Foundation Fieldbus Economics Comparison

1
Foundation Fieldbus Economics Comparison
Productivity 18 Harry Elliott

• Ian Verhappen
• Syncrude Canada Ltd.

2
Purpose of Work

• Objective
• Verify the installation of new control technology
  is more economic than present Analog Control
  Systems
• Why
• Strategic Projects planned over the next 10 years
  to double plant capacity

3
Basis for Calculations

• 3 Scenarios
• Conventional Installation
• Hybrid Installation
• Foundation Fieldbus Installation
• 3 Sizes / Types of Installations
• 20 point pilot plant
• 200 point plant migration
• 10,000 point grass roots facility

4
Basis for Calculations

• Data Sources
• 3 Distributed Control Systems
• 5 Device Manufacturers
• Signal mix
• 29 On/Off signals
• 75 of these were Digital Outputs
• 71 Analog
• 23 of these were Analog Outputs

5
Instrument DistributionAnalog Input
6
Instrument Prices
7
Assumptions

• 4 Devices/segment
• 300 meter Home Run
• 20 meter spurs

Host
8
FF Cable Specs
Twisted Multipair without shield, Max Length 400 m
Basis Belden 3077F
9
Hybrid Assumptions

• 2 increase in Engineering Costs
• 65 decrease in loop checks
• 70 decrease in tag/test terminations

10
Fieldbus Assumptions

• 20 increase in Engineering Costs
• 90 decrease in loop checks
• 25 decrease in tag/test terminations
• 75 decrease in home run cables
• Temperature Transmitters reduction
• 25 for fieldbus

11
Unclaimed Benefits

• Reduction in Cabling
• Reduction in Terminations
• Reduction in Control Room and Panel Space
• Reduction in Inventory Control

12
Installed Cost Comparison
1.2
1.0
0.5
13
Project Savings

• Based on Rules of Thumb
• Automation 15 of project cost
• Foundation Fieldbus saves 4 of Automation Budget
• 0.6 of Total Project Costs

14
Life Cycle CostsOperating Costs

• Maintenance
• 40 of Operating Costs
• Control System
• 45 of Maintenance
• OVERALL 18 of Operating Costs

15
Life Cycle Costs

• NAMUR
• 20 Maintenance support reduction
• 40 Inventory reduction
• Remote calibration
• 15 savings
• Single Loop Annual Cost
• 4,700.00 Analog loop
• 1,200.00 Fieldbus loop (field based control)

16
Life Cycle CostsMaintenance Costs

• Basis
• 80 of requests are unnecessary
• Embedded diagnostics identify 75 of false
  requests
• 60 savings

• Basis
• 33 of time is on actual repair
• Embedded diagnostics capture half of diagnostic
  time
• 17 savings

Combined Maintenance Savings 77
Offset by increased system complexity
17
Fieldbus Savings

• Initial Construction and Commissioning
• 4 minimum versus conventional system
• Ongoing Operations
• Maintenance 77
• Operating Cost 17
• Fieldbus provides savings now and in the future