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F OUNDATION Fieldbus™ -Practical Success Stories Phil Saward, Product Manager

F OUNDATION Fieldbus™ -Practical Success Stories Phil Saward, Product Manager. Introduction. Topics What is Fieldbus? Comparison with existing 4-20mA installations Typical field network F OUNDATION TM fieldbus in the Pharmaceutical industry When should Fieldbus be considered?

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F OUNDATION Fieldbus™ -Practical Success Stories Phil Saward, Product Manager

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  1. FOUNDATION Fieldbus™ -Practical Success Stories Phil Saward, Product Manager

  2. 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

  3. Fieldbus system niches

  4. How is fieldbus different from 4-20mA? 4-20mA fieldbus Power Supply Power Supply Input card • 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.

  5. Typical Fieldbus installation Fieldbus control system (DCS) Redundant, isolated Fieldbus power conditioner CONTROL ROOM FIELD Field wiring hub with spur short-circuit protection Safe area FOUNDATION Fieldbus Devices

  6. Fieldbus Today

  7. 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.”

  8. Market Distribution Global Industry

  9. Example FF applications in Europe

  10. 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

  11. 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

  12. Re-using Installed Cables Fieldbus devices J-Box T T Three existing 4-20 mA Pairs Three existing pairs, one used for fieldbus J-Box

  13. Economic Life Cycle Analog fieldbus Engineering, Construction, & Commissioning/Start-up Operations & Maintenance Replace Cash Flow Time

  14. Engineering, Construction & Start-up Engage in FEED stage Sooner and faster start-up Reduce implementation risk and cost startup Time Cash Flow

  15. Termination count I.S. Barrier I/O Assembly Marsh Cab. Junction Box FT-100 + - 1 2 3 4 + - + - + - + - + - + - + - + - + - + - + - + - + - + - 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 FCV-100 + - + - + - TT-100 PT-101 Conventional analog termination Fieldbus termination (also included in conventional termination count) Field 4 pr 4 pr 4 pr 1 pr 1 pr 1 pr 4 16 Totals: 75 Analog 34 Fieldbus 8 2 24 15 20 5 Marshalling done in Junction Box with Fieldbus so Marsh Cab is optional 8

  16. 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 Engineering - Network Loading

  17. Operations & Maintenance Longer duration to scheduled outage Safer operation Faster time-to profit Higher sustained production with minimize costs Shorter scheduled outage Fewer unscheduled outages Cash Flow

  18. Measurement accuracy 4-20mA Field JB + marshalling IS Interface I/O card PV = 392.8mb 12.83mA 12.86mA 12.87mA PV = 393.1mb Conversion error Leakage + noise Conversion error Fieldbus Field JB + marshalling IS Interface H1 I/O card PV = 392.8mb PV = 392.8mb PV = 392.8mb PV = 392.8mb PV = 392.8mb

  19. Diagnostics save wasted maintenance Shell Global Solutions 35% 28% 20% 6% 6% 4% 63% of instrument maintenance labour results in no action taken: waste of resources

  20. 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.

  21. Questions

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