Emerson Process ... Eames & Jörg Kempf); Vogel Business