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

Fieldbus system niches

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)

Fieldbus Today

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.

Questions