implementing a f oundation ™ fieldbus project...implementing a f oundation ™ fieldbus project...
TRANSCRIPT
In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 1
Implementing a FOUNDATION™ Fieldbus Project
Part Two of Eight
Contents
Introduction User Guide – Implementing a FOUNDATION Fieldbus Project
Chapter 1 Introducing the User Guide
1.1 Executive Summary
1.2 Recommended Technical Resources
Chapter 2 Overview of FOUNDATION Fieldbus
Chapter 3 FOUNDATION Fieldbus Project Management – Minimising Project Risk
3.1 Proven Technology
3.2 Project Evaluation
3.3 Training
3.4 Project Partners
3.5 Procedures, Work Processes and Documentation
3.6 Risk Management
3.7 Testing
Chapter 4 FOUNDATION Fieldbus Project Investment
4.1 Project Planning – CAPEX
4.2 Project Engineering and Installation – CAPEX
4.3 Commissioning – CAPEX
4.4 Project Start-Up – CAPEX
4.5 Operations and Maintenance – OPEX
Chapter 5 FOUNDATION Fieldbus Project Design & Engineering
5.1 Host Selection Considerations
5.2 Field Device Selection Considerations
5.3 Segment Component Selection Considerations
5.4 Network/Segment Topology Design Considerations
5.5 Host/Device Interoperability Testing
Chapter 6 FOUNDATION Fieldbus Project Implementation – Conclusion & Checklist
Appendix References/Sources
In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 2
Implementing a FOUNDATION™ Fieldbus Project
Chapter 3: FOUNDATION Fieldbus Project Management –
Minimising Project Risk
The Project Design & Engineering phase of a project that includes the integration of
FOUNDATION fieldbus is the cornerstone to delivering the full benefits of FOUNDATION
technology in the optimum project timescale; at the minimum overall project cost.
Project risk must also be minimised; with the minimal disruption to production
schedules; and with the maximum support in place for
streamlined on-going operations, maintenance and auditing
procedures once the final commissioning and start-up has been
completed.
Before the Project Design & Engineering phase can even begin,
there are certain fundamental concepts that need to be
embraced which will contribute towards the success of the
project.
Rigorous project planning and an unwavering attention to
established FOUNDATION fieldbus guidelines; appropriate industry
standards; documentation procedures; training; testing procedures; and best practice
principles will contribute to the overall success of the project especially in the limitation
of implementation challenges once the project is in the Project Implementation phase.
A smoothly executed project will maximise return on investment.
Similarly, there are specific methods and guidelines relating to FOUNDATION system
design and installation which should be understood and followed in order to ensure
successful Project Implementation - in particular host, device and component selection;
segment design; wiring and cabling; grounding and shielding; testing; and
considerations relating to hazardous area applications, Control in the Field and wireless
applications.
“Rigorous project planning and
an unwavering attention to
established FOUNDATION fieldbus
guidelines; appropriate industry
standards; documentation
procedures; training; testing
procedures; and best practice
principles will contribute to the
overall success of the project”
In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 3
3.1: Proven Technology
According to ARC Advisory Group, FOUNDATION fieldbus accounted for nearly three-
quarters of the total digital process fieldbus marketplace in 2011*1. With 75-80% of
field devices supporting FOUNDATION fieldbus and the fact that FOUNDATION technology
can be integrated easily into existing 4-20mA and other fieldbus systems via gateways,
the adoption of FOUNDATION technology into process automation is now mainstream
and the perceived risks associated with early adoption are significantly reduced.
The use of traditional technologies for process automation has often been the default
option and for many end users the integration of FOUNDATION fieldbus is still a step
into unfamiliar territory. However, this is changing. In addition to the implementation
of FOUNDATION fieldbus in Greenfield sites, it is now
routinely being incorporated into modernisation and
migration projects. In order to ensure the success of a
FOUNDATION project and thereby maximising the
achievable benefits that the technology offers, all parties
involved need to understand that the planning and
implementation of the technology requires a different approach to that of traditional
technologies. Although the approach may be different – it does not have to be
difficult.
Since all field devices and segments become an integral part of the distributed control
system (DCS), field network design requires an integrated configuration, data
management and systems architecture approach.
Furthermore, Project Management needs to understand the full functionality of
FOUNDATION fieldbus technology, the hosts, devices and components at the outset of
the project in order to maximise the return on investment and avoid changes and
revisions to the project, which would inevitably have implications on the cost and
scheduling of the project. FOUNDATION hosts, devices and components have a multitude
of functions that may be utilised – but the means of using this functionality needs to
be identified right at the beginning before final selection, for example, the full use of
advanced diagnostics within some devices requires the integration of a suitable asset
management system or host functions. Without a suitable means of retrieving its
diagnostic data, a field device may be limited to its basic function.
“FOUNDATION fieldbus accounted
for nearly three-quarters of the
total digital process fieldbus
marketplace in 2011”
In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 4
All host systems, devices and key components for a FOUNDATION project must have
been tested, approved and registered under the Fieldbus Foundation’s own test and
registration process and gained the ‘checkmark’. End users may be reassured that the
products they are selecting for their network have been tested against well-defined
criteria to maximise interoperability and minimise integration issues. Information about
the testing procedures and a full list of all registered products is available on
www.fieldbus.org/registration.
Rigorous project planning leads to greater project reliability.
Although more up-front, detailed planning may be required for
the implementation of a FOUNDATION project than for conventional
solutions, less time is required at the later stages of installation,
commissioning and start-up. The identification of work processes
and the impact of all aspects of the new project on these is vital, together with a
constant review and evaluation of risk assessments.
FOUNDATION fieldbus will continue to evolve to meet market demands in a wide range
of industries and will continue to be the right choice for the control systems of today
and the future. The Fieldbus Foundation’s development initiatives, including SIF, ROM
and EDDL enhancements, are driven forward with valuable end user input through the
active End User Advisory Council. Technical working groups include many of the
world’s major suppliers of process automation instrumentation.
Wise host and device selection will help avoid false economies and contribute towards
a longer system lifetime. It is also recommended that approximately 20% spare
capacity is built into the segment design at the initial stages. This safeguards against
unforeseen discrepancies between segment design
and implementation or allows for a more flexible
approach to system expansion with minimum
redesign.
“Wise host and device selection will
help avoid false economies and
contribute towards a longer system
lifetime”
In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 5
3.2: Project Evaluation
A detailed analysis of the anticipated use of FOUNDATION fieldbus is essential. A clear
understanding of where it can be used and where it may not be appropriate is
necessary to avoid wasting resources. To achieve this, a greater level of up-front
information and knowledge is required at the out-set of the project including a
thorough understanding of the full functionality of FOUNDATION fieldbus; certain key
installation criteria; and the options available in terms of host systems, devices and
components in order to make an informed selection prior to detailed network design.
Expectations of the achievable benefits should be identified and evaluated in the
context of realistic experiences, anticipated implementation challenges, and current and
future work processes.
In particular, the project team needs to quantify the savings attributable to capital
expenditure (CAPEX) through the reduction of project costs relating to reduced cabling;
wiring; control room requirements; and installation, configuration and commissioning
times. Similarly, it needs to quantify the potential savings attributed to operating
expenditure (OPEX) in terms of faster project implementation and process start-up;
reduced process disruptions or downtime; and more efficient maintenance processes
especially due to the implementation of advanced diagnostics and an asset
management system.
In applications when FOUNDATION technology needs to be integrated with existing
systems, the interfaces need to be clearly understood and identified. Consideration
must also be given to whether the FOUNDATION system will have segments operating in
hazardous areas; if FOUNDATION for Safety Instrumented Functions is required; and if
wireless connections are required and if the control should reside in the host or in the
field device.
The anticipated use of the inherent diagnostics information and the level of
information required from devices needs to be defined at the outset and appropriate
operations and maintenance processes and procedures developed. Whether simple
alarm functions or advanced diagnostics data are required this then has implications on
the selection of the host system, individual field devices, components, and the possible
integration of a suitable asset management system.
In a World of Choices, FOUNDATION™ Brings it All Together. ® 2013 Fieldbus Foundation 6
References:
1: ARC Advisory Group, Dedham, MA: “Fieldbus Solutions for the Process Industries: Worldwide
Outlook” market study, published Dec 13, 2011.
http://www.arcweb.com/market-studies/pages/fieldbus-solutions-process-industries.aspx