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

Implementing a FOUNDATION™ Fieldbus Project

Part Two of Eight

Contents

Introduction User Guide – Implementing a FOUNDATION Fieldbus Project

Chapter 1 Introducing the User Guide

1.1 Executive Summary

1.2 Recommended Technical Resources

Chapter 2 Overview of FOUNDATION Fieldbus

Chapter 3 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

Chapter 4 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

Chapter 5 FOUNDATION Fieldbus Project Design & Engineering

5.1 Host Selection Considerations

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

Chapter 6 FOUNDATION Fieldbus Project Implementation – Conclusion & Checklist

Appendix References/Sources

In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 2

Implementing a FOUNDATION™ Fieldbus Project

Chapter 3: FOUNDATION Fieldbus Project Management –

Minimising Project Risk

The Project Design & Engineering phase of a project that includes the integration of

FOUNDATION fieldbus is the cornerstone to delivering the full benefits of FOUNDATION

technology in the optimum project timescale; at the minimum overall project cost.

Project risk must also be minimised; with the minimal disruption to production

schedules; and with the maximum support in place for

streamlined on-going operations, maintenance and auditing

procedures once the final commissioning and start-up has been

completed.

Before the Project Design & Engineering phase can even begin,

there are certain fundamental concepts that need to be

embraced which will contribute towards the success of the

project.

Rigorous project planning and an unwavering attention to

established FOUNDATION fieldbus guidelines; appropriate industry

standards; documentation procedures; training; testing procedures; and best practice

principles will contribute to the overall success of the project especially in the limitation

of implementation challenges once the project is in the Project Implementation phase.

A smoothly executed project will maximise return on investment.

Similarly, there are specific methods and guidelines relating to FOUNDATION system

design and installation which should be understood and followed in order to ensure

successful Project Implementation - in particular host, device and component selection;

segment design; wiring and cabling; grounding and shielding; testing; and

considerations relating to hazardous area applications, Control in the Field and wireless

applications.

“Rigorous project planning and

an unwavering attention to

established FOUNDATION fieldbus

guidelines; appropriate industry

standards; documentation

procedures; training; testing

procedures; and best practice

principles will contribute to the

overall success of the project”

In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 3

3.1: Proven Technology

According to ARC Advisory Group, FOUNDATION fieldbus accounted for nearly three-

quarters of the total digital process fieldbus marketplace in 2011*1. With 75-80% of

field devices supporting FOUNDATION fieldbus and the fact that FOUNDATION technology

can be integrated easily into existing 4-20mA and other fieldbus systems via gateways,

the adoption of FOUNDATION technology into process automation is now mainstream

and the perceived risks associated with early adoption are significantly reduced.

The use of traditional technologies for process automation has often been the default

option and for many end users the integration of FOUNDATION fieldbus is still a step

into unfamiliar territory. However, this is changing. In addition to the implementation

of FOUNDATION fieldbus in Greenfield sites, it is now

routinely being incorporated into modernisation and

migration projects. In order to ensure the success of a

FOUNDATION project and thereby maximising the

achievable benefits that the technology offers, all parties

involved need to understand that the planning and

implementation of the technology requires a different approach to that of traditional

technologies. Although the approach may be different – it does not have to be

difficult.

Since all field devices and segments become an integral part of the distributed control

system (DCS), field network design requires an integrated configuration, data

management and systems architecture approach.

Furthermore, Project Management needs to understand the full functionality of

FOUNDATION fieldbus technology, the hosts, devices and components at the outset of

the project in order to maximise the return on investment and avoid changes and

revisions to the project, which would inevitably have implications on the cost and

scheduling of the project. FOUNDATION hosts, devices and components have a multitude

of functions that may be utilised – but the means of using this functionality needs to

be identified right at the beginning before final selection, for example, the full use of

advanced diagnostics within some devices requires the integration of a suitable asset

management system or host functions. Without a suitable means of retrieving its

diagnostic data, a field device may be limited to its basic function.

“FOUNDATION fieldbus accounted

for nearly three-quarters of the

total digital process fieldbus

marketplace in 2011”

In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 4

All host systems, devices and key components for a FOUNDATION project must have

been tested, approved and registered under the Fieldbus Foundation’s own test and

registration process and gained the ‘checkmark’. End users may be reassured that the

products they are selecting for their network have been tested against well-defined

criteria to maximise interoperability and minimise integration issues. Information about

the testing procedures and a full list of all registered products is available on

www.fieldbus.org/registration.

Rigorous project planning leads to greater project reliability.

Although more up-front, detailed planning may be required for

the implementation of a FOUNDATION project than for conventional

solutions, less time is required at the later stages of installation,

commissioning and start-up. The identification of work processes

and the impact of all aspects of the new project on these is vital, together with a

constant review and evaluation of risk assessments.

FOUNDATION fieldbus will continue to evolve to meet market demands in a wide range

of industries and will continue to be the right choice for the control systems of today

and the future. The Fieldbus Foundation’s development initiatives, including SIF, ROM

and EDDL enhancements, are driven forward with valuable end user input through the

active End User Advisory Council. Technical working groups include many of the

world’s major suppliers of process automation instrumentation.

Wise host and device selection will help avoid false economies and contribute towards

a longer system lifetime. It is also recommended that approximately 20% spare

capacity is built into the segment design at the initial stages. This safeguards against

unforeseen discrepancies between segment design

and implementation or allows for a more flexible

approach to system expansion with minimum

redesign.

“Wise host and device selection will

help avoid false economies and

contribute towards a longer system

lifetime”

In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 5

3.2: Project Evaluation

A detailed analysis of the anticipated use of FOUNDATION fieldbus is essential. A clear

understanding of where it can be used and where it may not be appropriate is

necessary to avoid wasting resources. To achieve this, a greater level of up-front

information and knowledge is required at the out-set of the project including a

thorough understanding of the full functionality of FOUNDATION fieldbus; certain key

installation criteria; and the options available in terms of host systems, devices and

components in order to make an informed selection prior to detailed network design.

Expectations of the achievable benefits should be identified and evaluated in the

context of realistic experiences, anticipated implementation challenges, and current and

future work processes.

In particular, the project team needs to quantify the savings attributable to capital

expenditure (CAPEX) through the reduction of project costs relating to reduced cabling;

wiring; control room requirements; and installation, configuration and commissioning

times. Similarly, it needs to quantify the potential savings attributed to operating

expenditure (OPEX) in terms of faster project implementation and process start-up;

reduced process disruptions or downtime; and more efficient maintenance processes

especially due to the implementation of advanced diagnostics and an asset

management system.

In applications when FOUNDATION technology needs to be integrated with existing

systems, the interfaces need to be clearly understood and identified. Consideration

must also be given to whether the FOUNDATION system will have segments operating in

hazardous areas; if FOUNDATION for Safety Instrumented Functions is required; and if

wireless connections are required and if the control should reside in the host or in the

field device.

The anticipated use of the inherent diagnostics information and the level of

information required from devices needs to be defined at the outset and appropriate

operations and maintenance processes and procedures developed. Whether simple

alarm functions or advanced diagnostics data are required this then has implications on

the selection of the host system, individual field devices, components, and the possible

integration of a suitable asset management system.

In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 6

References:

1: ARC Advisory Group, Dedham, MA: “Fieldbus Solutions for the Process Industries: Worldwide

Outlook” market study, published Dec 13, 2011.

http://www.arcweb.com/market-studies/pages/fieldbus-solutions-process-industries.aspx