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DCS ROI

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... Power Supplies ... Standard Ethernet Equipment and Wiring. Standard ... Echo Curve. Filter '...dedicated to a single international fieldbus.' 2003 ... – PowerPoint PPT presentation

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Title: DCS ROI


1
Technology with Purpose
2
Its a Digital World
3
Fieldbus Foundation Market Data
  • Today 341 Global Members Corporate Affiliates,
  • 257 Registered Devices, 11 Hosts
  • 5,000 fieldbus control systems installed or on
    order around the world
  • 400,000 FOUNDATION fieldbus devices in service
    world wide

4
Growing Membership
5
Geographic Membership
6
Device Registration Trend
7
Fieldbus Technology Expanding Across the Globe
Fieldbus Acceptance Has Been Outstanding
  • Foundation fieldbus installations include leaders
    in key industries
  • 9 of the top 10 oil and gas companies
  • 24 of the top 25 pharmaceutical companies
  • 23 of the top 25 chemical companies
  • 15 of the top 20 pulp and paper companies
  • 10 of the top 20 food and beverage companies

8
Fieldbus Technology Expanding Across the Globe
Global Market Acceptance of Fieldbus
9
Technology with a Purpose
  • What Does Fieldbus Enable?
  • A digital plant architecture that uses the
  • power of field intelligence to improve plant
  • performance

10
Why Change
  • Benchmark Results Indicate Room for Improvement
  • 20-40 of control loops in manual control
  • 80 of control loops demonstrate excessive
    process variability
  • Many potential Advanced Process Control (APC)
    benefits are
  • being missed
  • Unplanned downtime is the largest single source
    of lost revenue
  • 86 of maintenance is reactive (too late) or
    preventative (unnecessary)
  • - Best practice is 40 with
    predictive/proactive
  • Most Petrochemical companies are not
  • making returns greater than their cost of
    capital

11
Unneeded Trips To The Field - Avoided Through
Remote Diagnostics
12
The Digital Plant Changes the Game for a Step
Change in Results
13
  • Technology Update
  • Host Interoperability Support Test (HIST)
  • Interoperability Testing Kit (ITK)
  • Power Supply Registration
  • Standard Transducer Blocks
  • High Speed Ethernet (HSE)
  • Safety Instrumented Systems (SIS)
  • DD Cooperation Project

14
Technology with a Purpose
  • Committed to Continuous Improvement

15
FF Integrated Architecture H1 Field Device
Integration
16
HIST Release 1.2 ITK Release 4.6
  • HIST Release 1.2 New feature tests
  • HSE Linking Device Configuration
  • Flexible Function Blocks
  • Multi-Variable Optimization
  • Common Device Software Download
  • Device Replacement Support
  • ITK Release 4.6 Enhanced testing
  • Support for DD Self Re-registration
  • Support Capability File Changes for Instantiation
  • Library Support for Common Device Software
    Download

17
Standard Transducer Blocks
- End User Driven Project Test and register
standard transducer blocks to enhance
interoperability at the transducer level
  • Call for Volunteers Jun 2002
  • Kick-off Meeting at ISA Chicago Oct 2002
  • TEAM EH, Fieldbus Inc.,
    Magnetrol, Shell, Siemens Milltronics, Smar,
  • Syncrude, Yamatake,
    Yokogawa
  • Lab Test Prototype Vendors Identified May
    2003
  • Lab Validation Tests Completed for Pressure Dec
    2003
  • Final Specification for Pressure Approved by
    TSC Apr 2004
  • ITK 4.6 support for Pressure Transducer Block
    beta testing May 2004

18
Power Supply Registration
- End User Driven Project Procedures for
self-test of H1 power supplies and power
conditioners to enhance interoperability.
  • Project Kickoff May 2003
  • Draft Specifications Completed Jan 2004
  • Run Beta Registration Tests Feb 2004
  • Membership review of specification Mar 2004
  • TSC Release of Test Specification Apr 2004
  • First registered Power Supplies May 2004

þ
9 Power Supplies/Conditioners are registered on
the FF Web Site
19
FF Integrated Architecture HSE Subsystem
Integration
High Performance Control Backbone (100
Mbit/s) Standard Ethernet Equipment and
Wiring Standard Function Blocks PLUS Flexible
Function Blocks for Discrete/Batch/PLC Redundant
HSE Interfaces and Devices Linking Devices (LD)
Integrate H1 HSE Provides the Open Interface for
Data Servers
MIS
APPLICATION PACKAGES
Data Servers
HSE High Speed Control and Integration Backbone
LD
LD
20
High Speed Ethernet Device Types
þ
HSE Linking Devices
8 Linking Devices Registered on FF Web Site
In Final Beta Registration Testing
HSE Device running Function Blocks
Host
HSE Device with Redundant Interface
Final Specification Released by TSC
In Final Lab System Test
HSE Redundant Device
21
Safety Instrumented Systems
- End User Driven Project Extends FF
Technology to Safety Instrumented Systems
(SIS). IEC 61508 based, TÜV certified concept for
application of FOUNDATION fieldbus to Safety
Instrumented Systems.
  • Example Application Areas
  • Burner Management Systems
  • Fire Gas
  • Fuel Engineering

22
SIS Development Team
  • ABB AS Norway
  • ABB Instrumentation Italy
  • E.I. DuPont de Nemours, Inc. USA
  • ExxonMobil Research Engineering USA
  • Emerson Process Management USA
  • FlowServe USA
  • HIMA Germany
  • Honeywell SMS The Netherlands
  • ice-PROS Canada
  • Infraserv Höchst Technik GmbH Co. KG Germany
  • Invensys/Triconex USA
  • Metso Automation Finland
  • Rockwell Automation USA
  • Rotork Control Systems UK
  • Saudi Aramco Saudi Arabia
  • Smar Brazil and Singapore
  • Shell Global Solutions The Netherlands
  • Softing AG Germany
  • TÜV Germany

23
Key SIS End User Requirements
  • Reduced Total Cost of Ownership for FF-SIS
    applications
  • CAPEX - Hardware, Footprint, Commissioning, Power
    Consumption
  • OPEX - Advanced diagnostics, Reduced test
    interval
  • Suitable for SIL 2 and 3 applications
  • Password-protected (e.g. Write Lock) access to
    SIS field devices
  • Additional SIS Function Blocks (e.g. logic, 2 out
    of 3 voting)
  • Definable actions on diagnosed failures trip,
    message
  • Handle discrete signals (e.g. switches, motor
    trips, lights, push buttons)
  • Total system approach
  • Total Asset Management SIS and Non-SIS
  • Modular Logic Solver centralized and distributed
    option
  • Provide FF diagnostics
  • Hybrid system architecture mix SIS
    traditional hardware
  • Provide guidance to manual proof test
  • Signalling/procedures to enable automatic proof
    test
  • Information for opportunity-based proof test
  • Logging/documentation of results
  • Provide failure rate information

24
SIS Communication Extensions
  • The H1 Communication System (Black Channel) is
    unchanged.
  • A new SIS protocol above the Black Channel
    detects network faults and appropriate action can
    be taken without human intervention.

New SIS Communication Diagnostics
IEC 61508
Black Channel
IEC 61508
25
SIS User Layer Extensions
  • New Function Blocks for SIS Applications FBAP
    Part 6
  • New FBAP diagnostics detect application faults
    and appropriate action can be taken without human
    intervention.

New SIS Function Blocks Function Block
Diagnostics
IEC 61508
Black Channel
IEC 61508
26
SIS Open Fieldbus Solution
Total Asset Management
Operation
Engineering
Operation
Engineering
Proprietary Network
HSE
Ethernet Switch
SIS Logic
Linking Device
Linking Device
. . . .
H1
H1
Hardwired
Non-SIS FF Devices
SIS FF Devices
27
Example SIS ApplicationAnalog 2 out of 3 Voter
SIS_ WL
SIS_ AI
SIS_ RB
SIS_ DO
SIS_ AVTR
SIS_ WL
SIS_ AI
SIS_ RB
SIS_ DI
SIS_ WL
SIS_ AI
SIS_ RB
SIS_ WL
SIS_ RB
Write Lock (WL)
S
28
SIS Development Schedule
  • 2002
  • 4Q FF Board of Director Approval for SIS
    Project
  • 2003
  • 1Q Project Kickoff Meeting
  • 2Q Architecture Completed
  • 3Q Draft Preliminary Specifications (DPS)
    Version 0.4
  • 4Q TÜV Concept Approval for SIS
  • 2004
  • 1Q DPS Version 0.5 External Review
  • 2Q DPS Version 0.9
  • 3Q DPS Version 1.0, Develop Lab Test Tools
    and Lab Prototypes
  • 4Q Begin Specification Validation Lab Testing
    _at_ Infraserv in Frankfurt
  • 2005 Release Final SIS Specifications and Final
    TÜV Type Approval

  • 2006 First Safety-Certified, FF-Registered
    Devices

29
DD Cooperation Project
  • The DD Cooperation Project was approved by FF,
    PNO and HCF in October 2002 to specify Electronic
    Device Description (EDD) visualization and data
    storage management extensions.
  • Common EDD extensions for FOUNDATION fieldbus,
    PROFIBUS and HART preserves and protects the
    worldwide investment in EDD-based devices, tools
    and training.

30
DD Cooperation Project Objectives
  • Develop EDD specification for advanced
    visualization and data storage and protect the
    installed base.
  • Built upon the approved IEC 61804-2 International
    Standard
  • Independent of operating system and communication
    protocol
  • Single EDD for all EDD applications
    (PCs/Handhelds/etc.)
  • No changes to existing EDDs
  • Develop EDD Interoperability Guideline for the
    extensions.
  • Independent test and validation of extensions.
  • Specification extensions available to all
    consortiums and IEC.

31
DD Cooperation Project Team
ABB Emerson Process Management Endress
Hauser Fieldbus Foundation FlowServe HART
Communication Foundation Honeywell PROFIBUS
Nutzerorganisation e.V Siemens Yokogawa
32
DD Cooperation Project Extension Areas
  • Enhanced User Interface
  • Parameter organization
  • Windows, dialogs, group boxes
  • Images
  • Graphing System
  • Visualize complex data
  • Support for charts and graphs
  • Multiple plots
  • Interactive zooming
  • Direct editing of graphs
  • Emphasis, key points, notes
  • Persistent Data Storage
  • Store/access device data on the host
  • Independent of host file system

Applications
Sensor/Actuator configuration Motor
control Complex configurations
Radar level configuration Valve signatures
Valve diagnostics Sensor drift Sensor/Actuator
diagnostics Archived valve signatures
33
DD Cooperation Project Motor Control Example
Image
  • Static bit map
  • Objective is to provide a visual representation
    of the parameters


Enhanced MENUS and METHOD are used to build
dialog boxes displaying motor starts, operating
hours, number of overload trips, etc.
34
DD Cooperation Project Radar Gauge Example
  • A GRAPH is used to present the echo WAVEFORM to
    enable configuration of thresholds and false
    echoes areas in the device.
  • Trigger device to build WAVEFORM data
  • Retrieve WAVEFORM data
  • Update the GRAPH

GRAPH
WAVEFORM (Data from Device)
AXIS
MENUS METHODS (Enhanced UI)
35
DD Cooperation Project Valve Signature Example
  • A GRAPH is used to present the Valve Signature
    (Hysteresis) WAVEFORM as a measure of the air
    pressure to stroke the valve open and close.
  • Trigger device to build
  • WAVEFORM data
  • Retrieve WAVEFORM data
  • Update the GRAPH

GRAPH
WAVEFORM (Data from Device)
AXIS
MENUS METHODS (Enhanced UI)
ARRAY(s) (Device Data)
FILE/LIST (Persistent Data)
36
FF Application Coverage
Function Blocks
H1 HSE
Advanced Process Control
Basic Process Control
Basic Function Blocks Analog Input Analog Output
Bias Gain Control Selector Discrete Input
Discrete Output Manual Loader PD Control PID
Control Ratio Control
Advanced Function Blocks Analog
Alarm Arithmetic Deadtime Device Control Input
Selector Integrator Lead/Lag Setpoint Ramp
Generator Signal Characterizer Splitter Timer
  • Flexible Function Blocks - Basic
  • Multiple Input/Output - 8 Channel I/O
  • Discrete and Analog
  • Basic I/O Interfacing and Data Acquisition
  • Flexible Function Blocks -Application Specific
  • Batch/Discrete/Hybrid Control
  • PLC Sequencing Startup/Shutdown
  • Variable Speed Drive Control
  • Gateways to Other Protocols
  • Supervisory Data Acquisition
  • Advanced I/O Interfacing
  • Multivariable Control and Optimization

Safety Instrumented Systems
SIS Function Blocks Analog Input Analog Output
Discrete Input Discrete Output Analog
Voter Discrete Voter AND/OR/XOR
37
Summary of FF Technology Released Products
38
A Different Way of Working
  • Need to Handle a new wealth of information -
    imbedding and deploying predictive intelligence
    to the plant
  • Systems Networked rather than centralized
  • Standards used at every level
  • - Field Fieldbus,
  • - Platforms Commercial,
  • off-the-shelf software and hardware
  • - Network technologies OPC, .NET

39
FF Standards Summary
40
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