Fall 2008

Your Global Source for FOUNDATION™ Technology News

z SIF Demo In Amsterdam

z Latest DD & Spec Releases

z DART Technology Explained

z HSE RIO Project Update

z Wireless Kick-off Meeting

z Marketing Committee Activities

z Q&A: Digital Migration

z Bill Tatum On Global Marketing

z Economic Case For Fieldbus

z Middle East & Africa Roundup

z Fieldbus Product Highlights

z SIF Demo In Amsterdam

z Latest DD & Spec Releases

z DART Technology Explained

z HSE RIO Project Update

z Wireless Kick-off Meeting

z Marketing Committee Activities

z Q&A: Digital Migration

z Bill Tatum On Global Marketing

z Economic Case For Fieldbus

z Middle East & Africa Roundup

z Fieldbus Product Highlights

In This Issue:

AutomationInfrastructureFor OperationalExcellence.

AutomationInfrastructureFor OperationalExcellence.

In This Issue:

3

President’s LetterFOUNDATION Automation Infrastructure: Development Continues

Rich TimoneyPresident & CEO,Fieldbus Foundation

In today’s industrial manufacturing arena, end-userrequirements for control and instrumentationtechnology are always evolving. Plants are faced

with a changing kaleidoscope of market trends,customer demands and regulatory restrictions. Inorder to stay ahead, they must implement automationsolutions that keep pace with their business outlook.

The Fieldbus Foundation is committed to servingthe control industry through development of its open,non-proprietary FOUNDATION fieldbus technology.FOUNDATION fieldbus is a unified infrastructure managingdata, communication, plant assets and plant events,while providing highly distributed control functionalityand interoperability between devices and subsystems.This infrastructure is supplier-neutral and standards-based, and provides end users with a common framework to implement and manage strategies foroperational excellence and continuous improvementin process manufacturing.

At the forefront of our current developments isFOUNDATION for Safety Instrumented Functions (SIF).This project was initiated in response to process endusers, who want to realize the CAPEX and OPEX benefits of open and interoperable fieldbus technologyin their plant safety systems. FOUNDATION fieldbus, withits industry-proven distributed function blocks andopen communications protocol, is an ideal platformfor advancing standards-based solutions for SIFs.

At a recent SIF technology demonstration inAmsterdam, Shell Global Solutions conducted a seriesof tests proving the robustness of FOUNDATION fieldbus-enabled safety valves with partial stroke testing (PST)capability, as well as various pressure and tempera-ture devices. In addition, Shell evaluated system integration capabilities with asset management andbasic process control system (BPCS) platforms.

The Fieldbus Foundation and its members are alsoworking on new initiatives that will enhance the valueproposition of High Speed Ethernet (HSE). For example,our HSE Remote I/O (HSE RIO) specification willdefine the structure for interfacing remote I/O overthe HSE control backbone. The addition of remote I/O further tightens the integration of process instru-mentation within the FOUNDATION fieldbus architecture.

This solution will expand the presence of FOUNDATION

technology in hybrid environments such as thosefound in pharmaceuticals and chemical processing.

At the same time, we are moving forward on awireless project based on WirelessHART and theemerging ISA SP100.11a standard. Together with the HART Communication Foundation and ProfibusNutzerorganisation e.V. (PNO), we have formed awireless cooperation team that is developing a specification for a common interface to a wirelessgateway. This work will enable wireless communi-cation with intelligent field devices in a wide range ofprocess measurement and control applications.

The Fieldbus Foundation has begun final validationof a FOUNDATION fieldbus diagnostic profiles specifica-tion based on guidelines established by the NAMURWorking Group 2.6. The new specification builds uponthe robust diagnostic features already provided byFOUNDATION fieldbus devices. At the same time, itallows end users to harness enhanced ElectronicDevice Description Language (EDDL) technology toachieve true, actionable diagnostics.

By empowering both suppliers and end users,FOUNDATION fieldbus has gained acceptance throughoutthe global automation market. Our technology is nowregarded as a standard in all major process indus-tries, and has a strong foothold in developing regionssuch as China and India. FOUNDATION-sponsored marketing societies and end-user councils have beenestablished in many of the world’s major industrialcenters.

On behalf of the Fieldbus Foundation, I’d like tothank all of you who are helping to advanceFOUNDATION technology. We appreciate your support!

All the best,

Richard J. TimoneyPresident & CEOFieldbus Foundation

End users describe the

implementation of aFOUNDATION fieldbus-based automation

infrastructureenabling new levels

of operational excellence.

To download, go towww.fieldbus.org/

podcast.

Changingthe PlayingField with

FOUNDATION™

Technology

FeaturesFOUNDATION SIF Technology Demonstrated in Amsterdam 6Leading end users evaluate fieldbus for safety instrumented functions

Latest Device Description and Specification Releases 10Automation industry has access to enhanced development tools

DART Provides New Solution For Explosion Protection 12Technique combines benefits of intrinsic safety with high power levels

High Speed Ethernet Remote I/O Update 15Working group is currently completing HSE RIO specification

Wireless Cooperation Team Holds Kick-off Meeting 16Industry organizations launch wireless specification development

Marketing Committees Encourage Fieldbus Adoption 17Fieldbus Foundation supporters promote technology worldwide

Fieldbus Foundation Marketing Effort Goes Global 19An interview with the Fieldbus Foundation’s marketing director, Bill Tatum

Digital Migration: Commonly Asked Questions 21Learn how to plan and implement your first digital control system

Economic Case For Using FOUNDATION Technology 26Innovative segment design approach ensures greater ROI

Regional Roundup: Middle East & Africa 31FOUNDATION fieldbus gains acceptance in key process industry region

Fall 2008Your Global Source for FOUNDATION™ Technology News

FIELDBUS REPORT is published by the Fieldbus Foundation, 9005 Mountain Ridge Drive,Bowie Bldg – Suite 200, Austin, TX 78759 (Phone 512-794-8890, Fax 512-794-8893).Address all correspondence to Editorial at the same address. Printed in the United States. © 2008 Fieldbus Foundation. All rights reserved. The contents of this publication may notbe reproduced in whole or part without consent of the copyright owner.

FIELDBUS REPORT is written and produced by Industrysource – The Industrial MarketingResource (www.indsource.com).

5

FIELDBUS APPLICATION GUIDES

AVAILABLEThe Fieldbus Foundation offers a selection ofcomprehensive Application Guides that canhelp end users get on the “Fast Track to

Fieldbus.” These documents provide valuable informationregarding fieldbus installation procedures, wiring guidelines,network isolation techniques, and more.

To download the Application Guides, visit:www.fieldbus.org/About/FoundationTech/Resources

FOUNDATION SIF Technology Demonstrated in AmsterdamLeading end users evaluate fieldbus for safety instrumented functions

6

Peter Eigenraam, regional manager, instrumentationand plant automation DG, Shell Global Solutions,welcomes the global trade press to the FOUNDATION

SIF demonstration in Amsterdam.

The Fieldbus Foundation successfully demonstrated itsFOUNDATION for Safety Instrumented Functions (SIF) technology on Tuesday, May 20, 2008, at the Shell Global

Solutions technology center in Amsterdam, The Netherlands.The SIF demo attracted process automation end users andequipment suppliers from around the world.

7

Demonstration attendees heard severalleading energy companies describe the imple-mentation of FOUNDATION SIF in a wide range of industrial safety system applications.Participants included Shell Global Solutions,Amsterdam, The Netherlands; Saudi Aramco,Dhahran, Saudi Arabia; BP, Gelsenkirchen,Germany; and Chevron, Houston, Texas, USA.The demonstration was intended to promoteadoption of FOUNDATION-based safety solutionsin the process industries. The project alsoincludes development of SIF best practices andguidelines, training, and interoperability testtools for control system and instrumentationmanufacturers and end users.

Companies participating in the SIF demon-stration working group included: ABB, BIFFI,BP, Chevron, Dresser-Masonelian, EmersonProcess Management, Endress+Hauser, Field-bus Diagnostics, HIMA, Honeywell, Invensys,Magnetrol, Metso Automation, Moore Industries,MTL, Pepperl+Fuchs, Risknowlogy B.V.,RuggedCom, Saudi Aramco, Siemens, ShellGlobal Solutions, Smar, Softing, TopWorx,TÜV Rheinland, TÜV SÜD, Westlock Controls,Yamatake, and Yokogawa.

Powerful diagnostics improve safetyfunctions

Fieldbus Foundation President and CEO RichTimoney discussed the difference between aFOUNDATION SIF system and a conventionalemergency shutdown system (ESD), comparingthem to doing a forensic analysis on a bodyversus performing a proactive diagnosis beforedeath. Advanced diagnostics ensure that manyissues can be addressed proactively before theESD needs to activate.

“FOUNDATION SIF provides powerful diagnosticcapabilities improving a wide range of safetyinstrumented functions and streamliningdevice testing requirements,” said Timoney.“This technology offers new opportunities tooptimize asset management initiatives andreduce plant operating expenses.”

At the Shell Global Solutions technologylaboratory, FOUNDATION SIF demonstration working group members constructed a fieldbus-based safety shutdown system demonstrationrig, incorporating logic solvers, safety devices,and SIF functions. The live demo was designedto evaluate FOUNDATION fieldbus-enabled safetyvalves with partial stroke testing (PST) capabil-ity, as well as various pressure and temperaturedevices. It also evaluated system integrationcapabilities with asset management and basicprocess control system (BPCS) platforms.

The safety demo system included equipmentfrom a number of leading vendors: HIMA provided the actual safety system, andYokogawa supplied the BPCS and plant assetmanagement software. Companies such asEndress+Hauser, Magnetrol, Metso Automation,RuggedCom, Siemens, Softing, Smar and

Westlock also provided products. Demos running at Saudi Aramco, Chevron, and BPincluded systems and products from all majorprocess automation suppliers.

ABB Instrumentation participated in theFOUNDATION SIF program by providing threeModel 2600T differential pressure transmittersfor the field demonstrations. These devicesrequired no special configuration and demon-strated full interoperability with multiple third-party devices and control systems.

Another major controls manufacturer,Emerson Process Management, suppliedequipment from its FOUNDATION SIF demon-stration versions of the Rosemount® 3051S,DeltaV™ SIS, Fisher® FIELDVUE® DVC6000f SIS,and AMS® Suite: Intelligent Device Manager.Emerson’s FIELDVUE DVC6000f SIS instrumentwas also utilized in the project.

Shell Global Solutions conducts live demo

Audun Gjerde, Shell Global Solutions,conducted the live SIF demo at the Amsterdamevent. He demonstrated high- and low-leveltrips, partial stroke valve testing, and a partialstroke test interrupted by the ESD. The lastexample showed that, even in the middle of a partial stroke test, the ESD could take over and shut down the system successfully during an abnormal situation. Two-out-of-three (2oo3)voting was demonstrated using various FOUNDATION

SIF devices. The system also reacted success-fully to a temperature probe loss, a measurementvalidation alarm, and a diagnostic alarm

generated from a dry probe on a level device.According to Gjerde, the demonstration

project sought to have a logic solver fully operable with all available SIF devices, to integrate an asset management system withthe SIF devices, and to integrate SIF partialstroke testing/valve stroke testing within asafety system infrastructure.

Gjerde said, “By implementing FOUNDATION SIF,Shell expects enhanced diagnostics through afully integrated asset management system. Wealso anticipate less testing of final elementsthanks to smart testing and diagnostics, aswell as online testing and partial stroke testing.This will result in early detection of dangerousdevice failures — and fewer spurious trips.The added SIF diagnostics will help engineersand maintenance personnel increase theintegrity of the plant by ensuring maintenanceis performed where and when it is needed.With smart online testing and diagnostics, wewill be able to run for longer periods of timewithout shutting down the plant for testing purposes. We will also save on the cost ofadding a second or third device in manycases.”

FOUNDATION technology advances SIF performance

With its industry-proven distributed functionblocks and open communications protocol,FOUNDATION fieldbus is an ideal infrastructure for advancing standards-based SIFs. Processindustry end users requested the FOUNDATION

SIF solution in order to realize the CAPEX and

Fieldbus Foundation President and CEO Rich Timoney compared the differencebetween a FOUNDATION SIF system and a conventional emergency shutdownsystem with doing a forensic analysis on a body and performing a proactivediagnosis while the patient is still alive.

Audun Gjerde, Shell Global Solutions, conducted a live SIF demo at the Amsterdam event. He demonstrated functions such as high- and low-level trips, partial stroke testing of valves,and a partial stroke test interrupted by the ESD.

OPEX benefits of open and inter-operable fieldbus technology intheir plant safety systems.

For leading control systemsuppliers, such as HoneywellProcess Solutions, embeddingFOUNDATION SIF in the plant DCStopology offers significant benefits.For instance, enterprise-wide assetmanagement allows SIF and non-fieldbus information and assetsto be shared anywhere on thesystem topology. Safety-criticaldata and non-safety critical dataare separated on the lowest level,therefore, non-safety relevant SIFdata can be communicated directlyto higher level applications withoutthe need for passing it through thesafety processor. This increasesavailability, decreases the loadon the safety layer, and bettersegregates process safety fromprocess control, which is man-dated by several standards. Plus,no dedicated hardware is neededto configure or use SIF-capablefieldbus devices or employ theexisting infrastructure.

The FOUNDATION SIF solutionmeets IEC 61508 standard require-ments for functional safety ofelectrical, electronic, and program-mable electronic safety-relatedsystems, up to, and including,

Safety Integrity Level (SIL) 3. Endusers can build systems to theIEC 61511 standard covering SIFfunctional safety in the processindustries (IEC 61511 is alsoavailable as ANSI/ISA-84.00.01-2004 standard).

The FOUNDATION SIS (safetyinstrumented systems) protocolenables instrumentation suppliersto manufacture fieldbus devicesfor use in SIFs.Third-party agencieswill safety certify these devices,and the Fieldbus Foundation willtest and register them for inter-operability. End users can applyIEC 61511 standard requirementsto determine the SIL needed for aparticular application, then selectinteroperable, safety-certifiedfieldbus devices from multiplesuppliers for use in their safetysystems.

The Fieldbus Foundation workedclosely with TÜV RheinlandIndustrie Service GmbH, Auto-mation, Software, and InformationTechnology, a global, independent,and accredited testing agency,to achieve protocol type approvalfor its SIS specifications. Theapproval extends FOUNDATION

technology to provide a compre-hensive solution for SIFs inprocess plants worldwide.

8

In recent months, the Fieldbus Foundationhas released a number of Device Descrip-tion (DD) enhancements and technology

specifications intended to improve theFOUNDATION fieldbus development environment.The new tools will further strengthen the inter-operability of fieldbus-based control systems,and provide end users with even greater benefits in terms of automation performanceand cost savings.

DD 5.1 solutions provide rich development environment

The Fieldbus Foundation’s new releases forDD technology, which is fully compliant withthe IEC 61804 and ISA104 Electronic DeviceDescription Language (EDDL) profile, includeenhanced versions of DD Services (Version5.1.0), DD Integrated Development Environment(Version 1.1.0), Device Description LanguageInteroperability Specification (FF-901), DeviceDescription Language Specification (FF-900),and DD Library (Version 3.2).

The Fieldbus Foundation’s manager – field-bus products, Stephen Mitschke, commented,“The updated DD solutions build upon therobust functionality of the previous DD 5.0release, and are intended to help device devel-opers, system suppliers and end users improvethe performance of their FOUNDATION fieldbusproducts.”

Mitschke indicated the latest DD enhance-ments support Unicode, providing FOUNDATION

fieldbus device and system suppliers with an expanded ability to write and visualize DDs using local languages, including Asian languages. The enhancements also allowdevelopers to build device-level menus, thusenabling visualization of multiple blocks andsignificantly improving the device integrationexperience. In addition, support for newparameter attributes will ensure an enhanceduser interface for accessing devices.

Mitschke added support for device-levelmenus will become mandatory as part of the Fieldbus Foundation’s host profile test and

registration program. Like the current deviceregistration process, host registration willstrengthen fieldbus interoperability and systemintegration. Hosts successfully completing registration testing will be authorized to bearthe foundation’s official product registrationsymbol.

Both of the DD technical documents (FF-900and FF-901) fully describe the new enhance-ments, and are included in the FOUNDATION field-bus technical specification. These documentsare available for download on Fieldbus Forums(forums.fieldbus.org) to all foundation memberswith a specification maintenance agreement.

Device coupler spec ensures greaterrobustness

In addition to new DD solutions, the FieldbusFoundation has released the final FOUNDATION

Device Coupler Test Specification (FF-846 FS1.0). This specification is designed for couplermanufacturers to perform a standard set oftests against their implementation. The test

10

Latest Device Description and Specification ReleasesAutomation industry has access to enhanced development tools

Tools such as the DD Integrated Development

Environment (IDE) help device developers, system

suppliers and end users improve the performance

of their FOUNDATION

fieldbus products.

11

cases were developed by a teamof volunteers comprised of currentmembers of the foundation whomanufacture coupler products,as well as end users interested in the availability of registeredcouplers.

The FOUNDATION Device CouplerTest Specification includes criteriafrom IEC 61158-2:2003 andadditional functional tests suchas input impedance, short-circuitreaction time, and bus voltageconsumption. It builds upon theexisting power supply specifica-tion and registration procedure,and is intended to provide evengreater robustness in FOUNDATION

fieldbus systems. The resultingregistered products will be testedto perform optimally with regis-tered power supplies and condi-tioners, as well as registered H1cable.

The scope of the Device CouplerTest Specification includes wiringblocks and couplers that maysupport short circuit protection.A working group is developingPhase Two of the test specifica-tion, to be released during 2009,that supports couplers with elec-trical isolation.

Other new specificationsbenefit automation industry

The Fieldbus Foundation hasalso released an additionalFOUNDATION fieldbus specificationaddressing temperature trans-ducer blocks. This new specifi-cation includes features enablingautomation equipment suppliersto further improve the inter-operability and reliability of registered, FOUNDATION-compliantproducts.

The Temperature TransducerBlock Specification (Document FF-904) fully describes the FOUNDATION

fieldbus standard temperatureand calibration transducer block.Both single and dual temperaturesensor implementations fall underthe standard temperature block

specification. The standard setof parameters and view lists for these two transducer blockprofiles are included in the spec-ification.

With the introduction of theStandard Temperature TransducerBlock Specification, end users willhave even greater confidencewhen implementing FOUNDATION

fieldbus systems. The new specification demonstrates thecontinued commitment of theFieldbus Foundation to bolster its technology infrastructure forthe benefit of the industrialautomation market.

Lastly, the foundation hasannounced the availability of aFOUNDATION fieldbus H1 Cable TestSpecification (Document FF-844).The new specification includestest cases providing greaterassurance to automation endusers that their wiring systemsare suitable for fieldbus systemoperation.

The H1 Cable Test Specificationis designed for manufacturersdeveloping cables for FOUNDATION

fieldbus H1 (31.25 kbit/s) in-stallations. The specification testcases, based upon the IEC61158-2:2003 standard, include(but are not limited to) impedance,capacitive unbalance, connectorpin-outs, and attenuation.

Cable manufacturers can sub-mit their test reports to theFieldbus Foundation, which willinitiate a cable registrationprocess in the near future.

Mitschke concluded, “Thefoundation is one of the onlyautomation industry organiza-tions with a host and device registration program requiringmandatory testing of critical elements of its technology.This effort now encompassesFOUNDATION fieldbus host systemsand field devices, as well asphysical layer components suchas power supplies and devicecouplers.”

12

DART Provides New Solution For Explosion ProtectionTechnique combines benefits of intrinsic safety with high power levels

According to current automation industry standards, intrinsic safety also means limited powersupply. A new technology known as Dynamic Arc Recognition and Termination (DART) promises to eliminate this restricting factor. DART is based upon a revolutionary approach

to explosion protection combining all the benefits of intrinsic safety (IS) with high power levels,opening a wealth of new opportunities for process control.

By Andreas Hennecke, Product Marketing Manager, Fieldbus TechnologyPepperl+Fuchs

13

Enabling technology of a new generation

DART represents a simple and cost-effectiveway to solve the problem of limited power supply associated with intrinsic safety in fieldbussystems. The technology substantially increasesthe maximum power level, allowing the intrin-sically safe connection of devices requiringmore power than present technology is able toprovide.

According to IEC 60079-11, an electrical circuit is considered intrinsically safe if it can beguaranteed (according to specifically definedcriteria) that neither during normal operation,nor in case of a malfunction, a spark or anyother thermal effect can lead to the ignition ofa potentially explosive atmosphere.

Intrinsically safe system designs (Ex i) primarily rely on the limitation of the availableeffective power to less than 2 watts in order toprevent the buildup of sparks that might causean ignition within an explosion hazardous area.This power limitation results in significantrestrictions as to the types of devices that maybe used in hazardous areas.

DART, however, allows end users to employfield devices with a power rating of up to 50watts — even within an Ex-rated area. DARTmakes this possible by detecting failures of theelectric system right from the beginning andreacting within only 1.2 µs to shut down thepower supply before any critical situation canarise.

The DART technique is based on the factthat any spark produces a sharp voltage andcurrent peak within the respective electric circuit. This phenomenon follows specific characteristics which are known and can beused in order to detect the development of asituation which might cause a problem insidethe Ex zone. As soon as the formation of aspark is detected, DART responds immediatelyand shuts down the electric circuit before theflow of current reaches a level which wouldallow the spark to develop sufficient heat tocause an ignition.

Effective approach for fieldbus installations

DART represents an ideal solution to provideconsiderably more power via a FOUNDATION

fieldbus installation without being restricted bythe limitations imposed by the Ex e require-ments for increased safety.

Practically all field devices with intrinsicallysafe power supplies fulfill the requirements ofeither FISCO or Entity. DART supplies power to a field device at 24 volts, which is the maximum value according to Entity. In this

way, compatibility with almost all field deviceson the market is guaranteed. Provided thecable length does not exceed 1,000 meters, itis possible to supply up to 24 field devices witha total power rating of 8 watts per segment.

Elimination of distortions

A DART system consists of three primarycomponents: energy supply, wiring and fielddevice. In such a configuration, the length ofthe cable and the corresponding signal delayhas a significant influence on the responsetime for recognizing a spark. The characteris-tics of the device itself can also lead to signalsthat cannot be interpreted dependably.

DART deals with the power level issue byconnecting devices via a decoupling module tothe energy supply. This module needs to be

integrated into the device itself. It ensures aclearly defined electrical response pattern andresults in a soft start of the device with limitedcurrent increase. In this way, the DART systemis provided with a signal that allows thedependable detection of critical situationsrequiring immediate shutdown of the circuit.

Conclusion

DART promises to usher in a totally new erain process automation. The high-power trunk,which requires increased safety measures, cannow be realized as an intrinsically safe solutionwithout having to deal with the restrictionsimposed by limited power supply. In addition,DART opens the way to numerous additionalapplications in the process industries, such asvalve control, scales or emergency lighting.

Figure 1 — Electric behavior of a spark turned off by a DART power supply.

Figure 2 — Simple DART circuit consisting of power supply, cable and load.

15

High Speed Ethernet Remote I/O UpdateWorking group is currently completing HSE RIO specification

The Fieldbus Foundation has reported its High Speed Ethernet Remote I/O(HSE RIO) initiative remains on schedule.

A multi-vendor working group is completingspecifications for prototype development.Currently, four host system and four gatewaysuppliers are developing prototype products.

The HSE RIO project will standardize theinterface of remote I/O into the open, inte-grated FOUNDATION automation infrastructure.The new HSE RIO specification defines thestructure for interfacing remote I/O over theHSE control network. The addition of remoteI/O further tightens the integration of processinstrumentation within the FOUNDATION fieldbus architecture.

The initial HSE RIO work includes H1 linkingdevice functionality, discrete inputs and outputs, analog inputs and outputs, and HARTsupport. Future phases will include gatewaysto other protocols.

The HSE RIO team is directed by programmanager Ian Verhappen, MTL, and technicalleader Detlef Arndt, Pepperl+Fuchs. The groupis working to ensure the new functionalityrequired to support HSE RIO is compatible withthat for wireless communications. It is alsocoordinating its efforts with the FieldbusFoundation’s wireless project team in prepara-tion for a combined technology demonstrationwithin the next two years.

R. STAHL hosted the HSE RIO kick-off meetingin January 2007 at its facility in Germany.Based on the latest Ethernet system, it isdonating one of the prototypes for the plannedHSE RIO technical specification validation in2009. Besides this, the company’s future HSERIO strategy is mainly based on use of theFOUNDATION high-speed control network.

MTL, a leading physical layer supplier, willbe developing one of the HSE RIO gateways to validate the new specification. MTL is

leveraging its knowledge of fault-tolerantEthernet, along with other advanced Ethernetand wireless technologies, to provide a fullycompatible product meeting its customers’needs.

According to Fieldbus Foundation Presidentand CEO Rich Timoney, HSE RIO will benefitend users seeking a true, integrated controlsystem environment. He said, “The ability toincorporate remote I/O in the FOUNDATION infra-structure ensures that plants can leveragetheir existing automation investments, and atthe same time, realize the advantages of a

digital fieldbus control platform. I commend thefoundation employees and all of our volunteersand supporters, who have helped to make thisimportant technology development possible.”

Remote I/O working group membersinclude: ABB, Aniotek, APAT, Azonix Corp.,Emerson Process Management, Endress+HauserPCPS, Hodson Consulting, Honeywell, MicrocyberInc., MooreHawke, MTL, Pepperl+Fuchs,Phoenix Contact, R. STAHL, RuggedCom, ShellGlobal Solutions, Smar, Softing AG, SterlingValley Associates, Turck, Yamatake, andYokogawa.

HSE RIO defines the structurefor interfacing remote I/O over

the Fieldbus Foundation’s High Speed Ethernet (HSE)

control network.

A wireless technology cooperation project spearheaded by theFieldbus Foundation, HART Communication Foundation andProfibus Nutzerorganisation e.V. (PNO) recently held its kick-off

meeting. A technical group comprised of representatives of the three industry organizations gathered at Honeywell’s facility in FortWashington, Pennsylvania, to launch its wireless specification develop-ment process.

The wireless cooperation project, headed by technical team leaderMarcos Peluso, Emerson Process Management, and End User AdvisoryCouncil (EUAC) advisor Herman Storey, Shell Global Solutions, is anextension of the successful collaboration on Electronic DeviceDescription Language (EDDL). The industry groups are developing aspecification for a common interface to a wireless gateway. This workis based on WirelessHART and the emerging ISA SP100.11a standard.

The wireless project includes development of use cases, require-ments, and specifications for wireless communication with intelligentfield devices in process measurement and control applications. As with the EDDL cooperative effort, the Fieldbus Foundation, HART, andPNO groups are developing a common set of compliance guidelines forincorporation into their respective product registration processes.

The introduction of wireless technology into the manufacturing andprocess industries requires suppliers, end users, and internationalstandards bodies to address technical issues related to wireless applications. The Fieldbus Foundation, HART, and PNO are workingtogether to establish a common, open standard that also ensures complete compatibility with the existing wired versions of each participant’s technology. The intent of the collaboration is to facilitatethe acceptance of wireless technology in industrial automation.

The Fieldbus Foundation is focusing its efforts on developing a gateway at the High Speed Ethernet (HSE) level to ensure an open andfully functional point of integration for all wireless devices built uponemerging standards.

Wireless working group members include: Aniotek, Chevron,Emerson Process Management, Endress+Hauser, Hodson Consulting,Honeywell, Ise-Magtech, MTL, Phoenix Contact, R. STAHL, SaudiAramco, Shell Global Solutions, Shenyang Institute of Automation,Smar, Softing, Yamatake and Yokogawa.

16

WirelessCooperation TeamHolds Kick-offMeetingIndustry organizations launch wireless specification development

17

Marketing Committees EncourageFieldbus AdoptionFieldbus Foundation supporters promote technology worldwide

Around the world, proponents of FOUNDATION

fieldbus are joining together to formregional marketing committees promot-

ing the benefits of fieldbus-based control solutions to both automation suppliers and end users. From Asia to South America, thesegroups are helping to ensure the technologyremains strong.

In Europe and the Middle East, for example,the growing list of regional marketing committees is a significant step forward for the Fieldbus Foundation’s EMEA SteeringCommittee. New committees have been estab-lished in the Commonwealth of IndependentStates & Baltic States (CIS&B), Norway,Southern Africa, Sweden, and Central &Eastern Europe (CEE). These groups join sevenother marketing committees already active inGermany, France, UK, Italy, Belgium, TheNetherlands and the Middle East. The formerHungarian committee has been incorporatedinto the new CEE committee.

Marketing activities focus on end user education

Each marketing committee is committed topromoting FOUNDATION fieldbus in their areathrough local activities, including end userseminars, supplier training, trade shows, andtechnology demonstrations. Committee mem-bers are suppliers of FOUNDATION devices, hostsystems, tools and services, and representmany of the world’s leading automation equip-ment suppliers.

Among the most active marketing committeeparticipants, R. STAHL is a founding member ofcommittees in Brazil, Norway, Sweden, Russia,India and Thailand. As one of its corporate policies, R. STAHL supports all FOUNDATION field-bus regional marketing activities with fieldbusspecialists from company headquarters.

The Fieldbus Foundation’s new SwedishMarketing Committee (FF-SWMC) got off to asuccessful start with a well-attended end usertraining event. Some 22 delegates from theStockholm region attended the committee’sfirst FOUNDATION fieldbus training seminar onFebruary 5, 2008. The day featured an intro-duction to FOUNDATION fieldbus and terminology,followed by a series of hands-on training sessions.

In Scandinavia, the recently formed Fieldbus

Foundation Norwegian Marketing Committee(FF-NOMC) is focused on serving the North Seaoil & gas industry, which includes large-scaleimplementations of FOUNDATION fieldbus bymajor end users such as BP and Shell.

Marc Van Pelt, vice president of FieldbusFoundation EMEA Operations, welcomed theformation of the Norwegian committee. “Thedemand for FOUNDATION technology within the oil& gas and hydrocarbon processing industriesis well established, but there is a particularlydynamic and strong market for new auto-mation technology in the North Sea offshoreregion and Norway,” said Van Pelt. “TheNorwegian committee will play an importantrole in promoting the primary value proposi-tions of FOUNDATION technology, which includeprocess integrity, business intelligence, andopen and scalable integration of informationacross process manufacturing plants.”

Developing regions reflect demand for technology

In Africa — another promising market forFOUNDATION technology — the Fieldbus FoundationSouthern Africa Marketing Committee (FF-SAMC)was recently established to promote an in-creased awareness and adoption of FOUNDATION

technology throughout the region.The FF-SAMC was formally launched at

an inaugural meeting held in Johannesburg,South Africa, which was attended by repre-sentatives from many different automation companies. At the gathering, Van Pelt thankedparticipants for their support. “I am delightedthat such an enthusiastic committee has beenestablished in the Southern Africa region,” hesaid. “The automation market here is in needof a broad range of local support — from basic introductory training in the benefits of a fieldbus system through to advanced implementation assistance.”

Van Pelt added, “Training and technical support will be the committee’s primary focus.One key initiative will be the establishment of aregistered training institution to meet theregion’s need for comprehensive technologyinstruction.”

Across the globe, in Latin America, theFieldbus Foundation has formed a MexicanMarketing Committee (FF-MXMC) to encourageimplementation of FOUNDATION technology in theMexican market through trade show participa-tion, end user seminars, and other promotionalactivities. This group was formed at a meetingheld in Mexico City, Mexico.

Regional marketing committees, such as the new group in Southern Africa,are committed to promoting FOUNDATION fieldbus through end user seminars,

supplier training, trade shows, and technology demonstrations.

Fieldbus Report asked the FieldbusFoundation’s marketing director, BillTatum, about his plans for 2008/2009

promotional activities supporting the adoptionof FOUNDATION fieldbus throughout the industrialend-user community. Here is the interview:

Fieldbus Report: Over the past few years, theFieldbus Foundation has expanded its market-ing program addressing industrial automationsuppliers and end users. The organization hasalso established regional marketing committeesin key areas around the world. How has thiseffort evolved?

Bill Tatum: The demand for FOUNDATION fieldbusis global in scale. We are seeing an impressiverate of adoption throughout the world’s devel-oping industrial regions. This includes areassuch as Eastern Europe, Latin America,Asia/Pacific and the Middle East. In response,the foundation has broadened its marketingprogram to help manufacturers around theworld get started with the technology.

FR: What is the main objective of your mar-keting program?

Tatum: Technology education is a very impor-tant requirement for us. End users want toknow more about the advantages of FOUNDATION

fieldbus, and they’re seeking help in puttingfieldbus to work in their plants and factories.

FR: The Fieldbus Foundation offers a widerange of training courses for end users andsuppliers of all skills levels. Why is training so important to the implementation of anadvanced technology like FOUNDATION fieldbus?

Tatum: The key to successful fieldbus operationis the ability to effectively design, install, service,and operate a new breed of process automa-tion system. Fieldbus is not more difficult thantraditional automation technologies, but it isdifferent, affecting the planning, implementa-tion, and operational aspects of a project. Oncelearned, fieldbus is actually simpler than con-ventional control strategies in many respects.

FR: You conduct fieldbus seminars at variouslocations around the globe. Can you describethe format of these seminars?

Tatum: Our one-day seminars are orientedtowards end users and engineering firms.They cover all aspects of FOUNDATION automation

infrastructure management. Each of the coretechnology areas — Process Integrity, BusinessIntelligence and Open Scalable Integration —is discussed in detail, followed by a hands-ondemonstration to reinforce the subject matter.Local end users also present case studiesabout their fieldbus applications.

FR: Does the Fieldbus Foundation supportindependent, vendor-neutral training centersproviding instruction in your technology?

Tatum: Yes. Early on, for example, we formed a partnership with the Southern AlbertaInstitute of Technology (SAIT) to establish aFOUNDATION fieldbus training facility on the SAITcampus in Calgary, Alberta, Canada. Thisagreement was threefold as it mandated SAITto develop certified fieldbus training curricu-lum, to deliver this curriculum to end users inWestern Canada, and to establish a demon-stration site for FOUNDATION technology.

More recently, we established the FOUNDATION

Certified Training Program (FCTP) defining uniform standards for fieldbus training curricu-lum at certified training sites around the world,and identifying acceptable levels of learning forstudents of the technology.

FR: Besides seminars, training courses, tradeshow exhibits and other events, how do you

convey the benefits of FOUNDATION fieldbus tothe global automation market?

Tatum: The Fieldbus Foundation conducts anaggressive promotional campaign utilizing theresources of Control Engineering magazineand its sister publications in Europe andAsia/Pacific. This program includes a monthlye-newsletter, Fieldbus Facts, as well as amulti-page print publication, Fieldbus Report,providing in-depth coverage of fieldbus tech-nology. Plus, we recently launched a new web-site located at www.fieldbus.org that servesas a comprehensive online resource for ourorganization and its members worldwide.

FR: How do your members support this effort?

Tatum: Aside from their contributions to ournewsletters, supplements and other promotions,and their participation in our regional trainingseminars, many members promote FOUNDATION

fieldbus at their own events. For example, ourtechnology will be a key topic at RockwellAutomation’s annual Process Solutions UserGroup (PSUG), to be held November 17-20,2008, in Nashville, Tennessee. Like other sup-plier user groups, this event will facilitate peer-to-peer exchange and provide an environmentwhere users can hear innovative ideas, learnbest practices and seek solutions.

Fieldbus Foundation MarketingEffort Goes GlobalAn interview with the Fieldbus Foundation’s marketing director, Bill Tatum

According to Fieldbus Foundation marketing director Bill Tatum,FOUNDATION technology marketing has a global outlook.

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21

Digital Migration: Commonly Asked QuestionsLearn how to plan and implement your first digital control system

Increasingly, industrial end users are moving beyond traditional analog control systems andembracing the advantages offered by the latest digital automation solutions. The migration to digital technology requires careful planning, as well as an awareness of important consider-

ations involving network design, installation, commissioning and training.

Continued on next page

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Q: How can the many end users with existing,legacy hardwired networks learn about andbegin to migrate to digital networks such asfieldbus, Ethernet and wireless?

A: FOUNDATION fieldbus provides a modular,scalable automation infrastructure that makesmigration to a modern digital control networkboth easy and cost-effective. The technologyallows end users to migrate their existing hardwired systems at their own pace.Implementation of FOUNDATION fieldbus does not require a wholesale change to a plant’sexisting control data infrastructure. Rather,users have the flexibility to utilize existing plantwiring for new fieldbus installations, cuttingover their legacy system one loop or processunit at a time.

Any user considering the adoption ofFOUNDATION fieldbus should first gain a completeunderstanding of the technology by attendinginstructional courses at professional trainingsites around the world. A complete list ofFieldbus Foundation-certified training providersis available at www.fieldbus.org. Visitors tothe foundation’s website can also downloadfree technical guides.

In addition, companies installing FOUNDATION

technology can learn from the experiences of other end users by attending FieldbusFoundation-sponsored training seminars con-ducted around the globe. This peer-to-peerinteraction will help users take full advantageof all the CAPEX and OPEX benefits FOUNDATION

fieldbus has to offer, while also learning how tojustify future fieldbus projects.

Q: How should end users evaluate the needsof their applications to determine their network-ing requirements?

A: End users preparing for a FOUNDATION fieldbusproject should carefully evaluate their networkloading requirements. This, in turn, will help indetermining the number of interfaces neededfor a given application.

Fieldbus users must also decide whether tolocate control functionality in the host systemor in field devices. For control in the field oncritical applications, the Fieldbus Foundationgenerally recommends one control loop persegment. For non-critical applications, two orthree control loops can be implemented persegment while still providing reasonableupdate times.

To determine a suitable fieldbus networkingsolution, end users are encouraged to down-load the Fieldbus Foundation’s SystemEngineering Guidelines at www.fieldbus.org.A variety of tools are also available to assist theuser in making appropriate design choices.

Users who approach fieldbus as nothingmore than a digital replacement for hardwired

analog technology do not realize the full returnon their control system investment.

Q: How much more thorough do end usersneed to be ahead of time in designing andplanning their first digital network than theyused to be with hardwiring?

A: For traditional control systems, there arerules that must be followed to ensure a successful installation. The same is true for a fieldbus network. In this case, however,the rules are different. For example, fieldbus installations require segment drawings ratherthan loop drawings — but the concepts are notforeign to most users.

When it comes to adopting new technology,there is no substitute for education. End usersand integrators who get the most out ofFOUNDATION fieldbus do their homework inadvance. They establish their control infra-structure in the early stages of a project, andthen train their personnel to utilize all fieldbustechnology benefits. This includes: reducedwiring, multi-variables from a single multi-channel field instrument, simpler integrationand easier maintenance.

Ultimately, FOUNDATION technology is the key to greater manufacturing flexibility andproductivity, higher quality products, andimproved regulatory compliance. This can beachieved by predictive maintenance schedulingand better upkeep enabled by the diagnostics,performance analysis data, and operationalstatistics. Better-adjusted and properly calibrated devices ensure lower process variability.

Q: How can end users make their first fieldbus

network simpler and easier to install, while stillmeeting their needs?

A: Many plants choose to install their firstfieldbus network on a pilot plant or non-criticalcontrol loops. This approach allows operatorsand engineers to gain familiarity with the tech-nology before applying it in larger, more criticalapplications. For some end users, it may bebeneficial to enlist the help of an EPC firm withproven fieldbus experience. Also, most of themajor DCS suppliers can assist their customersin getting started with fieldbus technology.

Fieldbus physical layer suppliers havedeveloped special connector designs thatmake fieldbus device installations truly “plugand play.”

Q: Is it a good idea to test possible networksolutions before implementation?

A: End users should always plan for a FactoryAcceptance Test (FAT) when undertaking afieldbus project. The FAT procedure typicallyinvolves simulation and validation of the control system before it is installed at the site.It can also provide an opportunity to do somepreliminary operator training and “fine-tuning”prior to system delivery.

For a fieldbus installation, the FAT procedureshould include as many field devices as possible to verify the user’s network loadingcapabilities.

The Fieldbus Foundation’s System Engi-neering Guidelines, available for download at www.fieldbus.org, provides some recom-mendations for FAT. The document calls forstrategically testing different configurations,but not the complete network. All FOUNDATION

devices provide simulation, whichcan be used during such FATtesting.

Q: How can plants implement-ing fieldbus address safety andsecurity issues?

A: It should be noted this question does not address“availability,” which is an impor-tant fieldbus benefit related toOPEX. Data quality, diagnostics,and control in the field are keyenablers. When the subjects of“safety” and “security” are men-tioned in regards to fieldbus, thediscussion really should address“availability.”

Individual DCS suppliers ad-dress security considerationswith fieldbus-based control systems. FOUNDATION technology,as it exists today, does not provide a dedicated securitylayer. As a wired communica-tions bus, however, FOUNDATION

fieldbus provides a robust and

secure solution interconnectingthe DCS to field instruments.

For security, end users shouldconsult publications such as ISA 99 (Industrial Automation and Control System Security).Security is a complex topic —most DCSs implement a role-based authentication system thatprovides operators, maintenanceand engineering personnel withappropriate access levels. Plantprocedures are also very impor-tant.

As for safety, we are talkingabout specialized systems thatperform safety functions. TheFieldbus Foundation does have anew FOUNDATION SIF protocol,which will bring more diagnos-tics to safety systems, but its H1and HSE developments are notdesigned for safety applications.The foundation is responding tothe issue of safety through itsongoing High Speed Ethernet(HSE) Remote I/O and Wirelessdevelopment teams.

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26

Economic Case For UsingFOUNDATION TechnologyInnovative segment design approach ensures greater ROI

Modern DCS systems are major distributed networks with multiple data transmission paths, which, in the interests of security and the highest plant availability, are almost always duplicated and maderedundant. This article describes how FOUNDATION fieldbus systems can now incorporate redundancy

and fault-tolerance right down to the H1 field layer. The major impact is on project ROI and plant revenues, andonly FOUNDATION technology can offer this level of security and benefit to the plant operator.

By Mike O’Neill, DirectorMooreHawke Division of Moore Industries-International, Inc.

27

It’s almost ironic: network cablesin the benign, well-managed con-trol room environment are almostalways made redundant, whereasfield cables exposed to the harshand sometimes corrosive environ-ment of the modern industrialplant have to fend for themselves.Of course, while the field cablescarried simple point-to-pointcommunications as 4-20mA,then redundancy wasn’t really aconcern in general, and specificdevices could be duplicated asrequired. However, now that thelowest fieldbus physical layercarries data from up to 32devices, the vulnerability of thatcable can constitute a reliabilityissue, particularly if thosedevices are safety-related orprocess-critical.

Conventional fieldbus segmentdesign does not lend itself to anyversion of fault-tolerance exceptthrough complete and wholesaleduplication, and in a systemscontext, that duplication bringswith it a requirement for “special”software to implement 1oo2/2oo3 voting schemes and specialmeasures for safe maintenance,device replacement, etc.

In 2007, a new fault-tolerantsegment design was releasedthat permits a far higher segmentMTBF than conventional designswithout any special software inthe DCS and for only the additionalcost of an extra trunk cable.Working with a leading DCS supplier and a major oil & gascompany, this package wasinstalled on a set of platforms in

the South China Sea simply tomitigate the huge financial riskassociated with loss of control.The question is, does this in-crease in availability really makeany significant difference to theeconomics of the general field-bus installation?

The answer is not a simple yesor no, because a fault-tolerantsystem allows a user to makepermutations that match thedesire for high plant availabilityagainst a budget for the systemshardware. These permutations(simplex vs. duplex vs. fault-tolerant) were simply not possiblein previous fieldbus physicallayer products.

The standard segment designprocess takes two controllers (H1 cards) and two power condi-tioners and connects to the fieldusing a single cable. This can becalled a duplex segment design.Based on conventional MTBFdata books and data from othersources (Reliability, Maintainabilityand Risk, 7th Edition, by Dr.David J. Smith), we can evaluatethe MTBF of such a segment.Figure 1 below shows such asegment and the physical layercomponents in that configurationgive a calculated MTBF of some50 years.

Some users also admit to thepossibility that some FOUNDATION

fieldbus devices are not that critical to plant operation, andthat these devices can be con-nected via a single controller.If this were to be allowed, a newsegment design could be used,

Figure 1 — Conventional segment design.

called a simplex segment as indicated inFigure 2 above. The physical layer componentsin that configuration give a calculated MTBF ofsome 30 years. Regrettably, very few projectspecifications allow for simplex segments,which may be because most vendors only offerduplex segments.

The fault-tolerant design utilizes a uniquepower conditioner that can detect open-circuitand short-circuit conditions in the field at up to1,000 meters of standard cable. It is matchedto a field wiring hub that can react to the lossof a trunk cable (out of an active pair) by automatically terminating the segment via theremaining cable. (It may be a surprise to many,but standard power conditioners do not effec-tively detect field short-circuits over a coupleof hundred meters and, when faced with aremote short-circuit, the standard power conditioner simply tries to drive into what itthinks is a high load, getting progressively hotter and hotter until premature failure).

The fault-tolerant segment design takes twocontrollers, two advanced power conditionersand a high-integrity wiring hub, but connectsto the field with two trunk cables, one perpower conditioner. The segment layout is asindicated in Figure 3 on page 29, and the calculated MTBF is around 350 years. This is a factor of 10x the simplex segment, and 7x the duplex segment, for the cost of an extra cable.

Significantly, this version of fault-tolerancedoes not depend upon monitoring and switch-ing mechanisms. Both trunks are continuouslyactive as opposed to the alternative “oneactive, one hot spare” configuration. Designingsystems for redundancy using watchdogs andswitches is inherently complex and rarelyresults in improvements in MTBF, since thefailure rate of the switch acts against the parallel failure rate of the “spare” trunk.This version of fault-tolerance meets therequirements of FOUNDATION fieldbus Safety Instrumented Functions (SIF) since there are very few unrevealed faults, and the highly critical “Probability of Failure on Demand”

factor is kept low bycontinuous diagnosticsand simple non-destruc-tive testing — unpluggingone of the trunk cablesannually demonstratesthe safety functionalityin a similar fashion to partial stroke testing of shutdown/isolationvalves.

Segment designcosts

For example, let’s basethis discussion on a

plant with 120 segments, or about 1,440 field-bus instruments, such as flow transmitters,valve controllers, etc. This plant can bedescribed in terms of how many segments arerelated to control of the plant, and how manyare related to simple monitoring. Let’s say that80 segments are monitoring-only and 40 segments have control. Of the 40 control segments, let’s say that 12 segments have loops which are process-critical: failure in any of those segments would cause immediateplant shutdown or product that was out ofspecification and hence non-saleable).

Segment Types Number of SegmentsMonitoring 80Control-Related 28Process-Critical 12

Total 120

Let’s assume the following prices for field-bus equipment, which are typical across theindustry from physical layer vendors.

$390 Power Conditioner$240 Carrier, 4-segment, Simplex$320 Carrier, 4-segment, Duplex$280 Carrier, 4-segment, Fault-Tolerant$450 Diagnostics Module, Standard$350 Standard Coupler, 12-spur$700 High-Integrity Coupler, 12-spur$500 Trunk Cable

We can now start to compare costs betweenthe conventional design and the new approach.

Conventional Segments:

30 x $320 Carriers, 4-segment, Duplex (1 per 4 segments)

240 x $390 Power Conditioners (2 per segment)

30 x $450 Diagnostics Module, Standard (1 per 4 segments)

120 x $350 Standard Coupler, 12-spur (1 per segment)

120 x $500 Trunk Cable (1 per segment)

Total (Conventional) = $218,700

The conventional approach for 120 segmentstakes 240 power conditioners.

The new approach allows savings for the 80monitoring-only (simplex) segments as thesehave only one power conditioner. (Of course,the conventional system could also fit singlepower conditioners, but since they still haveduplex carriers, two power conditioners are fitted by everyone as a matter of routine.) Theduplex segments have dual power conditionersas is common practice, and the fault-tolerantsegments also have two power conditioners,but they are physically separated onto different carriers and connected to the fieldthrough two cables. In total, the new approachhas 160 power conditioners.

The net result is that this new approachleads to somewhat lower costs, even whenallowing for the additional trunk cable used in the fault-tolerant segment layouts. The savings may be greater still; many end user specifications restrict process-critical segments (commonly defined as “Level 1”criticality) to having just one valve and onetransmitter in that segment. It seems ridiculousto install a fieldbus segment with just twodevices, but in the conventional single-trunk

28

Figure 2 — Simplex segment design.

Simplex Segments:

20 x $240 Carrier, 4-segment, Simplex (1 per 4 segments)

80 x $390 Power Conditioner (1 per segment)

20 x $450 Diagnostics Module, Standard (1 per 4 segments)

80 x $350 Standard Coupler, 12-spur (1 per segment)

80 x $500 Trunk Cable (1 per segment)

Duplex Segments:

7 x $320 Carrier, 4-segment, Duplex (1 per 4 segments)

56 x $390 Power Conditioner (2 per segment)

7 x $450 Diagnostics Module, Standard (1 per 4 segments)

28 x $350 Standard Coupler, 12-spur (1 per segment)

28 x $500 Trunk Cable (1 per segment)

Fault-tolerant Segments:

6 x $280 Carrier, 4-segment, Fault-Tolerant(2 per 4 segments)

24 x $390 Power Conditioner (2 per segment)

6 x $450 Diagnostics Module, Standard (2 per 4 segments)

12 x $700 High-Integrity Coupler, 12-spur (1 per segment)

24 x $500 Trunk Cable (2 per segment)

Total (New Approach) = $198,170

Figure 3 — Fault-tolerant segment design.

29

configuration, that is deemednecessary to minimize the risk of accidental plant shutdown.

Failure analysis

Since we are comparing a con-ventional fieldbus physical layerwith a fault-tolerant physicallayer, we can effectively ignoreall other sources of plant stoppage(blocked lines, primary poweroutage, pump seal failure, etc.) in this analysis. We are concernedonly with the cost incurred if afieldbus power conditioner orsegment cable fails.

Let’s assume that the cost of aspurious trip in a plant of thissize is $250,000. The spurioustrip rate due to the standardfieldbus system is estimated asonce every five years, and thespurious trip rate resulting froma failure in the fault-tolerantfieldbus system is estimatedonce every 25 years (we can dem-onstrate that the fault-tolerantdesign generates a ten-foldimprovement in segment MTBF,so assuming only a five-foldimprovement is conservative).

The annual cost of spurioustrips for the conventional plant is$250,000 divided by 5 years, or$50,000 per year. The annualcost of spurious trips for a fault-tolerant plant is $250,000 dividedby 25 years, or $10,000 per year.The potential benefit is therefore$40,000 per year ($50,000 minus

$10,000).Another analysis concerns the

cost benefit over the investmentlifecycle of any plant, whichmodern technology has reducedto something like ten years. Inthis case, the fault-tolerant sys-tem represents a CAPEX saving($218,700 minus $198,170,or $20,530) which generates$33,441 at, say, 5% for tenyears.

Therefore, selecting a fault-tolerant system generates:

CAPEX Return: $33,441(savings in capital expense)

OPEX Return: $400,000(savings in spurious trips)

Total: $433,441(“free” additional income over ten years)

This is, of course, a very sim-plified argument made by a systems engineer and not anaccountant, and all the assump-tions are open to re-interpretationby appropriate financial expertsand operations managers. Forexample, there is no separateaccounting of systems designtime, maintenance costs, repairtimes, spares stock holding, etc.Current suppliers of power conditioners frequently sell atmassive discounts in order towin market share over theirrivals. However, the fault-tolerant

Continued on page 31

From oil and gas facilities on the Persian Gulf,to refineries in Kuwait and Saudi Arabia,FOUNDATION technology is improving the

business results of industrial end users through-out the Middle East and Africa — and around theworld.

This issue of Fieldbus Report includes aroundup of FOUNDATION fieldbus installation activityin the fast growing Middle East region.

ACBC To Expand Carbon Black Processing Unit

Alexandria Carbon Black Company (ACBC) ofAditya Birla Group, a carbon black producer,recently issued a letter of intent to EmersonProcess Management to supply a PlantWeb®

digital architecture scope with FOUNDATION fieldbustechnology to automate their expansion project in Egypt. This new project, which followsthe earlier successful installation of a DeltaV™

automation system, will use FOUNDATION technologyto communicate with intelligent field devices fromEmerson, including Rosemount® 3051 and 848Ttransmitters, Micro Motion® Coriolis flowmetersalong with AMS™ Suite to upgrade performancewith improved product quality.

For their expansion project, ACBC insisted onan automation technology that could deliverimportant benefits like reduced process variability,lower engineering and installation costs, anddecreased maintenance costs.

Scarab Saffron Gas Fields ReduceOperating Costs

The Scarab Saffron gas fields represent thefirst deepwater development to be undertaken inthe eastern Mediterranean. The fields lie in theWest Delta Deep Marine concession nearAlexandria, Egypt, and are the largest natural gasdevelopment in that country.

The latest FOUNDATION fieldbus technology provided by Yokogawa was chosen to reduceoperating costs at the new on-shore facilities.Design, engineering, procurement, supply, testingand commissioning were completed smoothly andon schedule, ensuring the benefits of FOUNDATION

fieldbus were quickly realized.

Qatar Shell Improves Efficiency of GTL PlantHoneywell was selected by Qatar Shell GTL Ltd.

to design and implement the integrated process

automation system for the Pearl Gas to Liquids(GTL) plant. This includes installation of theExperion Process Knowledge System (PKS)Release 300, with FOUNDATION fieldbus communi-cation, to tie together all critical subsystems in theplant.

With the integrated automation platform, QatarShell GTL Ltd. will be able to efficiently controlGTL operations from production at the platforms,to processing at the onshore plant, to shipping of the finished product. Data from equipment such as process controls, field devices and safetysystems will be sent to the control room, enablingoperators to make better decisions faster.

Shell Ensures Safety of Oil Storage TerminalThe Bonny Island Terminal Project in Nigeria

comprises 24 oil storage tanks for Shell PetroleumDevelopment Corporation. The main engineeringcontractor for the project chose the Korean subsidiary of Yokogawa to provide the CENTUMCS3000 control system with FOUNDATION fieldbuscapability for the site.

The fieldbus network at Bonny Island includesa total of 6,000 devices, of which 1,600 are located in Zone 1 hazardous areas. Intrinsic safety was selected as the preferred protectionmethod for the hazardous sector, with fieldbuspower provided by MTL’s FISCO power supplies.These devices are used in conjunction with two-way and four-way, intrinsically safe Megablockand FBT1-IS terminators to create fieldbus segments that may be “live-worked” throughoutwithout gas clearance procedures.

PDO Integrates Technology For Wellhead Control

Petroleum Development Oman (PDO), a Shelloperating company, selected Yokogawa to imple-ment its STARDOM solution for wellhead control.The automation system, utilizing FOUNDATION fieldbus,provides transparent information technology fromfield devices to SCADA and management tools.

PDO has benefited from flexible configurationsupporting redundancy and hot swapping of I/O,as well as seamless connections to secureIntranet/Internet and FOUNDATION fieldbus H1 networks.The system enables reporting and securing ofvaluable data under extreme ambient conditions,and also provides remote programming, diagnostics,maintenance and management functions.

Regional Roundup:Middle East & AfricaFOUNDATION fieldbus gains acceptance in key process industry region

system discussed here does notdemand any specialized atten-tion over the standard system,nor does it require any additionaldesign and service costs — nospecial software is required, andthe same power conditioner isused throughout. The only realdifference is that the fault-tolerantsegments should be tested oncea year, typically by unpluggingone of the power conditioners orits cable, to demonstrate that thesegment (and plant) continues to operate even with one failure.This level of testing helps to justify the low Probability ofFailure on Demand claimed forthe fault-tolerant segments.

Conclusion

It seems very clear that thisnew approach to segment designdoes not increase costs over aconventional “one-size-fits-all”design; when the concept isproperly applied, it actually costsless. The resulting improvementin real plant availability createsstill greater benefit for the plantoperator, and the positive cashflow generated is both dramaticand undisputable. Prospectivefieldbus users now have furtherevidence that FOUNDATION fieldbuswill be advantageous for theirplant and their management, andthe uptake rate for this technologycan only increase further, todominate the landscape forindustrial networking and processcontrol.

Continued from page 29

Economic Case For Using FOUNDATION

Technology

31

Emerson Introduces DeltaV ™ InSight Next-Generation Control PerformanceApplicationEmerson Process Management has announced the availability of theDeltaV™ InSight integrated control performance software. DeltaV InSightutilizes FOUNDATION fieldbus device diagnotics to monitor, analyze, diagnose,and improve control loop performance. The InSight application includes allthe basic monitoring and tuning capability of its predecessor products,

DeltaV Tune and DeltaVInspect, plus advanced diagnostics and adaptivetuning capabilities madepossible with embeddedlearning algorithms.

DeltaV InSight makes iteasy to improve processcontrol by monitoring control performance; identifying and diagnosing problem loops; recommending tuning and maintenance

improvements; and continuously adapting to changing process conditions.

DeltaV InSight automatically learns users’ processes with embedded learning algorithms running at the controller level and develops processmodels based on day-to-day operations. These models allow users toidentify operational benchmarks, diagnose problems and calculate optimum loop tuning across the entire control system.

Emerson Process Management • www.emersonprocess.com

New MTL Fieldbus ComponentsWhether you are planning your first fieldbus project or your twentieth, it pays to knowwhat is available. And MTL knows a thing or two about fieldbus networks, having beeninvolved in defining the early standards right up to supplying the power supplies,wiring hubs and components for the world’s largest fieldbus projects. So before youcommit your hard-won budget check out what’s available from the leading source of:

- Fieldbus power supplies - Wiring hubs and components- Field test equipment - Integrated fieldbus diagnostics- Fieldbus I/O and displays - FISCO and FNICO supplies- Surge protection devices - Fieldbus Barriers- Process junction boxes

For more information, request a copy of the latest product overview by e-mailing fieldbus.info@mtl-inst.com and read up on application stories that outline why MTL is the world’s leading supplier of fieldbus components.

MTL • www.mtl-fieldbus.com

Fieldbus Solution HighlightsFieldbus Solution Highlights

Invensys’ InFusion Field Device ManagerSupports Both FDT and Enhanced EDDL

A key component of the new InFusionEnterprise Control System from Invensys is the Field Device Manager — an open toolsetto configure, commission, maintain and diagnose FOUNDATION fieldbus devices throughout their lifecycle.

Field Device Manager provides a compre-hensive, fully integrated engineering and maintenance environment and is the first to offer support for both FDT and EnhancedEDDL technologies.

Invensys • www.foxboro.com

FREEFieldbusJargon BusterIf you mix up HIST and host, can’t tell a chicken foot from abackbone, or wonderwhat Kermit has to do with fieldbus technology, then the ABB FieldbusJargon Buster is the publication for you. It contains a clear explanation of dozens of

fieldbus technical terms and can be downloaded from

http://instrumentation.request-center.com/8.

ABB • http://instrumentation.request-center.com/8

iTemp TMT85 FOUNDATION Fieldbus Head Transmitter- 2-channel head transmitter for connection of all

sensor types

- Spring-loaded clamps or gold-plated screw terminals

- High accuracy through Callendar-Van Dusen coefficients for Pt100 resistance thermometers or a polynomial for copper/nickel resistance thermometers

- Diagnosis functions: open and short-circuit detection, incorrect wiring, and corrosion detection of sensor cabling on RTD 4-wire connection or thermocouples

- Backup function and sensor drift recognition in 2-channel-operation

For more information, go to www.products.endress.com/TMT85 andwww.fieldbus.org.

Endress+Hauser • www.products.endress.com/TMT85

32

Save Project Time and Expense with Honeywell’sPatented Link Schedule Optimization

Projects utilizing FOUNDATION

fieldbus technology have reachedtens of thousands of devices,creating the need to improve performance. One method is to optimize the fieldbus link schedules to deliver better control,more devices per link, and lesswork for the project engineers.

Honeywell’s unique time-saving algorithm optimizes the link function block publication schedule. This prioritizes and optimizes the link by maximizingparallel execution, minimizing

loop latency, and maximizing available communications bandwidth, resulting in significant savings.

Honeywell • hpsweb.honeywell.com/Cultures/en-US/Products/Systems/ExperionPKS/FoundationFieldbusIntegration/default.htm

New White Paper Gives Fieldbus BasicsMooreHawke, a division of Moore Industries-International,Inc., has released a new white paper called “Introduction toFieldbus.” This concise 8-page bulletin explains, in terms any engineer, technicianor operator can understand,how fieldbus works.It explains: the advantages ofusing fieldbus networks; the elements of fieldbus (H1 cards,power conditioners, segments,spurs, device couplers and segment terminators); and muchmore. To get your copy, go towww.miinet.com/moorehawke.

MooreHawke • www.miinet.com/moorehawke

Yokogawa’s digitalYEWFLO Vortex Flow Meter Available with a Multi-Variable OptionThe digitalYEWFLO Multi-Variable Mass Vortex Flow Meter is based on the field-proven sensor technology of the digitalYEWFLO series of vortex flow meters, which features a unique signal processing technique that extends the features of DSP. The advanced processing algorithms are known as Spectral Signal Processing (SSP). SSP analyzesthe vortex waveform into its spectral components to filter noise from the signal for the most stable measurementpossible. The meter will provide stable,accurate measurements at low flows,even in noisy environments, without anyneed for start-up tuning. The user benefitsthrough greater reliability, reduced maintenance and a lower total cost of ownership.

Now, in addition to the benefits of nostart-up tuning and low flow stability, theaddition of an integral temperature sensorextends the application of digitalYEWFLO to include the mass flow measurement ofsaturated steam based on steam tablesembedded in the software and the massflow measurement of liquids based on programmed fluid temperature coefficients.The measured temperature can be displayed onthe two-line LCD indicator and is also available through fieldbus for process temperature management. Additionally, mass flow rate, total and diagnostic information is also available.

Yokogawa • www.yokogawa.com/fld/FLOW/DYF/fld-dyf-ff-01en.htm

1757-FFLD FOUNDATION Fieldbus LinkingDevice from Rockwell AutomationThe FOUNDATION fieldbus standard provides you the ability to distribute architecture throughout a plant. This enables integrated, seamless distribution of data and the execution of process functions with multi-vendor devices.Rockwell Automation takes full advantage of the FOUNDATION fieldbus standardwith the combination of the linking device and RSFieldbus Software to bringfieldbus devices into the Integrated Architecture™. Control Loops can be run in a Logix Controller or in the FOUNDATION fieldbus devices. This device fully supports all FOUNDATION fieldbus control capabilities through HSE & EtherNet/IP.

The linking device offers you themost flexible FOUNDATION fieldbusdevice interface available and when used with IntegratedArchitecture, you can greatlyincrease the efficiency of yourmanufacturing. With the 1757 FFLD, you have the flexibility to do process control with any Logix controller while you are using the advanced capabilities of network based process instrumentation. The device also includes the unique ability to bridge both FOUNDATION fieldbus HSE & EtherNet/IP networks to FOUNDATION fieldbus H1 device networks.

Rockwell Automation • http://literature.rockwellautomation.com/idc/groups/literature/documents/td/1757-td003_-en-p.pdf

DataCELL FOUNDATION Fieldbus™ Cable — The Most Complete LineNorthwire’s third-generation designs include 16 and 18 AWG, single- andmulti-pair cables with alternate color, shielding and grounding; easy-to-strip,round, smooth jacket for effortless installation in cable glands. All are ITC-ER (no need for conduit), meet/exceed FF-844 for “Type A,”approved for Class I & II, Div. 2 locations,UL-listed ITC/PLTC-ER and CSA CMX-Outdoor-CMG-compliant. Dual-rated ITC and Arctic Grade Marine-Shipboard (to -60°C) version offered.

Complimentary Sample! 1-877-210-9945

Northwire • www.northwire.com/buscable

33Fieldbus Solution HighlightsFieldbus Solution Highlights

34 Fieldbus Solution HighlightsFieldbus Solution Highlights

Smar’s SYSTEM302 Remote Controllers Connect toHigh Speed Ethernet (HSE)Smar offers a series of advanced remoteI/O and controllers that are all connectedto FOUNDATION High Speed Ethernet (HSE).

Unique to SYSTEM302 are the gatewayconnections of your choice (FOUNDATION

fieldbus, Profibus, DeviceNet, and AS-i).All remote I/O can access conventional signals from a variety of discrete andanalog I/O cards, also having a Modbus connection for legacy equipment integration. Other capabilities include Function Block Programming and Ladder Logic via FFB (Flexible Function Block) and EDDL.

SYSTEM302 is the “all-in-one” structure that supports the use of many different technologies in a single, integrated and transparent environment for engineering, operation and maintenance of your plant.

Smar • www.smar.com

Yamatake Delivers Hybrid Smart Positioner,SVP3000 AlphaplusYamatake’s SVP3000 Alphaplus ModelAVP304/204 (Model 204:remote type positioner)obtains a unique functionthat is realized by hybrid technology. The ModelAVP304/204 adopts two signals — analog and FOUNDATION fieldbus.Users need not worry about positioner selection, since the Model AVP304/204 cancontrol a valve both by analog signal and FOUNDATION fieldbus signal. TheFOUNDATION fieldbus signal is for diagnostic purposes. The SVP3000 Alphaplus and control valve maintenance support system “Valstaff” provide Stick Slipdetection which is a dynamic diagnostic.

Yamatake • www.azbil.com

TURCK’s New Diagnostic Power Conditioner for FOUNDATION Fieldbus H1TURCK introduces a revolutionary new Diagnostic Power Conditioner system(DPC) for FOUNDATION fieldbus. The power conditioning system features an integrated diagnostics module that provides the end user with vital statisticsthat ease the task of diagnosing any problems associated with the FOUNDATION

fieldbus physical layer.

The system continuously monitors fieldbus physicallayer components to detectanomalies and long term subtle changes thatotherwise might not be evident.

Find out more at www.turck-usa.com.

TURCK • www.turck-usa.com

1 x 8 Instead of 2 x 4: More Compact, Cost-Efficient CouplersIntroducing a new Ex i coupler which connects eight instead of the usual fourintrinsically safe FISCO devices to a fieldbus, R. STAHL has extended its ISbus product range which consists of FOUNDATION fieldbus H1 and Profibus-PAcomponents and systems. The new 8-spur variants of the 9411 type couplershave the same size as previously available models. Two 8-spur couplers aresufficient to connect typical fieldbus segments with up to twelve devices.Compared with three conventional 4-spurcouplers, this requires 1/3 less space andsaves approximately 10 to 20% of expenses.With a total of 16 connections, this compactand cost-efficient solution also provides fourspare spurs.

The new coupler models retain all provenfunctions and features of R. STAHL’s couplers.They allow users to choose between differentgrounding and shielding concepts, such asSingle Point, Multi Point and capacitive grounding. The units feature an inte-grated, switchable terminator. They come with a power management which is unique on the market, reducing starting currents in the trunk and, in case of short-circuits in several spurs, minimizing fault currents in the bus. Signaland error status are signalized via clearly laid-out, multi-colored LEDs.

The 9411 couplers are suitable for use in Zone 1, Zone 2 and US Division 2.They are available with plastic or stainless steel housings which can be tailored to customer requirements.

R. STAHL • www.stahl.de

Softing’s FG-100 FF/M — New Features for a Field-Proven ProductSofting has updated its field-proven FOUNDATION

fieldbus to Modbus/TCP gateway FG-100 FF/Mwith its new field-device stack to enhance theproduct with the latest technology FOUNDATION

fieldbus has to offer. The Modbus/TCP gatewayrepresents an efficient, yet economical solution for control system manufacturers that want toavoid developing a dedicated H1 interface for their control devices.

The certified FG-100 FF/M offers one Modbus/TCPport that is connected to the control or visualiza-tion device (e.g., PLC or HMI) and four H1 portsthat connect to H1 field devices. The gateway isconfigured like any other H1 field device by usinga standard configuration tool and transparently maps the process data tostandard Modbus holding registers (4x Registers). A PLC controls H1 devicessimply by accessing the holding registers in the FG-100 FF/M.

For more information, please visit us online or call (978) 499-9650.

Softing • www.softing.com/home/en/industrial-automation/products/foundation-fieldbus/gateways/fg100-ff-m.php

Pepperl+Fuchs’ Award Winning Advanced Diagnostics Module Now Available in Mobile Configuration for Maximum FlexibilityThe Mobile Advanced Diagnostic Module from Pepperl+Fuchs is a comprehensive physical layer measurement tool for FOUNDATION fieldbus H1 and Profibus-PA installations that can be used in Zone 2/Class I, Div. 2 areas. The Mobile ADM creates a visual picture of the fieldbus communication signal to facilitate faster commissioning work and easy, efficient troubleshooting. Diagnostic data is easily integrated directly into DCS/PLC device configuration and asset management tools.

For more information, call (330) 486-0002 or e-mail sales@us.pepperl-fuchs.com.

Pepperl+Fuchs • www.fieldconnex.info

AutomationInfrastructure

For OperationalExcellence.

The Fieldbus Foundation is “Changing the Playing Field” in industrialautomation. The scope of FOUNDATION™ technology makes it a processautomation infrastructure—one of the most advanced and scalablesolutions available.

This infrastructure is supplier-neutral and standards-based, providingend users with a common framework to implement and manage strategies for operational excellence and continuous improvement in process manufacturing.

Today, FOUNDATION fieldbus dominates the worldwide process automation market—and is a growing solution for the hybrid industries. It’s the “technology ofchoice” for both earlyadopters and new end users around theglobe, especially indeveloping markets such as Asia-Pacific,Latin America andEastern Europe. Find out more.

Visit www.fieldbus.org.

9005 Mountain Ridge Drive, Bowie Bldg. – Suite 200Austin, Texas USA 78759Tel: 512.794.8890 • Fax: 512.794.8893E-mail: info@fieldbus.org

FOUNDATION

fieldbus: 68.1%

Other Protocols: 0.2%

Profibus-PA: 31.7%

Sponsors

Process IndustryMarket Share