8/3/2019 9.00-Foundation Fieldbus Saward MTL
1/22
Cooper Industries: Confidential
FOUNDATION Fieldbus -
Practical Success Stories
Phil Saward, Product Manager
8/3/2019 9.00-Foundation Fieldbus Saward MTL
2/22
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
8/3/2019 9.00-Foundation Fieldbus Saward MTL
3/22
Fieldbus system niches
8/3/2019 9.00-Foundation Fieldbus Saward MTL
4/22
How is fieldbus different from 4-20mA?
4-20mA
Power
Supply
fieldbus
PowerSupply
In 4-20mA circuits, the power supply, fielddevice and input card are connected in series.
In a Fieldbus system, the power supply, fielddevices and input card are connected in
parallel.
Input card
8/3/2019 9.00-Foundation Fieldbus Saward MTL
5/22
Safe area
Typical Fieldbus installation
Redundant,
isolated Fieldbus
power conditioner
Field wiring hub with
spur short-circuit
protection
FOUNDATION Fieldbus Devices
FIELDCONTROL ROOM
Fieldbus control
system (DCS)
8/3/2019 9.00-Foundation Fieldbus Saward MTL
6/22
Fieldbus Today
8/3/2019 9.00-Foundation Fieldbus Saward MTL
7/22
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 ofvalidation and regulatory compliance and the integrationof batch procedural operations with continuousprocesses. The function block structure of Foundationtechnology lends itself to these processes very well.
8/3/2019 9.00-Foundation Fieldbus Saward MTL
8/22
Market Distribution
GlobalGlobal
LA
12%
NA
43%AP
13%
MEA
7%
EUR
25%
Other
8%
Mining and
Metals
3%Education
3%
Pulp and
Paper
4%
Food &
Beverage
9%
Pharm-
aceutical
9%
Power
13%
Oil & Gas29%
Chemical
22%
IndustryIndustry
8/3/2019 9.00-Foundation Fieldbus Saward MTL
9/22
Example FF applications in Europe
Operator Location ControlSystem
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
8/3/2019 9.00-Foundation Fieldbus Saward MTL
10/22
When should fieldbus be considered?
Green Field FacilityFacility Upgrade
New unit operation
Process Automation Focus
60% of sensors are analogue
Existing cabling infrastructure is
overloaded
8/3/2019 9.00-Foundation Fieldbus Saward MTL
11/22
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
8/3/2019 9.00-Foundation Fieldbus Saward MTL
12/22
Re-using Installed Cables
Three existing4-20 mA Pairs
J-Box
TT
Fieldbus devices
Three existingpairs, one usedfor fieldbus
J-Box
8/3/2019 9.00-Foundation Fieldbus Saward MTL
13/22
ReplaceOperations & MaintenanceEngineering, Construction,
& Commissioning/Start-up
Economic Life Cycle
CashFlow
Analog
fieldbus
Time
8/3/2019 9.00-Foundation Fieldbus Saward MTL
14/22
Engineering, Construction & Start-up
Time
startup
CashFlow
Reduce implementation
risk and cost
Engage in FEED stageSooner and faster
start-up
8/3/2019 9.00-Foundation Fieldbus Saward MTL
15/22
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 included
in conventional termination count)Marshalling done in Junction Box with
Fieldbus so Marsh Cab is optional
Totals: 75 Analog
34 Fieldbus
4 pr 4 pr4 pr
1 pr 1 pr 1 pr
8/3/2019 9.00-Foundation Fieldbus Saward MTL
16/22
8/3/2019 9.00-Foundation Fieldbus Saward MTL
17/22
Operations & Maintenance
CashFlow
Higher sustained
production with
minimize costs
Faster time-to
profit
Safer operation
Fewer unscheduled
outages
Shorter scheduled outage
Longer duration to
scheduled outage
8/3/2019 9.00-Foundation Fieldbus Saward MTL
18/22
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 Conversionerror
Conversionerror
4-20mA
Fieldbus
8/3/2019 9.00-Foundation Fieldbus Saward MTL
19/22
Diagnostics save wasted maintenance
0%
5%
10%
15%
20%
25%
30%
35%
Routine
check
No
Problem
Calibration
shift
Zero Off Plugged
lines
Failed
63% of instrument maintenance labour results in no action
taken: waste of resources
35%
28%
20%
6% 6%
4%
Shell Global Solutions
8/3/2019 9.00-Foundation Fieldbus Saward MTL
20/22
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 2530%
However savings will only be realized if the projectis planned as a fieldbus project.
8/3/2019 9.00-Foundation Fieldbus Saward MTL
21/22
Foundation System Architecture
Sch
eduled Determinism Highly Reliable PerformanceAutomatic Addressing
Plug and Play
Functional Communication Peer to Peer More Powerful
Publisher/Subscriber Higher Performance
Alarms and Events Time Stamped, Auditable Records
Firmware Download Reduced Risk of Obsolescence
Rigorous Testing Host & Device
8/3/2019 9.00-Foundation Fieldbus Saward MTL
22/22
Questions