End User Workshop - Singapore

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End User Workshop - Singapore
FOUNDATIONTM Fieldbus - Challenges Latest
Developments - July 8, 2004 Hisashi
Sasajima Fieldbus Foundation
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Agenda

• Introduction
• About Fieldbus Foundation
• The History of Fieldbus
• End User Initiative
• Technology Updates
• Installations
• Benefit of Fieldbus
• Questions and Answers

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2
05/03/04
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Mission of the Fieldbus Foundation

• The Fieldbus Foundation is the leading
  organization
• dedicated to a single international,
  interoperable
• fieldbus standard. Established in September 1994
  by a merger of WorldFIP North America and the
• Interoperable Systems Project (ISP), the
  foundation is a not-for-profit corporation that
  consists of nearly 180 of the world's leading
  suppliers and end users of process control and
  manufacturing automation products.
• Working together, these companies have provided
• unparalleled support for a worldwide fieldbus
  protocol, and have made major contributions to
  the IEC/ISA fieldbus standards development.

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FOUNDATION fieldbus Digital presence
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Market Distribution
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Market Segmentation in the Region

• 1st 2nd 3rd
• N.A. (46) Chemical Electric Pulp Paper
• L.A. (14) Chemical Oil Gas Food
  Beverages
• EU (28) Chemical Oil Gas
  Pharmaceutical
• M.E. ( 2) Oil Gas Chemical
• SEA (10) Chemical Oil Gas Refining
• China ( 7) Chemical Refining Electric
• Others
• Total Chemical Oil Gas Electric Power

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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

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Stronger Than Ever!

• 338 Global Members Corporate Affiliates
• 176 Registered Devices
• 11 Hosts

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Freedom to Choose
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Marketing Committees in Asia Pacific
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FF Asia Pacific
Fieldbus Foundation Asia Pacific Operations
South East Asia
East Asia
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End User Council and Training/ Education Center
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The History of Fieldbus(IEC/ISA Standardization)

• 1984 New Work Item proposal in IEC for Digital
  Field Communication in Process Measurement and
  Control Instruments
• 1985 Working Group established in IEC
  (SC65C/WG6) and ISA (SP50)
• 1990 IFC(international Fieldbus Consortium)
• ISA SP50 Media Attachment Unit (MAU)
• Physical Layer Test at Exxon (92)
• BP Sunburry -1,-2
• Kaneka, Mitsubishi Chemical, Japan (93)
• 1992 1Nov. ISP was formed
• 1993 May WorldFIP was formed
• 1993 IEC Physical Layer became IS(IEC61158-2)
• 1994 Sept. Fieldbus Foundation established
• Field Trial at Monsanto, Tx (95)
• Field Trial at Syncrude, Canada(96)
• Chubu Electric, Japan (97)
• 2000 IEC Data Link/ Application Layer
  Standardized(IEC61158-3,4,5,6)

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The History of Fieldbus Foundation
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Original End User Requirements for Fieldbus

• Average distance between Control Room and Plant
  shall be
• Cable Distance 1,200m
• Transmission Distance 2,400m (8,000 ft)
• ? H1 Fieldbus Cable Distance 1,900m (with
  maximum nodes)
• Transmission speed considering for the anti-noise
  immunity, attenuation and reflection of signal
  shall be
• 50Kbps - 500Kbps.
• ? H1 Fieldbus 31.25Kbps
• H2 (High Speed) Fieldbus 1 Mbps or 2.5
  Mbps
• (FF Specification) H1 Fieldbus 100Mbps
  HSE(High Speed Ethernet)
• Cable Type Existing multi-core cables shall be
  applicable and device power / signal transmission
  shall be available through single pair cable
• ? Type A, B, C, D Cables
• The Fieldbus Devices shall be workable in
  Intrinsic Safe environment with flammable gas
  atmosphere in Hydrocarbon Processing Industry.
• ? Entity ModelCurrent Limit (19V?4060mA),
  10mA30mA/ Device
• FISCO Model (Fieldbus Intrinsic Safety
  Concept) 110mA
• FNICO Model (Fieldbus Non-Incendive
  Concept) 350mA

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IEC61158 Structure (as of June, 2004)

• IEC 61158 Part 1-Part 6 (PHL/DL/AL)
• Type Proposed by
• Type- 1 Fieldbus(ANSI/ISAS50.01) IEC/ISA
  Original Specification
• Type- 2 ControlNet ControlNet Intl
• Type- 3 Profibus DP/PA Profibus
  Organization
• Type- 4 P-Net Norwegian Fieldbus Consortium
• Type- 5 Fieldbus Foundation HSE Fieldbus
  Foundation
• Type- 6 Swiftnet
• Type- 7 WorldFIP WorldFIP
• Type- 8 Interbus S
• Type- 9 Foundation H1 Fieldbus Fieldbus
  Foundation
• Type-10 Profinet Profibus Organization

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Fieldbus Protocol Structure
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Humble Beginnings
H1 31.25 Kbps
Computers

Control
network

Process
controllers
H1 Fieldbus

Junction
box

Field
devices
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FOUNDATION Fieldbus Architecture
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Integrated System Architecture
Servers access data from the HSE Backbone Data
is used to support Application Packages such
as Enterprise Resource Planning Asset Management
MANAGEMENT INFORMATION SYSTEMS Access the
Data Warehouses Provide Management Reports
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Released Specifications
SYSTEM ARCHITECTURE FF-581 System Architecture
FUNCTION BLOCKS FF-890 Function Block Part 1
FBAP Model FF-891 Function Block Part 2
Basic FF-892 Function Block Part 3 Advanced
FF-893 Function Block Part 4 Multiple I/O
FF-894 Function Block Part 5 Flexible
DEVICE DESCRIPTION FF-103 Capability
File FF-900 DD Language (DDL)
USER LAYER
UTILITY FF-883 Common Device Software Download
H1 FIELDBUS (31.25 KBIT/S) FF-801 Network
Management FF-806 H1-H1 Bridge FF-816 H1 Profile
(Entity, FISCO, Fiber) FF-821 Data Link
Services FF-822 Data Link Protocol FF-870 Fieldb
us Message Specification FF-875 Fieldbus Access
Sublayer FF-880 System Management FF-940 H1
Profile
HSE FIELDBUS (100 MBIT/S) FF-586 Ethernet
Presence FF-588 Field Device Access FF-589 HSE
System Management FF-593 HSE Redundant
Interface FF-803 HSE Network Management FF-941 HSE
Profile
NETWORK
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FF Products Roadmap
FOUNDATION? fieldbus Specifications
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H1 Development History

• H1 Today
• Over 62 Registered Stacks from 26 suppliers
• Over 200 Registered Devices from suppliers
• Over 305,000 H1 Devices in the Field
• HIST Compliant Hosts sampling (4500)
• ABB
• Emerson Delta V
• Honeywell Plantscape and Experion PKS
• Invensys
• Smar System 302
• Yamatake Industrial DEO
• Yokogawa Centum and Stardom
• Rockwell Process Logix

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HSE Development History

• HSE Today
• 10 Registered Linking Devices
• ABB (2 versions)
• Emerson
• National Instruments
• Rockwell
• Smar(3)
• Softing
• HMS Networks
• HSE Function Block Devices in Beta Registration
  Test
• HSE Redundant Devices in Lab System Test
• Planning for FBCiHAB Demo at BP is Underway
• - Includes registered HSE Linking Devices, FB
  Devices, and HSE Redundancy

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Fieldbus Foundation Technology Updates
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Agenda

• 1. H1 Interoperability Improvement
• HIST Release 1.2
• H1 ITK Release 4.6
• H1 Power Supply Registration
• 2. Development Programs
• DD Cooperation Project
• Standard Transducer Block Specification
• HSE Registration
• HSE Device Redundancy
• Safety Instrumented Systems

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HIST Release 1.2

• HIST Release 1.2 adds the following feature
  tests
• Common Device Software Download
• Multi-Variable Optimization
• HSE Linking Device Configuration
• Flexible Function Blocks
• Device Replacement Support
• Release Schedule
• Comment Period 1 Dec 2003
• Comment Period 2 Jan 2004
• EUAC Comment _at_ GA2004 Feb 2004
• TSC Approval May 2004

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H1 ITK Release 4.6

• H1 ITK 4.6 - Basis for DD Self Re-Registration
• Update to support FF-103 FS 1.7 (Capability File)
  - Instantiation
• Library support for Common Device Software
  Download
• Minor bug fixes
• Release Schedule
• Beta Test Start Mar 2004
• Beta Test Complete Apr 2004
• TSC Approval May 2004

Policy All DD/CF files must be retested using
ITK 4.6 within 6 months of release. Either by
self-test or by FF
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H1 Power Supply Registration

• Develop self-test specifications and registration
  testing for power supplies to improve
  interoperability.
• Fieldbus Power Supply Test Specification
  Release 1.0
• BOD Approval Feb 2003
• Project Kickoff May 2003
• Draft Test Specifications Completed Jan 2004
• Run Beta Registration Tests Feb 2004
• (MTL, PF, Relcom)
• Membership review of preliminary
  specification Mar 2004
• TSC Release of Test Specification Apr 2004
• First registered Power Supplies Apr 2004
• Nine power supplies registered and on FF Web Site

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DD Cooperation Project FF/HCF/PNO
IEC 61804-2 EDDL based Extensions for
Visualization

• 2003
• Kickoff Meeting Completed Host FF Feb
• Project Plan Issued Mar
• 2nd Team Meeting Host PNO Jun
• Requirements and Use Cases Agreed
• Specifications and Guidelines Identified
• 3nd Team Meeting Host HCF Sep
• Specification Development
• 4th Team Meeting Host FF Oct
• Specifications Agreed
• Validation Planning Started
• 2004
• 5th Team Meeting Host PNO Jan
• Draft of Interoperability Guideline Completed
• Project Plan Updated (Revision 1.4) with
  Validation Plan
• 6th Team Meeting Host HCF Mar

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DD Cooperation Project
It is a Super Set Specification of Device
Description Languages (EDDL)
Working Group Members - Volunteers from FF, HCF
and PNO
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DD Cooperation Project

• FF Validation Schedule
• ? Populate Annex F of the IEC specification with
  the FF profile information. Jan
• ? Identify host and field device prototype
  suppliers Apr
• Develop extensions to the DD Tokenizer software
  and DD Services software. Sep
• Develop FF host and FF field device lab
  prototypes (2 vendors) parallel path to
  extensions. Sep
• Lab validation testing completed. Dec
• HCF Validation Schedule
• 2003
• ? Modify the HCF DDL specification to include DD
  Cooperation enhancements.
• ? Send HCF specification to HCF members for
  ballot (30 days).
• ? Approval of HCF specification. Dec
• 2004
• Modify HCF DD Tokenizer/development tools - make
  available to HCF membership for testing.
• Validation Testing Completed. Dec
• PNO Validation Schedule
• 2003
• ? Draft of specification in IEC format reviewed
  by the PNO TC4 WG EDDL. Oct

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Standard Transducer Blocks
Develop specifications and registration testing
for transducer blocks to improve interoperability
and ease of use (e.g. pressure, temperature)
Transducer Block Standard Structures Release
1.0 Standard Pressure Transducer Block
Release 1.0

• 2002
• 4Q Project Kickoff
• Team EH, Fieldbus Inc., Shell,
  Smar, Syncrude, Yamatake, Yokogawa
• 2003
• 1Q Project Plan Approved
• 2Q Pressure Specification Preliminary
  Specification
• 3Q Pressure Devices from 2 vendors Delivered
• 4Q Specification Validation Lab Test Completed
  for Pressure
• 2004
• 1st Half Release Pressure Final
  Specification
• 2nd Half Update ITK with Pressure Test Cases
  Beta ITK Testing
• 2005 First registered Transducer Blocks

Test Cases for the Standard Pressure Transducer
Block is included in ITK 4.6
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Standard Transducer Block Final Specification
Released

• Standard pressure transducer block is the first
  to be released
• Released - the final specification for a standard
  pressure transducer block (TB). Like function
  blocks, TBs are key components of open,
  integrated FOUNDATION fieldbus architecture.
  TBs reside at the fieldbus User Layer , used to
  make sensor-related parameters needed for
  calibration and diagnostics visible to the
  fieldbus network.
• Standard TBs enable end users to realize
  additional operational benefits from their
  FOUNDATION fieldbus system, reduced setup time
  when replacing devices, improved consistency -
  interoperability of operator and maintenance
  displays between devices from different vendors,
  and improved asset utilization.
• Tested, proven and easy to implement this
  significant step forward provides end users with
  improved access to maintenance and diagnostics.
  supporting operating system independent proven
  information in interoperable fieldbus devices.

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HSE Registration

• HSE Linking Device Class 42a-1
• Supports client/server - Enables H1
  configuration and operation from HSE
• ABB (2 versions), Emerson, Smar, and Softing
  devices are registered.
• HSE Linking Device Class 42a-2
• 42a2 includes Function Block Connect Option
  easier configuration from host
• National Instruments, Rockwell and Smar devices
  are registered
• HSE Linking Device Class 42c Registration 3Q
  2004
• 42c Includes 42a-2 H1-H1 Bridging,
• H1-HSE Publisher/Subscriber,
• Time Sync
• HSE Field Device Class 41c Registration 3Q 2004
• 41c HSE device with Function Blocks

þ
Total of Eight HSE Class 42a Linking Devices
Registered
Depends on vendor schedules
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HSE Device Redundancy
Priority 1 HSE Linking Devices Class 42a-1, 42a-2
?
Priority 3 HSE Device with Redundant
Interface Class 47
Host
?
Aug 04
Priority 4 HSE Redundant Device Class 46
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HSE Device Redundancy
Host
Single LAN that is Fault Tolerant
100 Mbit/s HSE Stitches

A
A
B
B
To H1
To H1
Redundant Pair of HSE Linking Devices
Redundant Pair of HSE Linking Devices

Vendor A
Vendor B
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HSE Device Redundancy

• Redundant Interface Class 47
• Class 47 Redundant Interface Lab Testing Mar
  2002
• System Test Plan Approved by TSC May 2002
• Vendors Update Prototypes Run System Test Jan
  2003
• TSC Release Redundant Interface Final
  Specification Feb 2003
• HSE Analyzer Toolkit Professional Released May
  2003
• - Supports Redundant Interface
  Capture
• Redundant Device Class 46
• Class 46 Redundant Device Lab/System Test Plan
  Approved May 2003
• Run Class 46 Lab Test (standalone) Dec 2003
• Update Specifications and Compete Test Cases May
  2004
• Update prototypes and Rerun System Test Jun
  2004
• TSC Release Redundant Device Final
  Specification Aug 2004
• Complete Beta Registration Testing for
  Redundancy 4Q 2004
• TSC Release Redundancy Test Purposes for
  Registration 1Q 2005
• First Registered Class 47/46 Devices 1Q 2005

Depends on vendor schedules
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Safety Instrumented Systems

• IEC 61508 based, TÜV certified, concept for
  application of
• FOUNDATION fieldbus to Safety Instrumented
  Systems
• 2002
• Project approved by BOD Oct
• 2003
• Kickoff (Requirements and planning) hosted by
  HIMA Jan
• Team ABB, DuPont, ExxonMobil, Emerson, FF,
  Shell, HIMA, Honeywell,
• Invensys/Triconex, Metso, Rotork, Saudi Aramco,
  Smar Softing, TÜV, Yokogawa
• Project Management Plan Approved by TSC Mar
• 2nd Full Team meeting (Architecture) hosted by
  Shell Global Solutions Jun
• WebEx Review of Architecture with Function
  Block/DD/CF Teams Aug
• 3rd Full Team meeting (Protocol and Safety
  Analysis) hosted by ABB Sep
• Technical Team Meeting (Protocol and Function
  Blocks) hosted by Smar Nov
• TÜV Approval of FF-SIS System Concept Dec 15

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Future Open FF- SIS
Today
Tomorrow
Operator Interface
Engineer Interface
Proprietary Network
SIS Logics
Hard Wired
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FF-SIS New Kid on the Block
USER LAYER IEC 61804-2
FF-SIS IEC 61508
COMMUNICATION STACK
Physical Layer
Physical Layer
H1/HSE
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FF-SIS Extension

• Communication Protocol
• IEC 61508 Part 2 Section 7.4.8 Compliant
• Communication Fault Diagnostic
• User Layer
• IEC 61508 Part 3 Section 7.4.4 Compliant
• Fault Diagnostic Function Block
• CRC(Cyclic Redundancy Check)

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FF-SIS User Layer Extentions

• FBAP(Function Block Application Process) Part 6
• SIS Write Protection Lock
• SIS Digital Input
• SIS Analog Input
• SIS Digital Output
• SIS Analog Value Selectior
• SIS Digital Value Selector
• SIS AND/OR/XOR
• In addition to Device Resource Block, FF-SIS
  Diagnostic and Statistical Function Block will be
  provided.

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Safety Instrumented Systems

• 2004
• Draft Preliminary Specification (DPS) Expert
  Review - hosted by Shell Mar
• 4th Full Team meeting (Validation Planning)
  - hosted by Shell Mar
• Identify Lab Prototype Suppliers and Lab Test
  site (Infraserve) Apr
• TÜV Agreement on Type Approval Steps for
  FF-SIS Protocol Apr
• Editors meeting to resolve DPS review
  comments hosted by Triconex Apr
• Update specifications to DPS 0.9 May
• SIS and FB Team Review of DPS 0.9 Update
  and release DPS 1.0 Jun
• Lab Conformance Test Tool Available Jul
• 5th Full Team Meeting (Profile and
  Application Guide) hosted by Infraserve Sep
• Lab prototypes available - Begin Lab
  Specification Validation Tests Sep
• Update Specification to Preliminary
  Specification (PS) status Dec
  

• 2005
• FF Membership Review of PS 1Q
• TÜV Type Approval for FF-SIS protocol 2Q
• TSC Release of Final Specifications (FS) 2Q
• Beta FF-SIS Testing Kits (Conformance and
  Interoperability) 3Q
• Beta Registration Test (2 beta
  products) 4Q
• Beta Product Evaluation Shell Global
  Solutions 4Q
• First registered FF-SIS devices TBD

Depends on vendor schedules
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End User Benefit
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Process Operator Benefits

• What can be achieved by Fieldbus?
• Device and Process Diagnostics available by
  multi-variable devices
• Detect gas substance in Mass Flow Meter
• Detect and Notify supply air drop of Control
  Valve
• Detect and Notify the stick of Control Valve Stem
• Historise the statistical data of Control Valve
  travel (stem time)
• Detect and Notify in-pulse stick of Pressure
  Transmitter
• Detect and Notify open thermocouple situation
• Detect and Notify the Unfilled water condition of
  Magnetic Flowmeter
• Detect and Notify the pipe vibration of Colioli
  Flow Meter
• Detect glass electrode corruption of pH Analyzer

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Unneeded Trips To The Field - Avoided Through
Remote Diagnostics
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Engineering Savings
Task Time/ Device
Analog Fieldbus
Development of Control Strategy (PID Development) 2 1
Instrument Index development / production 0.5 0.5
I/O Address assignments 0.3 0.1
I/O List Development 1.5 0.5
Instrument loop diagram design/documentation 4 2
Marshalling panel design / documentation .3 0
Field terminal box design / documentation .3 0.1
Electrical Cabling and termination lists 2.25 0.7
Precommissioning configuration of devices .5 0.5
Total 11.65 5.4
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Repeatable Savings
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CAPEX/OPEX Savings in Oil Production Platform
By JNOC Study

• Oil Gas Platform model
• Oil reserves 200 million barrels
• Gas reserves 100 billion cubic feet
• Oil production plateau 75,000 barrels per day
• Outage cost per hour US 100,000

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CAPEX/OPEX Savings in Oil Production Platform
By JNOC Study
Conventional Instrumentation Fieldbus Instrumentation Reduction()
Initial Expenditure(M) 19.07 12.20
Expenditure Reduction(M) - 6.87 36.0
Operating Expenditure(M) 103.57 69.33
Expenditure Reduction(M) - 44.21 38.9
Life Cycle Expenditure(M) 122.64 81.53
Expenditure Reduction(M) - 51.07 38.5
Total 100 M for 25 years
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Result End User Benefits
CAPEX

• Fieldbus reduces capital costs
• Reduced engineering and documentation time
• Reduced installation and startup time
• Reduced controller and I/O equipment
• Reduced control room space
• AndFASTER TIME TO REVENUE

OPEX
Output Efficiency
OUTPUT
Quality
Availability
Throughput
Operation Maintenance
Safety, Health Environment
Utilities
Waste/ Rework
COST
Cost Efficiency
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End User Participation
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End User Seminar Shenzhen, China ( May 26, 2004)

• Ronald Szanyi, P.E.
• Project Development Leader for ExxonMobil
  Research Engineering (EMRE), Fairfax, VA
• Member of the Fieldbus Foundation Board of
  Directors since 2000

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End User Seminar Singapore

• End User involvement in FF - Why is it important?
• Ensure interoperable system
• Ensure users needs are met
• Prioritize the enhancements
• Plan for technology improvement
• Take advantage of opportunities
• Field trial testing
• Identify economic drivers

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End User Seminar Singapore

• End User involvement in FF - Why is it important?
• (contd)
• Create internal practices - engineering
  maintenance
• Association with industry innovators and
  technology leaders
• Move to predictive maintenance
• Understand what you need to know to engineer a
  project
• Networking (FUN, Fieldbus Facts)
• Sharing of successes and failures

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End User Seminar Singapore

• End User involvement in FF - Why is it important?
• (contd)
• Input to new areas of development
• Access to System Engineering Guide
• Help educate engineering contractors

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End User Seminar Singapore

• Some examples of end user involvement successes
• Interoperability testing
• Device Descriptions enhancement
• Flexible Function Blocks
• FF-SIS
• Transducer Blocks
• HIST Host Interoperability Support Test

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End User Requests

• Strengthen HIST
• Interoperability issues are between hosts and
  field devices, devices are interoperable between
  selves
• Device Connections/ Physical Layer
  / Power Supplies
• Access and Integration of FF data and associated
  benefits.

• Focus on Management layer to define and show life
  cycle economics / lost opportunity
• Presentations to vertical industry groups
• Interoperability labs
• Regional Centers of Excellence
• Private or commercial ventures

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DirectionsShort Term (1-2 years)

• Technology Issues
• Fieldbus for Safety Applications
• Transducer Block standardization
• HSE Interoperability/ Control Backbone
• HSE Applications

• Adoption Issues
• Interoperability Labs (HIST)
• Fieldbus Economics
• Flexible Function Block Demonstration
• Revision Level Management
• FF Knowledge Base

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DirectionsLong Term (5 years)

• Standard Maintenance Suite
• Enterprise Integration
• ERP benefits
• Global Process Industry market leader
• Implement White Papers

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End User Seminar- Singapore

• How to get involved
• Sign up End User Society Membership
• Sign up for Fieldbus Member Forums
• Sign up for Fieldbus Users Network (FUN) List
• Sign up for Fieldbus Facts news

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The Future is Bright

• Major global projects are specifyingFOUNDATION
  fieldbus
• Demonstrated success on retrofit
  andre-instrumentation projects
• Technology enhancements under development!

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Fieldbus FoundationA Decade of Leadership
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