Proven Benefits in Projects WorldwideReduced cost, faster startup

Dong Manh HoangSEA Service Assistant ManagerEmerson – Fisher

On Behalf of Fieldbus Foundation

Vietnam 20132

Topics CoveredTopics CoveredReduced cable and installationReduced I/O cards, cabinets, and weightSmaller system footprintReduced device countFewer gateways and data mappingSimpler I/O designGreater flexibility to handle I/O changesFaster commissioning

Vietnam 20133

Reduced Hardware RequirementsReduced Hardware RequirementsEliminate physical signal marshalling and cabinets– Signal marshalling edited in software

Robust and reliable by eliminating failure points– Fewer wire connections to go bad

JBCONTROLLERS MARSHALLING

JB

FTA

FTA

FTA

FTA

FTA

FTA

PT

& I/O & POWER

PT

CONTROLLERS& INTERFACESWITH POWER

JB

JBFIELDBUS

FieldbusHardwired

Vietnam 20134

I/O Flexibility through VirtualMarshalling™ I/O Flexibility through VirtualMarshalling™ No custom hardware configurations (traditional I/O card selection) to accomplish marshallingMarshalling edited in software– All signal linking and changes without hardwiring

Fieldbus: 320 DevicesHardwired: 320 Signals

DIAC

AI AO DINA

DICO

DIAC

DORE

DODC

DOAC

AIAO DINA

DICO

DODC

AI

AO

DINA

DICO

DODC

AI

AO

DINA

DICO

AI

AO

DINA

DICO

DODC

DIAC

DIAC

DORE

DOAC

DIAC

DIAC

DORE

DOAC

DIAC

DIAC

DORE

DOAC

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

Vietnam 20135

The Smallest Hardware Footprint of Any I/O Technology in Process AutomationThe Smallest Hardware Footprint of Any I/O Technology in Process Automation

Significantly reducing the overall amount of hardware needed

Fiel

d Ju

nctio

n B

ox

Mar

shal

ling

Cab

inet

Sys

tem

Cab

inet

FieldbusHardwired

Fiel

d Ju

nctio

n B

ox

Sys

tem

Cab

inet

12 pairs12 signals

12 pairs12 signals

1 pair>24 signals

Mar

shal

ling

Cab

inet

Vietnam 20136

Dramatically Reduced Wiring and I/O Count for Complex DevicesDramatically Reduced Wiring and I/O Count for Complex DevicesHardwired

Multiple wire pairs per MOV

Fieldbus:Multiple MOVs per pair of wires

Cores I/O Description4 3 DO Open/stop/close control

2 1 AODesired valve position control

2 1 DO Emergency shut down

3 2 DIValve position status (limit switches)

2 1 AI Percentage open1 1 DI Available for control1 1 DI Local/remote switch

1 1 DIMotor running open direction

1 1 DIMotor running closed direction

1 1 DI Torque switch tripped2 1 AI Percentage torque

1 1 DIMotor thermostat tripped

1 1 DI Battery condition low22 16 ch TOTAL

With hardwired,

many device features

become too costly to use

Vietnam 20137

Eliminate Proprietary Protocols, Gateways, and SoftwareEliminate Proprietary Protocols, Gateways, and Software

Proprietary– Vendor dependency– Gateways, mapping…

Fieldbus– Standards-based– Simple architecture

MP T M

MP T M

M.O.V.CONFIG.

DEVICEMGMT

FF

MB

MB

FF GATEWAY

FIELDBUS MODBUS

PROPRIETARY

OPERAT.CONSOLE

MP T M

MP T M

DEVICEMGMT

FF

FF

FIELDBUS

OPERAT.CONSOLE

Vietnam 20138

Easy Handling of Late I/O Changes through VirtualMarshalling™Easy Handling of Late I/O Changes through VirtualMarshalling™

Easy late addition of signals:– For feedback and auxiliary

measurement– Without the need for

additional wiringEasy change of device kind without switching I/O cards– On/off valve to control valve– Control valve to MOV– On/off MOV to throttling MOV

More devices can be added without laying more cable

Vietnam 20139

Reduced WiringReduced WiringMultiple devices in parallel on the same pair of wiresA single pair provides both power and communicationLong distance is possibleField junction box hardware is rugged:– Encapsulated for harsh outdoor field conditions– Some passive

S

AIAODI-NAMURDI-ContactDI-ACDO-RelayDO-Transis.DO-Triac

12 pair = 12 signals

S

H1 Fieldbus

1 pair > 30 signals

FieldbusHardwired

Vietnam 201310

Reduced Installation LaborReduced Installation LaborReduces the need for hardware:– Cable, cable trays, and I/O cards etc.

Reduces installation labor:– Laying, cutting, stripping, crimping,

labeling and connecting at every intermediate point

For example;– A bus with 10 instruments– Three signals per device average – Takes the place of 30 pairs of wires

and I/O channelsThe resulting cost is even lower than hardwired remote I/O and local mounting

A 5,000 I/Ohardwired

system becomes a 1,700 fieldbus device system

Device I/OGas Chromatograph 25Electric Actuator (MOV) 16Process Gas Analyzer 5Mass Flow Meter 3On/Off Valve 3Amperometric Analyzer 2Conductivity Analyzer 2Control Valve Positioner 2Density Transmitter 2Flowmeter 2Flue Gas Transmitter 2Interface Level Transmitter 2Oxygen Transmitter 2

Vietnam 201311

Smaller System Footprint – Reduced WeightSmaller System Footprint – Reduced WeightHardwired

Each I/O signal:– One pair of wires– One I/O channel

Many I/O per device

FieldbusDrastic wire reductionFewer cabinets– Reduced I/O cards– No marshalling

Fieldbus: 320 DevicesHardwired: 320 Signals

DIAC

AI AO DINA

DICO

DIAC

DORE

DODC

DOAC

AIAO DINA

DICO

DODC

AI

AO

DINA

DICO

DODC

AI

AO

DINA

DICO

AI

AO

DINA

DICO

DODC

DIAC

DIAC

DORE

DOAC

DIAC

DIAC

DORE

DOAC

DIAC

DIAC

DORE

DOAC

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

FFH1

Vietnam 201312

Fieldbus Economically Enables Full Device Integration and CapabilityFieldbus Economically Enables Full Device Integration and Capability

Integration of all device signals, not just a subset– Fully utilize device capabilities, not just a partial

Continuous feedback available for all valves

Device Full Function I/O Actual Hardwired I/OGas Chromatograph 25 5Electric Actuator (MOV) 16 6Process Gas Analyzer 5 3Mass Flow Meter 3 1On/Off Valve 3 1Amperometric Analyzer 2 1Conductivity Analyzer 2 1Control Valve Positioner 2 1Density Transmitter 2 1Flowmeter 2 1Flue Gas Transmitter 2 1Interface Level Transmitter 2 1

Vietnam 201313

Simplify I/O DesignSimplify I/O DesignTransmitters, control valves, and two-wire on/off valves share the same busAll devices use the same single type of interface card– No need to select I/O card

All devices use the same single type of safety barrier– No need to select safety barrier

It is not necessary to know the exact type and quantity of signal for each device– Only how many devices

H1

Vietnam 201314

Multi-Channel Devices Reduce Both Device Count and I/O CountMulti-Channel Devices Reduce Both Device Count and I/O Count

Not limited to a single value per deviceMulti-input temperature transmitters– 8 sensor inputs, which are ideal for temperature

profiling applicationsMulti-point indicatorsDual input temperature transmitters

Vietnam 201315

Reduced Device CountReduced Device Count8-channel temperature transmitter takes the place of 8 hardwired transmitters– Reducing the overall device count– Reduced wiring– Reduced I/O card points

AI

8 pair = 8 signals

H1 Fieldbus

1 pair > 100 signals

FieldbusHardwired

Vietnam 201316

Reduced Cost by Shared Network InfrastructureReduced Cost by Shared Network Infrastructure

Eliminate proprietary protocols– Electric actuators/MOVs– Gas chromatographs– Tank gauging systems

No separate bus infrastructure required– Eliminating the need for separate networks, gateways,

and drivers

Vietnam 201317

Many Cost Effective SolutionsMany Cost Effective SolutionsDifferent brand components can share the same network– System, devices, power supplies, etc.

Ability to choose the best available instruments for the application

Vietnam 201318

Faster CommissioningFaster CommissioningNo traditional five-point loop tests– Replaced by a simple plausibility

checkSystem automatically confirms the correct device type has been installed– No need to visually inspect

No ranging required– Measurement in engineering unit

valueAlso for the discrete devices– Intelligent two-wire on/off valves– Electric actuators / motor operated

valves (MOV)

Vietnam 201319

Where Can I Learn More?Where Can I Learn More?What is FOUNDATION fieldbus?Breaking the Limits of Analog TechnologyProven Benefits in Projects Worldwide Enhanced Operations and Maintenance Ease of Use

http://www.fieldbus.org/images/stories/technology/aboutthetechology/overview

/fieldbus_brochure.pdf

Vietnam 201320

Shell Norco, USAShell Norco, USAEthylene Plant 9,000 fieldbus devicesImproved operations through control of key variables to reduce process variability in several major unitsEarly detection of potential device problems Over 340,000 man-hours of operation without a recordable eventZero unscheduled shutdowns or incidentsHigh degree of operator acceptance

Significant operation and maintenance benefits through predictive maintenance provided by FF and asset management technology.

– Improved hydrotreater steam shedding

– Improved heavy-gas stripper reflux flow

– Improvements in aromatics stripper reflux

– Significant improvement in steam usage

– Improved steam condensate drum operations

– Detecting and remedying valve malfunction

– Improvements in flow variability to Shell’s refinery

– Improvements in decoking– Early detection of excessive steam

tracing

Vietnam 201321

Nederlandse Aardolie Maatschappij BV (NAM) , The NetherlandsNederlandse Aardolie Maatschappij BV (NAM) , The Netherlands

Gas wellsJoint venture of Shell and Exxon2,500 fieldbus devicesMake it possible for the engineers to keep track of thousands of valves and instruments– When problems arise, the maintenance engineers can

get a quick picture of what is happening with the equipment.

Vietnam 201322

Qatar Petroleum, PS-2 and PS-3, Qatar Qatar Petroleum, PS-2 and PS-3, Qatar Offshore production platforms1,000 FOUNDATION fieldbus-enabled devicesSpace is very limited on offshore platforms and must be put to optimum use. The FOUNDATION fieldbus-based design enabled drastic reductions in the size and number of marshalling cabinets and in the amount of trunk cable that had to be laid.

Vietnam 201323

Petroleum Development Oman (PDO), Kauther Gas Plant , OmanPetroleum Development Oman (PDO), Kauther Gas Plant , Oman

Gas Plant Through the use of the latest control system and FOUNDATION™ fieldbus technology, process control and the diagnostic monitoring of field instrumentation is done from remote locations.

Vietnam 201324

Shell Expro, Brent Alpha, UKShell Expro, Brent Alpha, UKOffshore platformUsing FOUNDATION Fieldbus technology to reduce operating costsShell has selected FOUNDATION Fieldbus** as its solution because this technology provides the environment for ongoing cost reductions and is able to incorporate future technology advances that will further reduce operational costs

Vietnam 201325

CNOOC / Shell Petrochemicals, Nanhai, ChinaCNOOC / Shell Petrochemicals, Nanhai, China

16,000 FOUNDATION Fieldbus devicesPetrochemicals ComplexEnables a problem to be diagnosed and an alert issued before the instrument actually fails and disrupts a process– Continuously monitors the health of the

instrumentation• Resulting in increased reliability• Fewer suspect measurements

– Preventive maintenance capability• Plant operators can have greater confidence that their facility

will perform as expected.

Vietnam 201326

PTT LNG, Map Ta Phut, ThailandPTT LNG, Map Ta Phut, ThailandLNG import terminal The transmitters, flowmeters, and control valves throughout this terminal are all FOUNDATION fieldbusenabled and can be continually monitored– Alarms are issued before any device fails completely

• Enabling predictive maintenance that reduces maintenance costs throughout the facility lifecycle

Vietnam 201327

Merck Serono Biotech Center, Vevey, SwitzerlandMerck Serono Biotech Center, Vevey, Switzerland

2,000 FOUNDATION™ fieldbus devicesBiopharmaceuticalsAllows for a proactive maintenance approach and the scheduling of field device checksAll device data can be monitored online– The plant can be operated with a smaller field

workforce.

Vietnam 201328

Alcan, Gove, AustraliaAlcan, Gove, AustraliaBauxite to Alumina Refining6,600 FOUNDATION fieldbus devices30% savings in engineering & termination costsSignificant reduction in labour, installation and commissioning costsTime to engineer, wire & test DCS cabinereduced by 35%Time to assemble & pre-commission facility reduced by 25%

Vietnam 201329

BP/SECCO, ChinaBP/SECCO, ChinaPetrochemical processing complex producing ethylene and nine related productsWorld-class, 10-plant complex brought online three months ahead of scheduleSignificant savings on cablingMaintenance costs expected to be cut by one-third

Vietnam 201330

BP Chemicals (now Ashland), Lima, USABP Chemicals (now Ashland), Lima, USABDO plantIncreased process reliabilityConfiguration savingsIncreased process & diagnostics informationIncreased device health information

Vietnam 201331

TotalFinaElf , North Sea, NethernaldsTotalFinaElf , North Sea, NethernaldsOffshore Platform

15% reduced wiring and instrumentation cost20% reduced control system cost80% reduced engineering costsReduced building costsReduced operational cost

Vietnam 201332

Synthomer / Yule Catto, Malaysia Synthomer / Yule Catto, Malaysia Synthetic emulsion polymerReactor output increased to over 30% of design capacityBatch-to-batch repeatability improved by 30%Commissioning time reduced from 30 days to 8 daysNumber of aborted batches reduced by 50%Number of non-conforming batches reduced by 40%

Vietnam 201333

Reliance, Jamnagar, IndiaReliance, Jamnagar, India20,000+ Foundation fieldbus devicesRefineryMigration from a preventive to predictive maintenanceEnhanced diagnosticsStatus and signal-quality messages with every process variable update informs the operator that the signal is valid,– Also used by the control

algorithms to implement control only on valid signals.

Improved planning and scheduling of outagesReduction in maintenance costs.Improved loop operations– Problem loops can be

analyzed remotely and continuously monitored for sticking valves, questionable measurement etc.

Vietnam 201334

Fieldbus Project Business ValueFieldbus Project Business ValueReduced hardware cost– Less Wiring– Lower I/O Count– Reduced Installation Labor– Reduced Weight– The Smallest Hardware Footprint – Reduced Device Count– Fewer gateways

Faster design and changes– Simplified I/O design– Greater I/O flexibility– Easy handling of late I/O changes– Less proprietary protocol data mapping

Faster Commissioning