FOUNDATION Fieldbus Moving Forward

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© 2013 Fieldbus Foundation

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Seminar Outline
• We have some of the most knowledgeable fieldbus
people here today, both presenting and in our
audience. Use the opportunity to network and learn!
• We have designed this seminar to provide a hands on
perspective
• Fieldbus doesn’t need to be difficult
• Fieldbus can provide significant benefits throughout
the plant lifecycle

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Thanks to our Sponsors !

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Why FOUNDATION Fieldbus?
• Largest Installed Base
• Fit for Purpose
• End User Designed and
Supported
• More than a Network: A
Managed Infrastructure
• OPEN and Continuously
Evolving
• Wide Range of Tested and
Registered Product
• Training and Resources

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More Than a Network:
a Managed Infrastructure
• Function blocks enable control in the field, object oriented data
management

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Number One in Digital Communications
for Process Automation!
Market for Digital Fieldbus Products and Services by Protocol
(Source: ARC Advisory Group)

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FOUNDATION Fieldbus Breaks the Billion
Dollar Barrier
• Market for FOUNDATION
fieldbus products (excluding
EPC and system integrator
services) exceed $1 billion in
2012.
• The installed base of
FOUNDATION fieldbus systems
and devices is over $6 billion
• Celebrating 20 years in 2014!
Market for Digital Fieldbus Products and Services
(Source: ARC Advisory Group)

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Fit for Purpose, User Supported
• FOUNDATION Fieldbus was Built
from the Ground Up for
Process Automation
• We have the strongest end
user council of any
communication protocol in
process automation
• Users continue to drive
evolution in the standard
• More users are adding
FOUNDATION fieldbus to their
purchase requirements

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Open and Continuously Evolving
o We are a truly open standard
o We continue to add to our
specification
o NAMUR NE 107 Diagnostics,
advanced alarm handling
capabilities
o FOUNDATION for ROM
Specification integrates
wireless devices and remote
applications
o We can adapt to new
technologies as they come
along
NAMUR NE107 Diagnostic Categories

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We Test & Register Everything from Cable
to Host

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• Users need to take a lifecycle perspective to
understand the benefits of FOUNDATION fieldbus
• Defining the plant lifecycle
• The importance of the FEED phase
• Installation and Commissioning Benefits are
Considerable
• Operations: Managing data for true distributed
control
• Transforming maintenance and reducing cost
• The importance of training
The Benefits of Fieldbus Throughout
the Plant Lifecycle

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• If you are planning on installing fieldbus, it
behooves you to take a lifecycle
perspective
• Many users focus on the installation and
commissioning phase and achieving fast
startup, but only then do they consider
how to get the most out of the technology
in operations and maintenance domain
• One phase of the lifecycle affects the next.
Adopting a Lifecycle Perspective Helps
you Realize the Benefits

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Defining the Plant Lifecycle

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Automation is a Small Percentage of
Total Project Costs, But a Big Influence

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The Importance of Early Involvement in
the FEED Phase
• The Success of Your Operations & Maintenance Strategy
Depends on the FEED Phase
• Fieldbus and its impact should be considered in this phase,
where it can create a more powerful return on investment

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Cost Reductions: Engineering & Design
• Significant cost savings
can be achieved in the
engineering and design
phase
• “The Death of the Loop
Drawing”: “Some are
finding it easier to make
their segment diagrams
on DCS graphics, and
use the DCS database to
self-document all the
ways a given variable is
interconnected.

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Cost Reductions in Engineering and
Design can be Significant
Source: Alcan
Source: TotalFina Elf

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Reduced Engineering Means Faster
Time to Startup

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Installation and Commissioning
Benefits are Considerable
• We talk a lot about faster time to startup, but
FOUNDATION fieldbus also allows you to deal
with project changes more effectively, and
manage delays in preceding phases of the
project better
• Avoid shutdowns during performance runs
• Faster time to startup can provide a return on
the automation investment

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An Example of Installation Cost
Reductions
Source: Tecnimont 2009

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An Example of Commissioning Cost
Reductions
Source: Tecnimont 2009

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Drastic Reduction in Commissioning
Times
• Reduce your
commissioning
time by up to 50
percent.
• What used to take
2 hours per device
for two technicians
can be done in 25
minutes with one
technician.

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Operations: Functional
Expansion
NEW!

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How FOUNDATION Fieldbus can Help Reduce
Energy Costs
• An Ideal Solution for Predictive
Maintenance on Key Energy
Related Assets Like Heat
Exchangers, Burner
Management Systems
• Clean Heat Exchangers Before
they Choke Beyond Limit
• Tighter Control of Fan/Damper
Actuators
• Unparalleled Efficiency
Monitoring
• Monitor & Define Optimal Zone
of Operation for Equipment
Energy Consumption (Trillion Btu)
Petroleum
Chemicals
PaperPrimary
Metals
Food Processing
Nonmetallic
Minerals
Tobacco/Beverages
Furniture
Leather Machinery and Computers
Wood
Transportation
Fabricated Metals
Textiles/Apparel
Plastics/
Rubber
Electrical
Printing
Miscellaneous
1
10
100
1000
10 100 1000 10000
EnergyIntensity
(ThousandBtu/$GDP)
Energy-Intensive
Industries
Industrial Energy Intensity vs. Energy Consumption
Mining
Source: US Department of Energy

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Reduce Unplanned Shutdowns
• Unplanned Shutdown Accounts for 5 Percent
of Production in the Process Industries
• One Unplanned Shutdown can Wipe Out your
Entire Plant Profit for the Year
• Field Diagnostics Provide Advance
Knowledge of Impending Problems
• FOUNDATION technology enables truly
distributed and deterministic controls which
are designed to function regardless of host
issues

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Customer Experience: CIF Reduces
Unplanned Shutdown
FOUNDATION™ Fieldbus
CIF with inherent backup capability
prevented 2 incorrect plant
shutdowns, which would have
resulted from communication
interruptions.

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Fieldbus for New Projects and Modernization
• According to ARC, the
installed base of process
automation systems
reaching the end of their
useful life is $65 billion.
Most of these are 20
years old or older.
• FOUNDATION Fieldbus is
being chosen by more
major end users as they
begin to modernize their
installed base.
• Users want to avoid a
functional replacement.
Nobody Wants to Replace this with
“More of the Same”

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Modernizing with FOUNDATION Fieldbus:
from Refineries to Nuclear Plants

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FOUNDATION for ROM Device Consolidates Diagnostic
Data from Different Networks….
Conventional
I/O
WirelessHART
H1 HART
I/O
ISA100.11a
Diagnostic
&
Instrument
Data
Diagnostic
&
Instrument
Data
Diagnostic
&
Instrument
Data
Diagnostic
&
Instrument
Data
Diagnostic
&
I/O Data
FOUNDATION Infrastructure for Data Management and Diagnostic Information
FOUNDATION for ROM Device
Transducer
Blocks
Transducer
Blocks
Transducer
Blocks
Transducer
Blocks

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Managing Diagnostic Data from Multiple Networks in
a Single Infrastructure
• Easier audit trail and reporting
• Data is time-stamped
• FOUNDATION Fieldbus devices can
indicate data quality -- whether signals
communicating setpoints, PVs, etc.
have good, bad or uncertain quality.
• Structured data and data quality
means improved handling of failures
when one does happen.
• Failure is alarmed, handled by control
algorithm

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Reduced Maintenance Costs
0%
5%
10%
15%
20%
25%
30%
35%
Routine
check
No
Problem
Calibration
shift
Zero Off Plugged
lines
Failed
35%
28%
20%
6% 6%
4%
Source: Shell Global Solutions
63% of maintenance labor
results in no action!!

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Reduced Maintenance Costs
• 40% of Mfg. Cost is Maintenance
• 50% of Maintenance Is Corrective
• Corrective is 10 times More Costly
Than Preventative Maintenance
• Preventative Maintenance is Done
25% of Time and is 5 Times More
costly Than Predictive Maintenance
• 60% of Preventative Maintenance is
Unnecessary

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The Benefits of Predictive Maintenance are
Documented

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Think all Networks Offer the Same
Diagnostics? Think again.
• More Diagnostics, with
better granularity
• Better Management of
Diagnostic Data
• Data Quality and reliability
• Severity of Diagnostic
Conditions per NE 107

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ISA108 Provides Necessary Work Processes
for Proactive and Predictive Maintenance
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Summary
• You can realize significant lifecycle cost benefits with FOUNDATION
fieldbus
• Fieldbus is different, not difficult
• Remember, the right partner, training and work processes are the
keys to success

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FOUNDATION Fieldbus Moving Forward

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