FuRIOS 2 Feldbus und Remote I/OSystemvergleich Fieldbus and Remote I/O System Comparison

”The Fieldbus is ready for practical use“ FuRIOS 2 Fieldbus and Remote I/O System Comparison

Preface Prof. Dr.-Ing. Birgit Vogel-Heuser, Institute of Automation Technology/Process Informatics at Bergische University Wuppertal Preface to second, updated edition Prof. Dr.-Ing. habil. Lothar Litz Institute of Automation Technology Technical University Kaiserslautern FuRIOS: Fieldbus and Remote I/O – a system comparison Published in atp – Automatisierungstechnische Praxis 44 (2002), Edition 12/2002, pages 61 - 70 Dr.-Ing. Thomas Tauchnitz, Aventis Pharma Deutschland GmbH Dipl.-Ing. Wilfried Schmieder, Aventis Pharma Deutschland GmbH Dipl.-Ing. Sven Seintsch, Infraserv GmbH & Co Höchst KG Fieldbus and Remote I/O: System Comparison „FuRIOS“ Presentation at the NAMUR general assembly, 08.11.2002 Dr.-Ing. Thomas Tauchnitz, Aventis Pharma Deutschland GmbH Fieldbus Experience Reports Presentation at the NAMUR general assembly, 04.11.2004 Martin Schwibach, BASF Thomas Meier-Künzig, DSM Sven Seintsch, infraserv höchst technik Dr. Joachim Zobel, Novartis Push-button telephones were the first step on the way to the mobile phone Interview mit Dr.-Ing. Thomas Tauchnitz, Aventis Pharma Deutschland GmbH Manfred Dietz, Infraserv GmbH & Co Höchst KG Savings are not the goal of fieldbus Interview with Frans van Laak, Speaker of NAMUR working group 2.6 „Fieldbusses“ Harry van Rijt, DSM TechnoPartners From theorie to practical use Aventis applies FuRIOS study in real pharmaceutical plant Round Table with project participants FuRIOS Fieldbus and Remote I/O System Comparison

Opinions “In the meantime the advantages of the technology are undisputed” Dr. Oestreich, Managing Director Profibus Nutzerorganisation “A manufacturer can obtain enormous benefits from this technology“ Richard Timoney, President Fieldbus Foundation “Fieldbus technology is mature enough for practical use“ Martin Schwibach, BASF, Speaker of NAMUR AK 2.6 „Fieldbusses“ “Already today, users are clearly deciding in favour of fieldbus“ Marc Van Pelt, Vice President Europe Fieldbus Foundation “With fieldbus, we have got all this marvellous information with its huge potential” Ian Verhappen, Chairman Fieldbus Foundation Enduser Advisory Council “Things are looking good for fieldbus“ Dr. Joachim Zobel, Senior Automation Engineer Novartis Pharma Fieldbus is getting its wings Published in MessTec & Automation 12/2004, page 62 - 64 Dr. Christine Eckert, journalist Fit for the future Fieldbus technology at Clariant Published in CHEManager Edition 7, April 2005 Dipl.-Ing. Michael Pelz, Clariant GmbH Dipl.-Ing. Thomas Eichhorn, Clariant GmbH The applicability of the FuRIOS Study Published in atp – Automatisierungstechnische Praxis 45 (2003), Edition 3/2003, pages 51 - 54 Dipl.-Wirtsch.-Ing. Thomas Kasten, Pepperl+Fuchs GmbH Less handicaps in explosion hazardous areas Published in P&A Magazine Edition 1, March 2005 Dipl.-Wirtsch.-Ing. Thomas Kasten, Pepperl+Fuchs GmbH High-Power Trunk Concepts – with FieldConnex® Fieldbus Installation Technology

Presented with the kindest greetings from: Pepperl+Fuchs GmbH www.fieldconnex.info FuRIOS Fieldbus and Remote I/O System Comparison

Preface

FuRIOS: this title of a study comparing fieldbus and Remote I/O systems sounds promising. Indeed the FuRIOS “Fieldbus and (german: und) Remote I/O System Comparison“ is a major improvement with regard to the application of fieldbus systems in process automation. It systema- tically analyses, from the point of view of the user, the benefits and costs (investment costs and operation costs) of a real production plant.

To evaluate the benefits of fieldbus systems up to now only the NAMUR recommendation NE 74, checklists from other industries and supplier or user-specific reports and references have been available. Starting at the Interkama 2001 the FuRIOS study was initiated by Aventis, Infraserv and a group of suppliers. The results were presented for the first time at the annual NAMUR conference in November 2002.

A real plant from Aventis Pharma (D712), planned and built with Remote I/O, was chosen as the basis for the evaluation. With the exact requirements of this plant a concept with fieldbus technology was designed and evaluated by Infraserv, supported by relevant suppliers of sensors and actuators, Remote I/O and fieldbus systems as well as DCS suppliers. The study provides a systematic analysis as well as a result which is independent of suppliers: fieldbus technology is technically and economi- cally beneficial. The savings in investment costs alone range from 3.6 to 5 % compared with Remote I/O Systems, even when calculated very conservatively. Summarized under investment costs the costs of the field devices, communication system, engineering of field technique and control system as well as installa- tion, calibration, qualification and commissioning have been analysed.

The technical advantage of the fieldbus solution, e.g. from diagnosis and event-driven maintenance through to asset management, have not been taken into consideration. They are not to be underesti- mated for optimising the costs of the plant operation, especially in reducing down-time. The deve- lopment of even more powerful diagnosis capabilities is possible only with the use of fieldbus. This compendium provides you, as a reader and user, all the results of this supplier-independent study in detail as well as additional comments from the responsible project leaders of the FuRIOS project, Dr. Thomas Tauchnitz of Aventis Pharma and Manfred Dietz of Infraserv. Furthermore you will find some statements from the speaker of the NAMUR working group 2.6 “fieldbuses”, Frans van Laak, and his colleague at DSM TechnoPartners, Harry van Rijt.

The second part of the compendium presents an application-oriented realization of the study’s results using the fieldbus installation system FieldConnex™ . The economical results of the study are technologically substantiated and further variants of instrumentation concepts are shown.

Pepperl+Fuchs, with this compendium, makes an important contribution towards a more matter-of fact-style discussion about the benefits of fieldbus applications and offers concrete help. I hope you will enjoy reading this and wish you success in applying the results of FuRIOS in your future projects.

Prof. Dr.-Ing. Birgit Vogel-Heuser FuRIOS 2 Fieldbus and Remote I/O System Comparison

Preface to second edition

The break-through of Fieldbus in Process Automation – do we see it now? The possibility of technical realization has been proven for some time now: Fieldbus based solu- tions for automation of process production plants in explosion hazardous areas. We all know that a break-through does not automatically and immediately follow the technical realization. It took almost 10 years from the first Process Control System in a pilot plant to its routine operation. The break-through was somewhen in-between. How long is this way for Fieldbus and where are we today on this way? The first test and laboratory installations of fieldbus have been long ago. The first production plants are in operation now, several more are being commissioned today. Even more are in the design stage. Do we see the break-through? It certainly looks this way. The right evaluation at the right time: FuRIOS (Fieldbus and Remote I/O System Comparison). Nine manufacturers participated in this study which was conducted under the lead of an user company. It was the right time for this study since, with fieldbus barriers, segment couplers and valve boxes, it was able to include the latest technical developments. Without these the comparison of economic efficiency would have been in favour of Remote I/O. Similarly FuRIOS was the right study since it asks and answers all essential questions in a very methodical way. The manifold advantages of Fieldbus over Remote I/O are described in all details. Especially one important condition got not forgotten in FuRIOS: The long-term availability of the new technology. In terms of investment protection this is essential for production plants since – typically for process industry – they are in operation for at least 25 years. Ultimately long-term availability is one of the major differences to Fieldbus in factory automa- tion, were the break-through took place during a few years only, and this was several years ago. Studies like FuRIOS are essential milestones on the way to break-through. It finally takes place when people do not write about it any more, but when the acceptance is proven by the increasing number of fieldbus-based plants. The principle of positive feedback, known to every process control engineer, will help. Any break-through profits from feedback, without it a break-through is hardly possible. A major argument for an investment decision is the economic efficiency. Lower investment costs for a new technology lead, due to economies of scales, to a price decrease and therefore to further reduction of investment costs. Each new plant working on fieldbus is part of the proof of acceptance and therefore an important step on this way. Each one of these plants is a part of the break-through, which we indeed see today.

Prof. Dr. Ing. habil. Lothar Litz March 2005 Institute of Automation Technology Technical University Kaiserslautern Operate and Observe

FuRIOS: Fieldbus and Remote I/O – a system comparison Wilfried Schmieder und Thomas Tauchnitz, Aventis Pharma and Sven Seintsch, Infraserv GmbH

Translation of the german article “FuRIOS: Feldbus und Remote I/O – ein Systemvergleich”, originally published in atp Automatisierungstechnische Praxis 44 (2002), Edition 12, pages 61-70

In contrast to the Remote I/O systems, which have reached a wide market penetration within few years, the technically superior Fieldbus does not see a market breakthrough yet. It is frequently said that the Remote I/O system achieves almost all advantages compared to the conventional cabling of field instruments so that the move towards Fieldbus does not pay any more. On the other hand Remote I/O systems are often seen as interim solution. In order to help clarify this contradiction the companies Aventis and Infraserv performed a system comparison of Remote I/O and fieldbus in cooperation with the IGR (Industrial Practices Interest Group, see www.igrtechnik.com) and sever- al instrument manufacturers. The project name FuRIOS (Fieldbus and Remote I/O – System com- parison), in German language associating “race”, might provoke exaggerated expectations. The result, however, is that the Fieldbus is superior to Remote I/O in many aspects: It brings further sav- ings in investments, accelerates project execution and startup and so provides the migration to a new technological platform that enables the development of innovative and attractive instruments. Manufacturers and users are encouraged to make intelligent use of these new opportunities and do more than just transfer the conventional instruments and operations without modifications to the Fieldbus.

1. Introduction ment manufacturers and users. In addition, there were technical problems and bottlenecks. However, since the Mature Remote I/O systems have been on the market for international standardisation came to a temporary finish several years. Many companies have made extensive use of with the ratification of IEC 61158 (2) and with Profibus PA this technology in new production plants, allowing it to and Foundation Fieldbus two systems are now on offer for prove its worth in extremely large and complex applica- the processing industry, the technical base for the use of tions. It has demonstrated that it is a “feasible method”, the fieldbus is now given. There is a large offering of field- see (1). The cost savings in comparison to conventional bus-capable devices, while certification centres offer their wiring using field distributors, multicore cables and patch services. cabinets are huge. Certain disadvantages, such as in the In a technological sense, fieldbus is one generation ahead plant-specific structure, in physical location within the of Remote I/O systems. The field signals can be transmitted plant, a more complex configuration and additional train- digitally, in the same format as they exist in the field device ing requirements, are accepted. anyway. The elaborate and often fault-risky conversion into The situation relating to fieldbus in the processing indus- an analogue signal and back again is no longer necessary. try is entirely different. For many years, the competition Diagnosis data can be transmitted without difficulty along between several fieldbus standards only confused equip- with the measurement signal and need not to be encrypt-

atp 44 (2002) Heft 12 61 Operate and Observe ed into the signal, like when using the HART protocol. The 2. Methodical Approach of the FuRIOS Project standardisation means that many signals are coded in the same way in all devices, so that they are available in a stan- Like with the introduction of all new technologies, the dard form without requiring any specific decoding for indi- introduction of fieldbus technology initially requires a com- vidual devices. Measurement devices that offer entirely new parison of benefits and costs, whereby the costs must also possibilities (e.g. simultaneous measurements of different include the risk that the new technology may lead to plant physical factors) are in development or already available. standstill. Accordingly, which methodical approach could Despite these advantages of the fieldbus it has not suc- we use to compare new and existing technology? The cri- ceeded in achieving the long-expected market break- teria are: through. Although the headlines read “Fieldbus in Process • Practical approach: a comparison which is intended to Engineering reaches Adulthood” (3) as early as in 1992. assess the suitability for direct use in industrial practice Regular reports on successful applications, e.g. (4), the cannot be abstract or theoretical, but must assess the ranges of products presented at trade fairs (5, 6) and stud- planned production plant in its entirety. ies on the economic efficiency of using fieldbus technolo- • On time: the comparison must only take into considera- gy did not lead to the expected success. What reasons tion arguments that can take effect in the short-term. could there be for this delay in market breakthrough, espe- Speculation concerning future possibilities confuse the cially in the German process industry? Is it a certain reti- issue and simply make a decision more difficult. cence when faced with new, as yet untested technology? • Completeness: a solution with the new technology must It appears not, as laboratory tests and smaller pilot plants completely satisfy the tasks at hand. Partial solutions that confirm that the fieldbus is ready for use. Are there doubts avoid critical points only lead to false statements. that the fieldbus can provide advantages compared to a • Definition: hundreds of general conditions must be Remote I/O system – especially as Remote I/O systems taken into account in order to determine the costs and already offer the substantial cost cuts compared to con- benefits. These include standard equipment lists, hour ventional wiring? Are users unaware of the technological rates, tools and procedures in the respective environ- edge offered by fieldbus technology, or is it impossible to ments. The comparison must be based on absolutely convey this message? Or are important components still definite framework conditions if one wishes to avoid missing for its use? being lost in generalities. Users and manufacturers have discussed these questions. The project was launched by Aventis, Infraserv and In order to meet these criteria, the comparison between Pepperl+Fuchs. IGR (Interessensgemeinschaft Regelwerke Remote I/O and fieldbus was carried Technik) provides the platform for a specialist discussion out on the basis of a real, newly constructed production between the companies that emerged from Hoechst. plant for pharmaceutical active During these discussions the idea for the project FuRIOS substances. The comparison solution was drafted on the was born. FuRIOS is an acronym, meaning “Feldbus und basis of the following criteria: Remote I/O – Systemvergleich” (Fieldbus and Remote I/O system comparison) and describes the intention of this • No changes in the plant requirements: any temptation to study: the two systems should be subjected to a practical facilitate or obstruct the comparison solution by making system comparison. Not only users have a vested interest subsequent changes to the requirements was avoided. in this form of system comparison. Manufacturers of field • Greatest possible equality of the solutions, e.g. with devices and automation systems are also concerned, as regard to availability, especially by using partial redun- they invested a lot of money over many years in the devel- dancy. opment of Remote I/O systems and fieldbus components. • Greatest possible equality of the solutions, e.g. with Today they are still required to equip each device with the regard to equipped or unequipped reserves. option for analogue signalling and with interfaces for both • Whenever possible, use of the same field devices as in fieldbusses. For how long are manufacturers expected to the real plant, provided they are available with fieldbus continue with this parallel development of equipment and interfaces. Otherwise devices with similar characteristics systems, which ultimately pushes up the prices? This is the were used. Participation of manufacturers in this study background why the following nine manufacturers provid- had no influence on the selection of equipment. ed financial support or, in some cases, technical coopera- • “Sensible” solution: the criterion for the solution was tion in this project: ABB, Emerson, Endress+Hauser, that we would build the plant as planned, in accordance Camille Bauer, Honeywell, Pepperl+Fuchs, Samson, with our criteria and standards. Therefore, the compari- Siemens and Wika. son solution was not “made feasible” by waiving sensi- The following section 2 presents the methodical approach ble requirements, but also not “made infeasible” by of the FuRIOS project. Section 3 presents the solution defining additional requirements. developed for fieldbus; section 4 compares the investment • No medium-term dependence on one manufacturer: costs and section 5 deals with the operative aspects of the solutions were not accepted if they could only be pro- fieldbus compared to the Remote I/O. Section 6 provides a vided by one manufacturer in the medium-term. The summarised assessment of the results of sections 4 and 5. chemical-pharmaceutical industry would not accept any Section 7 then gives an outlook for users and manufactur- solution of this nature which could therefore not be used ers. The article concludes with a bibliography and an index as the basis for any technological decision. of abbreviations. • Availability of the PA devices no later than 10/2002.

62 44 (2002) Heft 12 atp Operate and Observe

• 62 drives (controlled by means of Profibus DP) • 2 converters (controlled by means of Profibus DP) A comparison solution was drafted for this specific plant, based on fieldbus (figure 1). The Profibus PA was selected as fieldbus. The main reason for this is that for this fieldbus currently there are more devices and tools on the market which meet the european requirements for explosion protection. As base concept of the topology the use of fieldbus barriers and valve interface boxes has been defined. The power to the passive fieldbus barriers is supplied by the bus cable respectively the power • Conservative calculation: in general “prudent calcula- link module. This connection is tions” were used. It is fair to assume that some of the designed in the ignition protection class “increased safety” results will prove to be more in favour of the fieldbus in Ex e, while the designated connections of the field devices an a-posteriori analysis than specified in this study. have the ignition protection class “intrinsically safe” Ex i. Although this deviates from the intrinsically safe design of A comprehensive comparison means that as many other cri- signal transmission preferred in Germany, we believe it is teria as possible that may become relevant over the life the most sensible method. The probability that individual cycle of the plant are taken into account in addition to the field devices must be replaced is considerably greater than investment costs. Systematic reasons dictated a clear sepa- changes in the fieldbus segment itself. In that respect the ration between the assessment of investment costs (section application of explosion protection class “intrinsic safety“ 4) and operational factors. Ex i is of greater significance. A rough estimate indicated In order to ensure the currency of the comparison equip- ment and connection technologies were required to be that if one does away with the fieldbus barriers and designs available immediately. Of course time is in favour of the the fieldbus lines to be entirely intrinsically safe, the fieldbus fieldbus in this respect, as more and more devices with solution would be considerably more expensive than the fieldbus interface are coming to market, while the required solution with Remote I/O. This statement is so important periphery such as connection technology, field measure- that it should be repeated in other words: the fieldbus ment technology and software are being developed. would not be economically feasible without the fieldbus barriers! The use of valve interfaces is also of considerable econom- 3. Presentation of the Comparison Solution ic significance. The quantity framework indicates that there are roughly three times as many binary signals as there are Used as a reference was a production plant for chemical analogue signals. Bundling of the binary signals in the valve synthesis of pharmaceutical active substances, located in interfaces significantly reduces the costs. Moreover, some of building D712 of Aventis in Frankfurt-Höchst, Germany. This plant was constructed during 2001 and 2002 and was these field appliances could otherwise not be integrated commissioned in 2002. It is characterized by: into the PA bus at all. This, too, would mean that an eco- • Project costs 13.8 Mio. €, including 3.5 Mio. € costs for nomic assessment of the fieldbus would be negative. Process I & C The planned fieldbus solution is characterised by the fol- • Automated using the process management system lowing figures: Industrial IT by ABB • 2 redundant Profibus DP lines for the field devices, • Remote I/O: S900 from ABB • 1 Profibus DP line for drives and converters, • Area with explosion risk: zone 1 • 2 segment couplers (SK2), which – unlike the corre- • Pharmaceutical requirements (cGMP) sponding Remote I/O solution – cannot be made entirely • Planned using the CAE system Comos PT from Innotec redundant through to the respective PA segments, The following quantity framework applies: • 17 Profibus PA segments respectively power link modules, • 369 Process I&C points connected to Remote I/O (with • 64 fieldbus barriers (bus: EEx e, signals EEx i), 821 I/Os) • max. segment length without spurs 210 m, - 155 analogue inputs • max. 17 subscribers to one segment (spurs 15 m each), - 58 analogue outputs • the total cycle time of the Profibus PA slaves is less than - 405 binary inputs 364 ms and therefore meets the existing requirements. - 203 binary outputs There was a small number of devices that were not available

atp 44 (2002) Heft 12 63 Operate and Observe with a fieldbus interface (see below). This requires a “rag in the existing Remote I/O solution – the 21 specified mea- collector” solution. A brief estimate revealed that Remote surements are wired conventionally to the process man- I/O solutions would not be economical for these few sig- agement system and connected to its conventional I/O nals (21 signals). Consequently they were wired directly to cards. At this point reference should be made to the pro- the switch room and there connected to conventional I/Os ject methodology of realising a 1 to 1 solution to the of the process control system. On top of the additional greatest possible extent. In specific terms, multi-variable hardware costs for a Remote I/O system it also would cre- devices were not used (e.g. for flow, temperature and ate training and commissioning costs, which are omitted pressure), as these appliances were also not used in the here due to the direct connection to the control system. original reference solution and the measurements in the flow and instrumentation diagram would be at different points. Here is additional potential to cut costs if the pos- 4. Comparison of Investment Costs sibility of using multi-variable devices could be taken into account when drafting the flow and instrumentation dia- This section provides a detailed comparison of the effects gram. of fieldbus installation on the individual components of The economic assessment of the field devices specified in the process control system. In addition to a description of this section indicates an additional cost of 4,489 €. The the technical characteristics it also contains the economic cost savings for the solenoid valves of 7,400 € are faced analysis. with additional costs of 11,889 € for the field devices with 4.1 Field devices fieldbus interfaces. Therefore, the additional costs add up to 0.6 percent, based on the costs for the field devices of The technology that has been used until now has necessi- 770,000 € for the overall project. tated equipping the control valves with limit switches. The digital positioners report electronically when the limit is 4.2 I/O System reached and transmit this information over the bus. Accordingly, a decision was made to do without the limit The use of the fieldbus replaces the Remote I/O system switches. In the comparison plant a solenoid valve was with all its components entirely. This refers to 20 Remote positioned upstream from the control valves in order to I/O systems distributed throughout the plant as well as the shut down the flow of products completely. A decision corresponding power supply modules and explosion pro- was made in this study to do without this feature when tection barriers. On the other side we have: using the fieldbus, as positioners enable a complete sys- • Additional PLC I/O cards (for the “rag collector” signals) tem deactivation which can be monitored by the integrat- • Components of the fieldbus system (fieldbus barriers, ed valve position signalling. However, this does not apply valve interface boxes, segment couplers, power link to solenoid valves used for safety critical functions. modules) Satisfactory fieldbus components could not be found for • An additional process-near component was also required the following tasks: for the process control system in use, as the components • Signal lamps integrated in control units require so much offered by that specific DCS manufacturer offered only power that they cannot be supplied by the intrinsically four Profibus DP connections, but five were needed. The safe fieldbus. Despite the mainly automatic operation, 5 corresponding additional costs are specifically linked to local control units and 2 separate signal lamps were used this DCS manufacturer, as other systems have more and in our plant. sometimes less than four fieldbus connections per • For rotation measurements and current conventional process-near component. If we had done a more plant- quantity measurements the signals come in the form of specific allocation of the functions to several process- counting pulses. There are no fieldbus-compatible input near components this additional cost would not have devices for these functions, albeit they could conceivably occurred. Therefore the PA solution would have been be binary input signals. The actual plant required a solu- even more cheaper. tion for four separate rotation measurements. • While there are fieldbus-compatible analysis devices for The economic assessment of the I/O systems described in the major applications available, such as PH and Redox this section leads to cost savings of 76,212 €. The cost values as well as conductivity and O2 analysis, the analy- savings of 138,562 € for the unnecessary Remote I/O sys- sis devices for less frequently used applications such as tem are faced with additional costs of 46,350 € for all opacity measurements do not usually come with a field- fieldbus components as well as 16,000 € for an additional bus interface. In our case technical safety requirements process-near component. The cost savings amount to 18.1 dictated the conventional installation of three O2 mea- percent, based on the costs for the I/O system of 420,000 €. surements. • In scaling technology, the signals from the scales cells 4.3 Engineering of the Field Technology must be processed using an evaluation device. In gener- al, these are not installed in the field, but in the control The Remote I/O systems that have been used until now room and can be controlled and actuated per Profibus DP. require a significant level of engineering costs; in addition, As we have already mentioned – and this is also the case the considerable space they required necessitated specific

64 44 (2002) Heft 12 atp Operate and Observe consideration in the location planning. The decentral I/O device to define the significance of each code pattern of cabinets had to be positioned throughout the plant and the status bytes. Fieldbus status information is coded in a equipped with I/O cards in an optimal way. Therefore one standardised manner so that device-specific configuration, has to define in advance which devices will be connected implementation and analysis of typicals are not necessary. to which cabinet. Very often this is an iterative procedure. This allows configuration in the DCS independent of the Detailed plans with corresponding documentation were measuring devices and to a certain extent independent of necessary for the Remote I/O. Some I/O systems require a the measured factors, too. special calculation of the heat dissipation in order to com- Another difference becomes obvious when planning the DCS: Remote I/O connects the field devices via an interface ply with the requirements of explosion protection. The as “external systems”, whereas with fieldbus the commu- intrinsic safety has to be confirmed for each specific com- nication with the devices is transparent, as if they were bination of field device and Remote I/O card. connected directly to the DCS. This facilitates engineering, When using fieldbus technology many of these activities commissioning and testing. are not necessary while others are considerably simplified. The economic evaluation of the DCS engineering described The topology of the fieldbus is rather simple with just a in this section indicates cost savings of 24,795 €. This few, compact components inside the plant, therefore amounts to 4.7 %, based on the total costs of engineering; requiring considerably less planning. Due to the free com- it accounts for almost twice as much, based on DCS engi- bination of devices connected to a fieldbus segment a neering alone. more precise allocation in the plant can be achieved com- pared to Remote I/O, without any additional expense. 4.5 Installation Thanks to FISCO the confirmation of intrinsic safety is con- siderably easier. By changing from conventional wiring to Remote I/O the The used planning tool has a significant influence on the greatest potential for savings on installation costs has costs relating to the plant documentation. If a databased already been realized. Former conventional plant commu- CAE tool is used, like Aventis uses the Innotec tool “Comos nications had required local distributors, multicore cables PT”, the documentation costs are low – for both the and patch cabinets. Later Remote I/O systems were Remote I/O and the fieldbus. However, the cost savings installed directly in the field, the only individual connections were between field device and Remote I/O. From the latter that can be achieved with fieldbus are firstly due to the to the control room a bus cable was used. All that was fewer connections, such as with the valve positioner, and required in addition to the bus cable was an auxiliary power secondly due to the fact that the PA connection is identical supply to the Remote I/O station. Considerable cost savings at all devices. This means that the otherwise necessary have been achieved in wiring, in the cable tracks and in transfer of device and manufacturer-specific graphic sym- terms of space in the control room. But this was not a topic bols and connections to the standard library of the CAE of this study. tool is no longer necessary. Now costs can be even more reduced by changing from The economic assessment of the fieldbus technology engi- Remote I/O to fieldbus. In general, the cable lengths for the neering described in this section indicates to cost savings of spurs are shorter, since the fieldbus barriers are more 9,076 €. The main items are the obsolete I/O allocation decentralized located than the Remote I/O stations due to planning, the simplified confirmation of intrinsic safety and their greater number. The installation of the extremely the simplified creation of typicals in the CAE system. These small and light fieldbus barriers forms no problem, where- savings reflect 3.2 % of the total costs of engineering in as the large Remote I/O stations must be assembled very the project, amounting to 280,000 €. The cost savings carefully. Wiring of the I/O stations with auxiliary power would have been considerably greater if the plans had not supply is also no longer necessary. Due to the larger num- been created with the CAE system, but rather – like Aventis ber of fieldbus segments and the “rag collector” signals did until two years ago – with a relatively high cost for the number of cables to be laid between the field and the manual labour. Estimates indicated that the fieldbus cost control room remains approximately the same. The eco- savings would then have been 33,188 € or 11.9 % of the nomic assessment of the installation described in this sec- tion leads to savings of 10,732 €. These are 1.5 percent, engineering costs. based on the costs of Process I&C of 700,000 €. Although this is not very much, it must be seen in the context with 4.4 Engineering of the DCS the high savings that were achieved already by replacing conventional wiring with Remote I/O. At first glance it may appear surprising that the choice between Remote I/O and fieldbus influences the DCS engi- 4.6 Calibration and Qualification neering. Nonetheless, this influence is really quite signifi- cant for the overall result. This is ultimately due to the fact In general, the type of connection technology has no influ- that the level of fieldbus standardisation is rather high – ence on the calibration of the equipment and the costs this unlike with Remote I/O. When using Remote I/O separate accrues. However, the situation is very different with regard programming respectively evaluation is necessary for each to the calibration and qualification the process control

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sification of the measurement values Table 1: Influence on investment costs (all prices in € ). and therefore does not have to be cal- Costs RIO Price changes Costs PA: Min. (%) ibrated, the conventional analogue Electrical.: 0% 140,000 0 140,000 0,0 % signal path is subject to faults, thus generating calibration, qualification Analysis devices.: 0% 140,000 0 140,000 0,0 % and documentation costs. Further- Project handling: 0% 280,000 0 280,000 0,0 % more the setting and validation of the Field devices: +0,6% 770,000 4,489 774,489 0,6 % measurement range is no longer nec- I/O-System: –18,1 % 420,000 –76212 343,788 –18,1 % essary; only a plausibility test is DCS incl. Engineering.: – 4,7 % 525,000 – 24,795 500,205 – 4,7 % required for the qualification. Installation: –1,5 % 700,000 –10,732 689,268 –1,5 % The economic assessment of the cali- bration and qualification described in Calibr./Quality: – 4,3 % 140,000 – 5,976 134,024 – 4,3 % this section leads to savings of 5,967 €. IBS: – 2,3 % 105,000 – 2,400 102,600 – 2,3 % This amounts to savings of 4.3%, Engin.: – 3,2 % 280,000 – 9,076 270,924 – 3,2 % based on the total costs of calibration Total all Process I&C 3,500,000 –124702 3,375,298 –3,6 % € and qualification of 140,000 for the Total relevant Process I&C 2,940,000 – 124,702 2,815,298 – 4,2 % whole project. tion describes the other effects and evaluates them to the 4.7 Commissioning greatest possible extent. Firstly, this relates to the effects on the life cycle of the plant which cannot be defined as pre- As already mentioned on several occasions, the integration cisely as the investment costs. Secondly, it also relates to of the field devices into the overall process control system the indirect effects, which are manifest, for example, in works considerably better with the fieldbus than with the higher production rates of the plant and therefore in ben- Remote I/O. The reduction of error sources, the use of stan- efits outside of the Process I&C area. Because these factors dards and the easier fault diagnosis due to the greater are always dependent on the type of production and mar- transparency mean that commissioning is much faster. ket situations, the actual benefits cannot be estimated in a Testing of the entire, readily installed Process I&C point, the general sense. Readers are encouraged to determine the so-called loop check, is no longer necessary. It has only to effects in their industries and production plants themselves. be checked whether the correct device is connected and whether it emits a “sign of life”. The economic assessment 5.1 Influence on the project running time of the savings relating to the commissioning described in this section amounts to 2,400 €, based on half an hour sav- Section 4.7 has already made reference to the considerable ings per analogue device. This amounts to 2.3 %, based on effects on commissioning. Whereas that section dealt with a total cost of commissioning of 105,000 €. the direct savings in investment costs over the course of the project, this section discusses the influence on the project 4.8 Summary of the results running time. Our calculations revealed that – if there are realistic team Table 1 provides a summary of the additional costs respec- sizes – four days could be saved during installation, five tively savings specified in the above chapters. In total, the days during qualification and two days in commissioning. savings in terms of Process I&C investment costs amount to This may not appear sensational at first glance if one con- approx. 125,000 €, or 3.6 % of the total Process I&C costs. siders the 12-18 months that are usually estimated for such The table also indicates that some parts of the project are a project. However, upon detailed analysis of the project not affected by the communication technology, for example plans one can see that the installation, the qualification the electrical engineering, the analysis appliances and the and the commissioning of the Process I&C are always time project realization itself. If one deducts these areas, the total critical areas. Put in colloquial terms: the Process I&C peo- savings amount to 4.2 % of the relevant Process I&C costs. ple are always the last in and have to be the first out. So it Reference should be made once more to the influence of the is fair to say that the use of fieldbus can speed up the over- used CAE tool on the savings in engineering, as indicated all project by about 10 days! above in section 4c. Without this influence, the savings Any attempt to estimate these savings in Euros and Cents would amount to 4.2 percent of the total Process I&C costs is doomed to failure. The benefit depends on whether or 5.0 percent of the relevant Process I&C costs. these two weeks can be turned into earlier market pres- ence, a bigger market share or an increase in turnover or 5. Comparison of Operational Factors whether they are wasted somewhere else in the project, in production or in marketing. In general, however, the pres- The previous chapters dealt with the effects of the fieldbus sure to meet tight project deadlines is growing from year to on the investment costs. We were dealing with “hard year, so any acceleration in project finalization is of consid- facts” that could be calculated precisely. The following sec- erable value. In order to estimate this value, readers are rec-

66 44 (2002) Heft 12 atp Operate and Observe ommended to calculate the turnover of a new product in 5.4 Influence on fault correction two weeks, based on the annual turnover, and the corre- sponding profit margin in their respective markets – the The fieldbus increases the transparency of the system. project acceleration could create considerably more value Therefore fault detection is much faster or, even better, than the entire savings in investments! faults are reported actively. Fieldbus technology allows the use of “intelligent” devices featuring superb self-diagnosis, 5.2 Influence on the training of technical staff even up to signalling the need for preventive maintenance. On top of the faster fault detection the increased reliability In general, Remote I/O as well as fieldbus requires trained, of error diagnosis will have a positive influence, too. If the well-qualified process control specialists. We estimate that devices run a reliable self-diagnosis and send an “ok”-sig- technicians require two days of training on fieldbus tech- nal they need not to be removed, tested and re-installed on nology in order to learn installation, diagnosis and fault suspicion. repair. The same amount of time would be needed for The calculated direct economic benefit of this simplified training on Remote I/O. However, the manufacturer specif- error handling is disappointingly low. We estimate about ic Remote I/O variants require specific training for deci- 500 € a year. This is due to the low failure rate of the phering the codes. Due to the standardized protocol this is nowaday’s technology – we estimate it at 0.5 % per year. not necessary with fieldbus. These savings are estimated to This again is a direct success of the rather conservative be 2.5 days of training per technician. In case of three tech- habit of commissioning new devices only after extensive nicians within the plant we estimate the savings on training testing in the laboratories of NAMUR member companies to be about 4,000 €. or after solid operation experience. This is a remarkable result since it contradicts the general The indirect benefit is several times bigger but cannot be assumption that a new technology is always more complex calculated universally. However, if fieldbus technology helps than the old, replaced technology and therefore training levels are continually rising. This result is due to the stan- to avoid faulty batches or the loss of just one day of pro- € dardisation of fieldbus which avoids special training as well duction, this benefit may amount to several 100,000 . as to the increase of transparency and constancy thanks to fieldbus technology. The system now works fully digital, 5.5 Influence on maintenance and inspection thus gaining the advantages of this homogenity. Section 5.3 describes how possible error sources in signal conversion and transmission are avoided due to fieldbus. 5.3 Influence on quality Therefore the calibration of the production line during the Due to fieldbus two signal conversions are omitted: often annual testing is not necessary any more. This annual test- the measurement signal is generated digitally and then ing is mandatory, at least in pharmaceutical production converted to an analogue output signal, which then is re- environments. In the reference plant this applies to 25 cal- converted to digital in the process control system – and vice ibrations, adding up to savings of 2,500 € p.a. Furthermore versa for actuators. Two systematic sources of errors are it allows to omit the calibration of an installed device by removed with the disappearance of these signal conver- simply replacing it by a readily calibrated one. This speeds sions. Fault reproduction no longer needs to be considered up the annual tests and shortens the period of production and the entire signal loop is exactly as accurate as the sen- interruption, which has a significant economic value. sor or actuator itself. Ultimately the measurement toler- Another topic cannot be clarified definitively. It is possible ances are significantly smaller. This could either be used for that the calibration cycles of the sensors can be increased more precise measurements or settings with the same field significantly – even beyond the current minimum of once devices or to achieve the same total tolerance with devices per year. of lower tolerance quality. Especially the latter could This results from the fact that very often the sensors have a become economically significant in cases where up to now higher long-term stability than the signal conversion elec- the required tolerances could only be reached by special tronics in the analogous devices. Since the signal conver- and therefore expensive precision measuring equipment. A sion is omitted the calibration cycle could be adjusted to general statement on the economic benefit cannot be the long-term stability of the sensor. Once this will be given here – but it could be very significant. accepted by the quality departments and control boards – Two more factors influence the total quality of the process surely only after extensive practical experience – even more control system: Many chances for errors are avoided direct- savings are possible. In terms of the Process I&C of the ref- ly at the source, e.g. if the alias values have not to be attrib- erence plant this would mean 7,500 €, the operational uted individually any more. Errors which cannot occur at all benefit due to reduced downtimes cannot be estimated. cannot lead to losses in quality. Furthermore – and this is second factor – error detection and correction is much faster due to the transparency of fieldbus. Therefore the resulting damage is considerably less. An economical assessment of these factors is not pos- sible at the moment, too.

atp 44 (2002) Heft 12 67 Operate and Observe

6. Assessment of the Results In a methodical sense the approach of drafting a compar- ison on the basis of a real, operational plant is highly in 6.1 Assessment of the investment costs danger of subjective errors. The selection of plant location, size, type and equipment leads to specifications that can- The above presented savings in the Process I&C costs not be generalized. Furthermore, the point in time of this which amount to 3.6 through 5 percent, depending on the study could have a significant influence, too. The results perception, may seem disappointing at first glance. The may be different in six months from now. Accordingly, one values of about 20 percent which former studies indicated should be careful in transferring the results to other plants led people to expect more. However, it is to be recalled or in assuming that the results are generally valid. There that these studies (8) determined the potential savings may indeed be plant sizes for which the Remote I/O solu- relating to fieldbus technology in comparison with con- tion is the best. The evaluation of continuous processes ventional wiring. Roughly it can be said that Remote I/O with respective availability requirements may lead to dif- saves about 15 % over conventional wiring and fieldbus ferent assessments. With revamps of existing plants technology saves an additional 5 %. Remote I/O allows to continue using the installed field Taken realistically, greater savings in investment costs could devices. On the other hand, for example, fieldbus technol- not really be expected by changes of the communication ogy would be even more beneficial to larger, more spread technology alone, as the number of cables laid between out plants than our reference plant. Specialists around the the control room and the field remains approximately the world should feel invited to apply the methods of this same. However, these savings are relevant: it is a consider- study to other plant types and to communicate the results able leap if the introduction of a new technology leads to so that more general statements will be possible. a 5 percent drop in investment costs for a certain field – Another uncertain area of the FuRIOS project is that the even without the discovered additional benefits during the comparison was carried out on the basis of Profibus PA life cycle. Which other technology leap over the last few and not Foundation Fieldbus. Without having considered years has generated savings of 5 % off overall costs in the details of a solution with FF, we would venture the other fields such as construction engineering or apparatus opinion that the results of a study with Foundation engineering? Fieldbus technology would be similar. Advantages and dis- advantages of the different fieldbusses would be apparent 6.2 Assessment of the operational factors here and there, but this would not affect the result by any- thing more significant than 10 %. Besides some relatively small factors, like training or costs One more critical statement about the FuRIOS project is of Process I&C maintenance, there are major changes in necessary: This study was carried out to the best knowl- the operational factors: if plants can be put into operation edge of the authors, using their experience with fieldbus faster thanks to fieldbus technology, if they have less test systems. However, there is a lack of practical experi- downtime during malfunctions or can be run with greater ence. Some assumptions may be overly cautious; problems precision, then this is the major benefit of fieldbus tech- may occur in the implementation of a real project which nology. One day of production profits in a plant operating have been overlooked here. Most certainly there are € at maximum capacity can easily generate 500,000 . Or “teething problems” to be expected in the first projects, vice versa, one day of downtime can destroy the same which could eat away the estimated savings. Faster com- amount. Unfortunately the benefit potentials cannot be missioning is also unlikely to be possible in the first project. determined universally since the influences of plant load levels, market situations and profit margins are far too big. However, the benefits in operation surpass the savings in 7. Outlook investment costs by far. From our perspective it is a pleas- ant bonus that these benefits in operation – unlike as with The methodology of this project was the 1 to 1 reflection most other innovations – must not be paid for by higher of a real plant realized with Remote I/O to a plant using investment costs, but are accompanied by additional sav- fieldbus. Used cleverly, the fieldbus technology will lead to ings, even if they are relatively small. further cost savings and increased benefits. On one hand the user is asked to be flexible in his thinking while on the 6.3 Assessment of the methodology other hand the manufacturers face new requirements. An assessment of results would be incomplete without an 7.1 Outlook for users assessment of the methodology. The methodology described and substantiated above led to a conclusive, The fieldbus technology is the technological platform for comprehensible assessment within a relatively short period further development of the field devices. Already the first of time. Of course it cannot yet be concluded with an eval- products are available: So-called multi-variable devices can uation of a real project, since the decision for future plant measure several physical factors at the same time, for designs with fieldbus will be based on this study. It has to example flow rate, pressure and temperature. Devices of be noted explicitly that there is a certain risk to find some this kind are inexpensive and – thanks to fieldbus – can be differing results in a real practical comparison. connected just as easily as single value devices. In FuRIOS

68 44 (2002) Heft 12 atp Operate and Observe it was not possible to use them anywhere since tempera- • A process-near component should not be limited to two ture and pressure measurements were never taken at the redundant Profibus DP lines only. This increases the num- same pipe or at the same installation point. The users are ber of components unnecessarily. However, many systems requested to become aware of the possibilities of multi- already satisfy this wish. variable devices and to take them into account when draft- • Software tools for calculating the manufacturer specific ing the flow and instrumentation diagram. connections are required. At the moment, not all manu- Fieldbus is the technological basis for new device develop- facturers of fieldbus components offer them. ments. A rod probe that measures a temperature profile, a • A simple bus monitor system for Profibus PA for diagno- valve that counts how often the valve opens, an analysis sis at the Ex segment would be sensible. The FF already device monitoring itself – only fieldbus allows a sensible offers it. and efficient integration of all this into process automation. • At the moment, Profibus PA does not have the option of This insight was published years ago: “Fieldbus technology continuous redundancy, at least up to the respective PA as the driving force behind automation engineering” was segment. the name of an article back in 1999 (9). The common term Manfred Dietz, Infraserv Hoechst, Harald Hauch and Josef Will, Aventis, cooperat- at the moment is enabling technology, which means the ed on the project in addition to the named authors. Staff from the manufacturers same thing. Fieldbus represents an innovative technological involved also cooperated, and our thanks goes out to them at this point. platform – manufacturers and users have to decide which devices will use this platform and how they will be utilized. Bibliography: Fieldbus is also the fitting technological basis for asset man- (1) Gangbarer Weg – Remote I/O-Systeme in der Prozessautomation. agement systems. Until now, these systems have required Chemie Technik, 28 (1999), Nr. 4, S. 38–40. separate bus systems for transmitting the device informa- (2) Klemm, E.: Internationale Feldbusnorm IEC61158 ist Realität. tion. This is no longer necessary since fieldbus transports etz, Heft 6/2000 these informations. This may (finally) help asset manage- (3) Hils, F., Lindner, K.-P.: PROFIBUS – Der Feldbus für die Verfahrenstech- ment systems to achieve the breakthrough that has not nik wird erwachsen. atp – Automatisierungstechnische Praxis 34 (1992), H. 12, S. 661–667. happened until now. However, the discussion on how the tasks should be optimally distributed between CAE system, (4) N.N.: Zielsichere Vorlage. Chemie Produktion, H. 3/1998, S. 44–47. asset management system and ERP system is not over yet. (5) Rathje, J.: Der Feldbus in der Verfahrenstechnik. atp – Automatisie- The cost/benefit analysis of asset management systems has rungstechnische Praxis 35 (1993), H. 2, S. 135–137. been consciously left out of this study, it has to be discussed (6) Rathje, J.: ACHEMA 97: Der Feldbus kommt ins Rollen – Ein Situations- at some later date. bericht. atp – Automatisierungstechnische Praxis 39 (1997), H. 10, S. 56-59 (7) Max, G., Heidel, R., Frehse, K. P.: Wirtschaftlichkeit des Feldbuseinsatzes. atp – Automatisierungstechnische Praxis 34 (1992), H. 9, S. 507–512.

7.2 Outlook for manufacturers (8) Rathje, J.: Braucht die chemische Industrie den Feldbus? atp – Auto- matisierungstechnische Praxis 36 (1994), H. 4, S. 22–30.

Not only users are encouraged to make more intelligent use (9) Neumann, P.: Die Feldbustechnik als Motor der Automatisierungs- of fieldbus than simply replicating current tasks 1 to 1. technik. atp – Automatisierungstechnische Praxis 41 (1999), H. 7, S. 27-34 Manufacturers are also called on for further developments, in particular to pursue the following ideas: • Feeder devices (power modules) with a higher supply cur- rent (considerably more than 400 mA) would be sensible, as many appliances – sometimes with good reason – require considerably more than 10 mA. A higher supply current would not only reduce the number of fieldbus lines, it would also enable more and more devices to change from four-wire supply to two-wire supply. • A valve interface box for Profibus PA with bus connection in increased safety Ex e would allow the control of more powerful intrinsically safe solenoid valves (this is already available for Foundation Fieldbus). • A “mini Remote I/O” for the Profibus PA, also with bus connection in increased safety Ex e, would make conven- tional wiring (for frequency inputs, too) or a separate Remote I/O as “rag collector” superfluous (at the moment, the only available solutions use auxiliary power). • The address scope of 126 addresses with Profibus DP is a limiting factor. The standardisation committees should attempt to achieve a revision of this limit.

atp 44 (2002) Heft 12 69 Operate and Observe

Dr.-Ing. Thomas Tauchnitz is head of the Technology Abbreviations: and Projects group within the Technical Engineering CAE: Computer Aided Engineering Active Substances Department at Aventis Pharma DCS: Distributed Control System Deutschland GmbH. Within NAMUR, he is coordinator for working field 2 Integrated Solutions and Systems. FuRIOS: Fieldbus and Remote I/O system comparison He heads the working field Management Technology Process I&C: Process Intstrumentation and Control within IGR (Interessengemeinschaft Regelwerke FISCO: Fieldbus Intrinsically Save Concept Technik). Address: Aventis Pharma Deutschland GmbH, ITW, PLC: Programable Logic Controler D610, D-65926 Frankfurt/Main, Profibus DP: Decentral Periphery (see IEC 61158) phone (069) 3 05-41 94, fax -8 30 98, Profibus PA: Process Automation (see IEC 61158) e-mail: [email protected]

Dipl.-Ing. Sven Seintsch is head of analyses on various Dipl.-Ing. Wilfried Schmieder is head of the Project fieldbus test installations within the test laboratory of Process Control Technology team within the Infraserv GmbH & Co Höchst KG. He is member of the Technical Engineering Active Substances Department NAMUR working group 2.6 Fieldbus. He is also head of at Aventis Pharma Deutschland GmbH. the working group Fieldbus within IGR Address: Aventis Pharma Deutschland GmbH, ITW. (Interessengemeinschaft Regelwerke Technik). DS581, D-65926 Frankfurt/Main, phone (069) 3 05-1 Address: Infraserv GmbH & Co Höchst KG, MSR- 21 22, fax -31 10 46, Technik, Prüflabor, D710, e-mail: [email protected] D-65926 Frankfurt/Main, phone (069) 3 05-1 32 60, fax: -1 59 78, e-mail: [email protected] FuRIOS Fieldbus and Remote I/O System Comparison

Fieldbus and Remote I/O: System Comparison „FuRIOS“ (Feldbus und Remote I/O: Systemvergleich)

ƒ A practice-oriented comparison of costs and benefits between Fieldbus and Remote I/O-Systems ƒ Prepared by the companies – InfraServ GmbH & Co Höchst KG (Sven Seintsch, Manfred Dietz) and – Aventis Pharma Deutschland GmbH (Wilfried Schmieder, Harald Hauch, Josef Will, Dr. Thomas Tauchnitz) – In the scope of the IGR (Interessengemeinschaft Regelwerke Technik) ƒ In cooperation with the manufacturers ABB, Camille Bauer, Emerson, Endress+Hauser, Honeywell, Pepperl+Fuchs, Samson, Siemens, Wika Result presentation FURIOS 2002-11-08 1 IGR Interessengemeinschaft Regelwerke Technik

Task of this project

Hypothesis: ƒ The Fieldbus is here, it could be put to use. ƒ A current evaluation of the cost/benefit aspects does not exist and could cause the acceptance. Savings ?? Benefit ??

Conv. Rem.I/O Fieldb. Conv. Rem.I/O Fieldb. Target of the project: ƒ Investigation of the feasibility and the cost/benefit aspects of fieldbus from the user's point of view, as close as possible to the typical frame conditions of a pharmazeutical – chemical production plant. Result presentation FURIOS 2002-11-08 2 IGR Interessengemeinschaft Regelwerke Technik FuRIOS Fieldbus and Remote I/O System Comparison

Methodology of the project

ƒ Selection of one real, typical plant with Remote I/O which had been commissioned a short while ago ƒ Planning of a (as far as possible) 1:1 comparable solution with Fieldbus (concrete: Profibus PA) ƒ Comparison and assessment of the cost/benefit aspects between the batch processing plant realized with Remote I/O and the plant planned with Fieldbus, taking into consideration the complete live cycle

Result presentation FURIOS 2002-11-08 3 IGR Interessengemeinschaft Regelwerke Technik

Characterization of the plant D712 ƒ Project costs 13.8 Mio €, whereof 3.5 Mio € Process I&C costs ƒ Remote I/O (S900 from ABB) ƒ DCS (Industrial IT from ABB) ƒ Explosion hazardous area: Zone 1 ƒ Pharmaceutical requirements (cGMP) ƒ Planned with the CAE-System Comos PT ƒ Bill of material: – 369 Process I&C Points on Remote I/O (with 821 I/O‘s) ƒ 155 Analogue Inputs ƒ 58 Analogue Outputs ƒ 405 Binary Inputs ƒ 203 Binary Outputs – 62 Drives (connection through Profibus DP) – 2 Transformers (connection through Profibus DP) Result presentation FURIOS 2002-11-08 4 IGR Interessengemeinschaft Regelwerke Technik FuRIOS Fieldbus and Remote I/O System Comparison

Criteria of the Comparison Solution

ƒ No modification of the requirements on the plant (no subsequent optimization) ƒ Solution as equal as possible, e.g. in respect of reliability, reserves ƒ Aim for „sensible“ solution, which one would build exactly as is (no „positive calculation“) ƒ No solution which is proprietary of one producer in the medium term ƒ Availabilty of the devices latest 10/2002 ƒ Conservative calculation, „on the safe side“

Result presentation FURIOS 2002-11-08 5 IGR Interessengemeinschaft Regelwerke Technik

Topology of comparison design

Profibus Segment Power Link DP red. Coupler Modules (not red.) (400mA) Ex Profibus PA

SK 2 Power line 1 Ex e Fieldbus- Fieldbus- barrier barrier Link

Power line 2 Link Ex i Valve Valve Valve Box Box Box

MU MU Valve MU Box

Power in total Link • 2 Segment Couplers Power line n • 17 Power Link Modules Link • 64 Fieldbus Barriers

Result presentation FURIOS 2002-11-08 6 IGR Interessengemeinschaft Regelwerke Technik FuRIOS Fieldbus and Remote I/O System Comparison

Characterization of comparison solution

ƒ 2 redundant Profibus DP lines for the field devices ƒ 1 Profibus DP line for Drives and Transformers ƒ 2 Segment Coupler (SK2) (unfortunately not redundant!) ƒ 17 PA segments resp. Power Link Modules ƒ 64 Fieldbus barriers (bus:Ex e, signals Ex i) ƒ Max. segment length without spurs 210 m ƒ Max. 17 participants per segment (spurs 15 m each) ƒ The total cycle time for the PA - Slaves is below 364 ms, therefore meeting the present requirements ƒ Connection of devices which are not available with Profibus PA directly to conventional I/O‘s („Rag Collector“) ƒ Note: Without Fieldbus barriers and withour valve coupler the task would not have been solveable in an economically efficient way!!! ƒ The combination of Fieldbus and Remote I/O would have been economically unefficient as well Result presentation FURIOS 2002-11-08 7 IGR Interessengemeinschaft Regelwerke Technik

Summary Investment Costs Costs RIO Price change Costs PA Min. (%) Electrical 140,000 0 140,000 0.0% Analysis devices 140,000 0 140,000 0.0% Project handling 280,000 0 280,000 0.0% Field devices 770,000 4,489 774,489 0,6% I/O System 420,000 -76,212 343,788 -18.1% DCS incl. Engineering 525,000 -24,795 500,205 -4.7% Installation 700,000 -10,732 689,268 -1.5% Callibration / Quality 140,000 -5,976 134,024 -4.3% IBS 105,000 -2,400 102,600 -2.3% Engineering 280,000 -9,076 270,924 -3.2% Total all Process I&C 3,500,000 -124,702 3,375,298 -3.6% Total relevant Process I&C 2,940,000 -124,702 3,375,298 -4.2% Savings: 338 € per Process I & C point. Note: without Comos PT the saving on engineering would be about 22,752 € higher, resulting in 147,454 € = 4.2/ 5.0% Result presentation FURIOS 2002-11-08 8 IGR Interessengemeinschaft Regelwerke Technik FuRIOS Fieldbus and Remote I/O System Comparison

Summary of operation factors

ƒ Faster commissioning (10 days) ƒ Reduced training expenditure (4,000 €) ƒ Better quality, measuring more accurate ƒ Faster fault repair due to more precise diagnostics ƒ Less calibration repetitions (2,500 € p.a.) ƒ Possibly longer calibration cycle (7,500 € p.a.) ƒ Possible savings by Multi-Variable deviceds ƒ No more linking between measuring range and recipe

Note: All details of this study you will find in the comprehensive publication in atp magazine in Dezember 2002 Result presentation FURIOS 2002-11-08 9 IGR Interessengemeinschaft Regelwerke Technik

Wishlist to manufacturers

ƒ Power supplies (Segment Coupler) with higher supply power (>> 400 mA) would be usefull since many devices need more than 10 mA (is in development) ƒ A valve coupler for PA with Ex(e)-input would allow the actuation of more powerful solenoid valves (exists with FF) ƒ A „Mini-Remote I/O“ for PA with Ex(e)-input (for pulse input, too) would allow the omission of conventional cabling or of a separate Remote I/O als „Rag Collector“ (currently only solutions with auxiliary power are available) ƒ The address range of 126 addresses with Profibus DP is a limiting factor ƒ A Process Near Component should not be limited to two redundant Profibus DP lines (increases the number of Process Near Components, is achieved by many systems; depending on the decentralization concept) ƒ Software for calculation of the producer specific connections is necessary ƒ A simple PA bus monitoring system (trouble shooting in the line) for Resultthe presentation Ex-area FURIOS 2002-11-08 would be useful10 (exists with FF) IGR Interessengemeinschaft Regelwerke Technik FuRIOS Fieldbus and Remote I/O System Comparison

Reminder: methodology of the project

ƒ Selection of a real, typical batch process plant with Remote I/O which had been comissioned short ago ƒ Planning (as far as possible) of a 1:1 comparable solution with Fieldbus (Profibus PA) ƒ Comparison and appraisal of the cost-benefit aspects of the plant realized with Remote I/O versus the plant planned with Fieldbus under consideration of the complete live cycle Æ A generalization or transfer of the results to other requirements (e.g. in respect of redundancy, continuous production, plant orientation) is to be investigated very critically! Æ Clearly the results of this study are not based on the experiences of a completed project Æ In the first projects 'beginners problems' will be encountered. Perhaps the mentioned cost savings cannot be realized. On the other hand: the calculation was rather 'on the safe side".

Result presentation FURIOS 2002-11-08 11 IGR Interessengemeinschaft Regelwerke Technik

Summary of FuRIOS

ƒ For a real, concrete production plant the cost/benefit aspects of Fieldbus versus Remote I/O have been investigated ƒ Without Fieldbus barrier and without valve coupler the utilization of Fieldbus would not have been economically efficient ƒ A combination of Fieldbus and Remote I/O is not economically efficient ƒ In respect of investment costs – under conservative calculation – savings of about 125 k€ resp. 338 € per Process I&C point are to be expected. This is 3.6% of the Process I&C costs and 0.9% of the project costs. Without integrated engineering tool the savings would be 4.2% resp. 1.1% ƒ Project running time is possibly shortened by 10 days resp. 1.5% ƒ In general the results are valid for FF, too (this has not been investigated specifically) ƒ Many of the possible advantages will be realized only when the user makes intelligent use of the new possibilites, not just copies the previous technology 1:1 Result presentation FURIOS 2002-11-08 12 IGR Interessengemeinschaft Regelwerke Technik FuRIOS Fieldbus and Remote I/O System Comparison

Assessment of FuRIOS

ƒ „In view of the relatively small savings, makes the change to this new technology sense?“ ƒ Or, from the other angle: „Isn't it great that a change to a new technology platform is rewarded with savings, even if they are small?“ ƒ Thesis: The Fieldbus will trigger an innovation push with field devices and with users (!), the performance spectrum of which can be realized with Fieldbus only. ƒ Due to these results and considerations Profibus PA is intended for a new plant with Aventis ƒ In one year from now there will be a first experience report, hopefully!

Result presentation FURIOS 2002-11-08 13 IGR Interessengemeinschaft Regelwerke Technik

Statement of the NAMUR-AK 2.6

ƒ The results of this study are plausible and reproduceable for the investigated example. ƒ The study confirms for this specific application the commonly publicated savings potential. ƒ The study confirms that the Fieldbus technology helds additional savings potential over Remote I/O. ƒ Naturally no generalization of the results (dependant on the structure) for all applications is possible. ƒ This working group will investigate if further examples of other plant types should be calculated. ƒ This working group perceives the Fieldbus as a platform for the employment of further functionalities.

Result presentation FURIOS 2002-11-08 14 IGR Interessengemeinschaft Regelwerke Technik FuRIOS 2 Fieldbus and Remote I/O System Comparison

NAMUR General Assembly 2004

Fieldbus Experience Reports

November 04th, 2004

Martin Schwibach, BASF Thomas Meier-Künzig, DSM Sven Seintsch, infraserv höchst technik Dr. Joachim Zobel, Novartis Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 1 Page

Fieldbus Experience Reports

NAMUR General Assembly 2001

Manufacturers and users have to promote Fieldbus technology together.

But:

"Both harm themselves - he who promises too much and he who expects too much."

[G.E. Lessing] Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 2 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

What has happened? / What is new?

Diagnostic function of field devices – workshop on Thursday

Experience reports of 3 users: – DSM – Vitex, the largest Profibus PA application in Switzerland – Aventis/Infraserv – FuRIOS 2 years later – Novartis – Foundation Fieldbus in pharmaceutical environment

Conclusions - "Lessons learnt" Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 3 Page

Fieldbus Experience Reports

Three Multivendor Projects ...

Profibus PA Foundation Fieldbus Version I Version II Device description FDT/DTM

Engineering PCS Cyclic communication

GSD GSD DD DTM CFF DD

fhx

Acyclic communication Engineering field devices Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 4 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Three Multivendor Projects ...

Profibus PA Foundation Fieldbus Version I Version II Device description FDT/DTM

Engineering PCS Cyclic communication

GSD GSD DD DTM CFF DD

fhx Thomas Meier- Acyclic communication Künzig Sven Seintsch Dr. Joachim Zobel Engineering field devices Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 5 Page

Fieldbus Experience Reports

Experience Report

Vitex The largest Profibus PA application in Switzerland Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 6 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Vitex - The Largest Profibus PA Application in Switzerland Ground-breaking Putting up the steel construction ceremony Aug. 01 July 02

25 m high! Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 7 Page 1 year in operation June 04 Start of PCS line test Dec. 02 Fieldbus Experience Reports

Why Fieldbus?

• Successful pilot project with 30 devices in 2000

• The process control system Siemens PCS 7 was already decided -> Profibus PA and not Fieldbus Foundation (FF)

• Cost-neutral compared with 4 .. 20 mA technology

• Advantages with of complex devices (level radar, control valves, flow, ...)

• Sufficient device types available on the market

• Central device parameterisation & diagnosis Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 8 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Why Fieldbus?

• Successful pilot project with 30 devices in 2000

• The process control system Siemens PCS 7 was provided -> Profibus PA and not Fieldbus Foundation (FF)

• Cost-neutral compared with 4 .. 20 mA technology

• Advantages in the case of complex devices (level radar, control valve, flow, ...)

• Sufficient device types available on the market

• Central device parameterisation & device Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 9 Page diagnosis

Fieldbus Experience Reports

Vitex Automation Topology / Electro 4700 I/O

27 units of Siemens PCS-7, V5.2

Profibus DP Total of 450 Total of HART devices 940 PA devices Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 10 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Vitex Topology Profibus PA

Process control system

Profibus DP In praxis 40 to 70 devices (of theoretically 124) Pepperl+Fuchs SK2

1 coupler = 4 devices x 6 multi-barriers x 4 segments = 96 devices

ABB MB 204 Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 11 Page

Random device selection Fieldbus Experience Reports

Vitex Topology Profibus PA

Process control system ABB ProfibusS900 DP In praxis 40 to 70 devices (of theoretically 124) RemotePepperl+Fuchs SK2 I/O 1 coupler = 4 devices x 6 multi-barriers x 4 segments = 96 devices Multi-

ABB MB 204 Festo barriers valve cluster Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 12 Page

Random device selection Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Integration Gaps, Additional Expenditure for Operation

• For radar units, the Endress+Hauser Tool is required (e.g. for envelope curve)

85% • No integration in PDM • Thus, parameterisation of the HART is very laborious Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 13 Page

Fieldbus Experience Reports

Namur NA 64, Status Messages of Field Devices

Example Measures

Failure Device is defective Alarm Change of colour on display Replace device Maintenance Calibrate pH probe Alarm request Change valve head Change of colour on display Plan repair / maintain

Maintenance / Parameterisation at Alarm Function the device Change of colour on control Simulation of the display process value Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 14 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Profibus PA: Diagnosis Prepared for the Operator

NA 64 Maintenance

NA 64 Failure, flashing NA 64 Maintenance request Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 15 Page

Fieldbus Experience Reports

Vitex – Conclusion 1: Earthing & EMC

Plant/Field

S7 ABB Box CPU/CP MB200 PA device

Grounding line, bar locally

EMC • grounded at both cable ends, • Anchor rails are welded to the reinforcing bars acting as grounding bars Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 16 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Vitex – Conclusion 2 • Commissioning • Profibus communication works without problems with all manufacturers • Line test is very simple, self-diagnosis of the bus

• Field device management /central parameterisation • Not all devices completely in PDM • Great advantages with complex devices • Slow (3 – 6 minutes for reading all parameters)

• Diagnosis / maintenance • Realised according to NA 64, well accepted • Status "out of specification" would be helpful • Diagnosis information in conjunction with central Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 17 Page operation promise cost advantages for maintenance Fieldbus Experience Reports

Experience Report

FuRIOS 2 years later Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 18 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

2 Years after FuRIOS

• FuRIOS (Fieldbus and Remote I/O System Comparison) Analysis of the feasibility and the cost/benefit aspects of the Fieldbus from the users' point of view. Presented at the NAMUR General Assembly 2002

Basis for a decision in favour of a Fieldbus installation at Aventis Pharma

• Presentation of the plant

• Have the assumptions of FuRIOS come true? Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 19 Page

Fieldbus Experience Reports

Scope of the Ketek Project

• Process measuring technology realised with Profibus PA • 11 Process-near components • 22 Profibus DP segments

250 drives and inverters • 200 Profibus PA segments • 1600 Profibus PA devices

1230 converters, 160 positioners, 190 valve boxes for the connection of solenoid valves, 20 sensor boxes • 50 Segment couplers • 470 Fieldbus barriers Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 20 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Components

• Control system ABB Melody • Field devices engineering FDT/DTM technology in the PCS • Segment coupler Pepperl+Fuchs SK2 • Fieldbus barriers Pepperl+Fuchs • Field devices Profibus PA: 15 different device types (ABB, Endress+Hauser, Krohne, Knick, Pepperl+Fuchs, Samson, Vega) • Decision in favour of Profibus in November 2002 • Commissioning started May 2004 Commissioning of the first part of the plant is completed Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 21 Page

Fieldbus Experience Reports

Structure

15 different device types

Typically: 4 Fieldbus barriers, 12 devices

Power Link Segment Module Ex coupler (400mA) Line 1 Profibus PA

Line 2 Ex i Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 22 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Special Features of the Project

Creation of a test scenario - Setup of a test segment with different field devices Designing of a commissioning strategy - Address assignment - Communication test - Parameter download Training for installation (method of connection, screening) Project management by the Aventis Engineering Group Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 23 Page

Fieldbus Experience Reports

Experiences

FDT/DTM – Initially, DTMs version 1.2 were not available (or were not operatable) – Full integration of FDT in PCS difficult – Test and certification absolutely required – Status: except for one DTM, all initial problems have been solved Commissioning – Loop check simplified and faster (specialist personnel required) Proof of intrinsic safety – Simplification due to FISCO Training demand for installation and maintenance – New procedure for bus installations – Training demand for all PCE workers Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 24 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Conclusion

• The Profibus technology works, regardless of the manufacturer!

• The use of the FDT/DTM concept integrated into in the PCS is checked for further projects

• The technology makes it necessary to rethink planning and mounting

• There are advantages in terms of time during commissioning

• Future projects at the location Frankfurt Höchst

Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 25 Page are planned to be realised with Fieldbus technology Fieldbus Experience Reports

FuRIOS / Ketek

Ketek confirms the FuRIOS study in regard to the following points: • Faster commissioning • Simpler installation • In the first projects, "teething troubles" must be expected. • Additional benefits cannot be estimated yet, e.g. diagnosis, maintenance, ... Demands on manufacturers • Redundant coupler, higher power output • Field devices in two-wire technology Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 26 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Experience Report

Fieldbus Foundation Applications at Novartis Pharma AG Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 27 Page

Fieldbus Experience Reports

Foundation Fieldbus DeltaV V6.3/7.3 (Emerson) CEP & WSH2984/B150 projects CH, UK

Project No. of Installation Note devices status

Production CEP 2 1200 800 Performance Control development Basel/CH (67%) Qualification in the field

WSH2084 1500 260 In FF as Basel/CH (18%) operation I/O bus

B150 4600 830 Performance FF as Grimsby/UK (18%) Qualification I/O bus Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 28 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

What do we expect from Fieldbus systems in production plants?

• All functionalities of 4…20 mA devices reliability, Ex, 2-wire technology, simple layout …

• Additional expectations for Fieldbus systems include improvements regarding: - Commissioning - Validation - Maintenance/diagnosis (workshop)

• Costs: if possible lower! Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 29 Page

Fieldbus Experience Reports

Foundation Fieldbus in Novartis WSH2084/B150 Projects

Server Operator Station

Ethernet

FF H1 card Power PCS supply

350 mA Foundation Fieldbus 3 field barriers (max.)/segment Repeater 4 Fieldbus instruments (max.)/field barrier

Remote I/O T

Scales (NAMUR) Exotics Contacts Foundation Fieldbus: - Control valves - Flow - Temperature - Pressure Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 30 Page - pH

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Multivendor Instrumentation

Ɣ ABB Ɣ Krohne Ɣ Samson

Ɣ Endress+Hauser Ɣ Pepperl+Fuchs

Ɣ Topworx

Ɣ Emerson/Fisher Rosemount Ɣ Relcom Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 31 Page

Fieldbus Experience Reports

Installation in the Field Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 32 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Experiences: As reliable as 4…20 mA???

All Fieldbus devices cyclically transfer their measurement value to the PCS correctly!!!

BUT: Fine tuning is required:

- Optimisation of the communication - Additional functionalities of the Fieldbus system Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 33 Page

Fieldbus Experience Reports

Experiences: As reliable as 4…20 mA???

Errors occurred:

Cause Remedy/ Note updates

Interoperability Hardware: 2 Communication error Software: 2 & optimisation Non-volatile Hardware: 1 Expected more often in memory Software: 1 case of control in the Ongoing field! New device Software: 2 Identified by means of diagnosis & audit trail

Diagnosis, Hardware: 1 "Cosmetic errors" DD: 1 Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 34 Page operation

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Experiences: Commissioning

• Here: Start-up time comparable with 4…20 mA

• Potential for optimisation detected: Automatic identification (serial number) insufficient ĺ Instruments must be pre-parameterised (manufacturer)

Parameterisation with a central engineering tool ĺ Very helpful and simple functionality (control system specific) Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 35 Page

Fieldbus Experience Reports

Experiences: Validation

• Continuous audit trail up to the fieldbus device - GxP-complient records for all changes of the device software ĺ (also helpful for identifying software bugs) - Control system specific!

• Greater calibration ranges with the same accuracy

• Currently no paper printout possible (addressed) - Control system specific! Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 36 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Experiences: Costs

Number of Fieldbus devices / segment

FOUNDATION Fieldbus max.: 12!

Caused by the higher data flow on the FF bus! Influences cycle time! Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 37 Page

Fieldbus Experience Reports

Experiences: Costs

• Slightly more expensive than 4…20 mA because: - Lower number of Fieldbus devices/segment - Additionally 2 Remote I/O systems installed (solenoid valve cluster, collector for remaining signals) Optimisation by reduction to 1 Remote I/O!

• User demands: - Possibility of connecting binary signals - Safety functionality (SIL) via the bus Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 38 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Conclusion

Ɣ Main problems of the new technology have been solved, Proven Solutions have been installed at Novartis. Ɣ A fundamental advantage of Foundation Fieldbus & Delta_V for Novartis is the audit trail integrated in the control system.

Ɣ Potential for optimisation identified: - Commissioning - Diagnosis - Cost reduction Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 39 Page

Fieldbus Experience Reports

Working Group 2.6 Fieldbus

Conclusions - "Lessons learnt" Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 40 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

NE105 - Integration of Field Devices

Investment protection The device integration as part of the automation system must not reduce the life cycle of the overall system. A core demand: Configuration tools Device description

Version 1.0 Version 1.0 9

Version 1.2 ? ! Version 1.2 9

Version 2.5 Version 2.5 Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 41 Page ? Fieldbus Experience Reports

NE105 - Integration of Field Devices

Investment protection The device integration as part of the automation system must not reduce the life cycle of the overall system. A core demand: Configuration tools Device description Manufacturers accept the NE 105 Version 1.0 Version 1.0 in its entirety 9

Version 1.2 ? ! Version 1.2 9

Version 2.5 Version 2.5 Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 42 Page ? Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Breakthrough in Connection Technology: Fieldbus Barriers

Typical Fieldbus technology in the year 2000

Profibus DP

... Segment coupler Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 43 Page

Fieldbus Experience Reports

Breakthrough in Connection Technology: Fieldbus Barriers

Typical Fieldbus technology in the year 2004

Profibus DP

Segment coupler Termination

Fieldbus barrier Fieldbus barrier Fieldbus barrier Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 44 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Breakthrough in Connection Technology: Fieldbus Barriers

Typical Fieldbus technology in the year 2004

••ReductionReductionProfibus of of the the DP wiring, wiring, planning planning and and installation installation costscosts •• Greater GreaterSegment flexibility flexibility due due to to spurs spurs (30-120m) (30-120m) •• Greater Greatercoupler number number of of field field devices devices per per segment segment ••IncreasedIncreased availability availability:: Termination •• Each Each channel channel short-circuit short-circuit protected protected Fieldbus•• Intrinsically Intrinsically barrier safe safe EEx EExFieldbus ia ia IIC IIC barrieroutputs outputs according accordingFieldbus to to FISCO FISCO barrier ••44 providers providers on on the the market market (ABB, (ABB, CEAG, CEAG, P+F, P+F, Turck) Turck) ••ReplacementReplacement of of a a field field device device during during operation operation possiblepossible Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 45 Page

Fieldbus Experience Reports

Knowhow Change in Planning and Maintenance Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 46 Page

Fieldbus Experience Reports FuRIOS 2 Fieldbus and Remote I/O System Comparison

Knowhow Change in Planning and Maintenance

Planning • Location and functionality of the field devices determine the bus topology • Simple segment planning • Simple proof of intrinsic safety due to FISCO

Commissioning • Less sources of error •Faster • Preconfiguration of the device identification (tag) by the manufacturer on placing the order recommended

Maintenance / diagnosis • Different troubleshooting procedure • Different qualification profile for service personnel • Profibus PA: diagnosis standardisation suitable for practice

Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 47 Page • Foundation Fieldbus: Manufacturer-specific diagnosis possible

Fieldbus Experience Reports

Final Conclusion

• Better economics due to fieldbus barriers • Diagnosis offers new possibilities • Profibus PA is ready for use • Users that have experience with RIO and Profibus DP will be able to use PA • Positive experiences in multivendor projects • Foundation Fieldbus can be used in principle: • Complexity requires special knowledge • Functionality is sometimes PCS-specific • In case of multivendor installations, teething troubles must be expected • Device integration • Existing problems are not fieldbus-specific

Martin Schwibach, BASF AG BASF Schwibach, Martin DSM Thomas Meier-Künzig, Infraserv Seintsch, Sven Novartis Joachim Zobel, 48 Page • NE 105 must be implemented (certification ...)

Fieldbus Experience Reports FuRIOS Fieldbus and Remote I/O System Comparison

Push-button telephones were the first step on the way to the mobile phone New technological platforms in the field of automation technology can only be achieved with the fieldbus

The results of the fieldbus and Remote I/O system comparison FuRIOS caused quite a stir at the NAMUR general assembly beginning of November 2002 and triggered off renewed discussions between manufacturers and users about the application of the fieldbus technology. Over the last few months several enterprises have decided to start with fieldbus projects. FuRIOS could prove to be the breeze that fans the further development of the fieldbus. The journalist Dr. Christine Eckert spoke about this with two of the initiators of the FuRIOS study: Manfred Dietz from Infraserv Höchst and Dr. Thomas Tauchnitz from Aventis Pharma Germany.

Dr. Eckert: FuRIOS compares the costs of a real, one solution, nothing can be changed here. The use of working plant equipped with Remote I/O sys- the ABB control system inevitably leads to the use of tems with those of a calculated one-to-one refer- Pepperl+Fuchs couplers. They are not in the program ence solution based on the fieldbus technology. merely because Pepperl+Fuchs were the instigators of How does that work? FuRIOS. It would quite simply have cost us our credi- bility if we had chosen couplers from someone else. Dr. Tauchnitz: Well, it’s basically a thought experiment. We take a reference plant – one that Dr. Eckert: Why are the segment couplers, valve is so new that it would be equipped in exactly the coupler boxes and fieldbus barriers so crucial for same way again – and we ask the question: How the economic feasibility? would it have looked like if it had been based on Dr. Tauchnitz: They make it possible to connect a the fieldbus? It’s a very simple concept. larger number of devices to a PROFIBUS PA line. Discussing the benefits and disadvantages of This saves on installation and cabling costs. If we fieldbus on the basis of virtual solutions is too assume that 500 signals have to be collected and complex and abstract. Other companies have each PA line can deal with only six or seven sig- other methods, they structure their plants differ- nals, 80 segment couplers would have to be used ently. We tailored our approach to our plants. The and 80 cables have to be led? from the non-ex other users should now look at the calculations area to the hazardous area. This costs twice as for their plants. I think the comparison of the much as 40 segment couplers and 40 cables. If we results could be very interesting. had had such a small number of signals per PA M. Dietz: There would always have been doubts as to line and needed that many cables for it, it would whether our assumptions were realistic. Now the users quite simply have been more expensive than the can say: "Our plants are different" if they want, but Remote I/O. they cannot go past the fact that a real plant has been M. Dietz: In other words, connecting seven devices to investigated. one line means only one seventh of the cables are need- Dr. Eckert: What were the criteria for choosing ed. Just imagine the fieldbus as a kind of high-tech the components for the calculation? washing line – you hang your shirts and trousers on it and save yourself a lot of work compared to if you had M. Dietz: We had an unrestricted choice of the field- to drive new posts into the ground and stretch out bus components. It must be said, however, that the new washing lines for each garment individually. It Pepperl+Fuchs FieldBarrier is currently the only field- halves the expenditure for installation and compo- bus barrier we accept, as it is the only one with the nents. A doubling to up to 30 devices is possible once required galvanical isolation. In the case of the cou- the energy supply problem is solved. With 2 amperes plers, the control system was the decisive factor. The of supply current we could have hung a lot more same control system will be installed in the new plant washing out to dry – to stay with that metaphor. At as is in the reference plant. Of course, with a one-to- that time we didn't have a 2 ampere coupler available. FuRIOS Fieldbus and Remote I/O System Comparison

However, we currently have one under test. FuRIOS get that little bit closer to the summit – the last has shown that fieldbus barriers with more supply four percent. But what they are forgetting is that current are needed. If we had started the project a year the mountain is a volcano. It is growing all the earlier, the result would have been clearly in favour of time. New technologies are becoming available the Remote I/O systems. I am absolutely convinced of that don’t work without the fieldbus. For exam- that. As it turned out, this was just the right point in ple the famous thermometer probe. It measures time, although we didn't know that beforehand. With the temperature at ten places in the boiler. That every year that passes, the result will be more and simply isn’t possible with 4 to 20 mA. You can more in favour of the fieldbus. only make full use of the growth of this mountain and the benefits of the technology if you climb Dr. Eckert: What speaks for the fieldbus technol- that last little bit as well. Technologically speak- ogy and what additional possibilities does the ing the Remote I/O was not an innovation. What new technology open up? remained was the same mountain and an ana- Dr. Tauchnitz: With regard to the required invest- logue signal. ment, the result is quite sobering. Saving four Dr. Eckert: What benefits do modern field percent on the investment costs is not chicken devices have and what might the device of the feed, but it’s not the world either. A cost calcula- future be like? tion without couplers, fieldbus barriers and valve coupler boxes would presumably have been four M. Dietz: A field device connected to Remote I/O is percent more expensive. Then we would have an appendage tagged onto the system, and you have to had to base our argumentation on the life-cycle see how you can gain access to the parameters. A field costs alone. The way it turns out now, it is much device on a fieldbus is an integral part of the system. simpler. Both the investment costs and the life- That alone just about says it all. With Remote I/O sys- cycle costs can be named as benefits. In the inter- tems you isolate yourself from this development. The nal discussions those four percent are definitely field device of the future will be multi-functional and an issue. will make asset data accessible. Even if we only want to mention diagnosis briefly – we can expect all sorts M. Dietz: FuRIOS compares fieldbus and Remote I/O of things to happen there. All the companies that cur- with the same equipment functionality. Today I always rently speak of diagnosis on the field devices have just end up with the same measurement, regardless of developed the kilometre counter. If I take my car to the whether the pressure transmitter is connected to the garage nowadays, they stick a diagnosis plug into it fieldbus or to the Remote I/O. In five years from now and it tells me what I did wrong, what is broken and the discussions will be completely different. The addi- what maintenance means. The basis for all this was tional opportunities provided by the fieldbus technolo- the kilometre counter, and in the field of diagnosis gy couldn't even be considered in this comparison of tools we have only just reached this level. What can be the two systems. At this moment the difference is min- expected from future diagnosis alone already justifies imal, but that will change. Those who have fieldbus the fieldbus. Diagnosis means: I ask the appliance if it will be prepared for a world of innovative measure- will require servicing already at the next plant stand- ment technology. Those with Remote I/O systems will still in four weeks or whether it can wait till the fol- only be able to look back to the past. There is nothing lowing standstill in thirteen months time. This is the new coming to keep Remote I/O up to date. way towards predictive maintenance and can only be Dr. Tauchnitz: Mr. Rathje from Bayer, a member realized with the fieldbus technology. of NAMUR, once said: “When we have fieldbus, Dr. Tauchnitz: Only the fieldbus technology can we will save 40 % of our costs”. I like to use the keep up with the growth of the mentioned vol- analogy of a mountain. Remote I/O takes us cano. The devices that will be on the market in around 90 percent up the mountain. That means ten years time will have possibilities that cannot around 36 percent of savings. Many people now be utilized with 4 to 20 mA. Dr. Kegel from say: It isn’t worth changing the technology just to Pepperl+Fuchs once compared this to the devel- FuRIOS Fieldbus and Remote I/O System Comparison opment of the telephone: “At some stage the dial nology that won’t support new appliances in five had to be replaced by buttons. It didn’t have any years time. Engineers don’t like to gather old significant benefits at the beginning, but mobile material that costs, and then has to be disposed telephones would never have been possible with- of. Using a new technology holds the same risk out push-buttons. Today we can do our banking than sticking too long to an old one. We are con- with the cellular phone or send pictures all over vinced that the project will be a success, other- the world at the touch of a key. So the step from wise we wouldn't be doing it. the dial to the button was essential. And this is M. Dietz: All plants are unique. As long as there is exactly the same step we have to take today, oth- new equipment being launched onto the market there erwise we won’t be able to make the technologi- will be start-up difficulties. This is true of all devices, cal transition to a new platform. be they fieldbus or not. We calculated everything in Dr. Eckert: The industry park Höchst is a pioneer FuRIOS. Even more, the testing laboratory at in this field. What problems do you anticipate Infraserv Höchst is at our disposal at all times, with when building the first plant? its manpower and specialist know-how. If any suspi- cion should ever arise that something doesn’t work Dr. Tauchnitz: With Remote I/O systems we properly, every manufacturer involved will do every- already have the PROFIBUS DP interface in oper- thing in his power to solve the problem. Do you think ation. Instead of Remote I/O a fieldbus isolator a project fails because one manufacturer doesn't do will now be used and the fieldbus barriers and what is required of him? Perhaps the follow-up pro- valve coupler boxes lie beneath them. If there jects will be a little less expensive, but never before has ever will be a communication disturbance a technology been as perfect before its market launch between the process control system and one of as the fieldbus is now. We are convinced that it will the field devices, that device and only that one work. If we weren't, how could we possibly expect will have a problem. I don’t see any risk that our others to be? complete plant could be brought to a standstill. It is still the same PROFIBUS DP as is being used with the Remote I/Os, and it has proven itself there.

M. Dietz: The team at Infraserv Höchst will test the communication of the entire system in advance and will support the project team throughout the entire completion time. The key to success is the timely training of planners, plant administrators and man- agement staff. It would be very counter-productive if the staff suddenly had to go to a training course just when the commissioning of the plant is entering the critical phase. I hope that we will be able to start the training courses for the PROFIBUS PA at the begin- ning of March latest.

Dr. Eckert: Won’t the other users wait until all the start-up difficulties have been done away with?

Dr. Tauchnitz: There are no signs that the other companies intend to sit back comfortably and watch for a year and a half until our plant is fin- ished. In those eighteen months they would acquire new equipment that is based on a tech- FuRIOS Fieldbus and Remote I/O System Comparison

Savings are not the goal of Fieldbus Digital communication technology makes user’s dreams come true in regard of diagnosis

The dutch chemical and pharmaceutical company DSM is among the first in the use of fieldbus technology. Future oriented diagnosis and device functions in process automation are based on this technology. Frans van Laak, leader of the NAMUR working group „fieldbusses” and his colleague at DSM TechnoPartners, Mr. Harry van Rijt, are advocates of this new technology. The journalist Mrs. Dr. Christine Eckert talked with these two automation experts about their experiences with fieldbus and its future aspects.

Dr. Eckert: Which chances does the fieldbus offer for testing purposes. Following that we conduct- in process automation? ed a field test with an existing plant with eight buses. After some start-up problems it is running F. van Laak: Certainly the fieldbus does not have the smoothly since one year. All these projects are main goal to save on cabling costs. On this basis, in based on Foundation Fieldbus since, several years my opinion, we do not need to discuss. If we want to ago, our company took the decision to use move on in our field of expertise, make it broader and process control systems from Honeywell und better, than we need the fieldbus. Especially in regard Emerson. But DSM operates a Profibus plant, too. of diagnoses we expect quite a lot of this technology – not only for individual devices, but for whole segments Dr. Eckert: In regard of the real plant, which of a plant. What has been there first: the egg or the forms the basis of the calculations of FuRIOS, chicken? Without fieldbus there will be no develop- there are savings of about four percent to be ment in diagnosis. expected. Is it worth to implement a new technol- ogy for that? Dr. Eckert: Will DSM only use fieldbus technology in the future? F. van Laak: When Mr. Tauchnitz presented the results of the study at the NAMUR general assembly H. van Rijt: This is a complicated question. Fact 2002 he made pretty clear: “Isn’t it great that we talk is, that in April we will comission a production about a new technology and can achieve cost savings plant with 28 lines and 300 devices, all based on already in the investment phase?” Cost savings are fieldbus technology. happily accepted but they are not the main reason. In Dr. Eckert: This is a different level of size com- that respect I can only agree. pared to the plant planned by Aventis with about Dr. Eckert: Do you think that the savings could 2000 devices. Is DSM moving towards bigger be even higher after a certain start-up period? projects step by step? F. van Laak: Yes, certainly. Nowadays fieldbus F. van Laak: I would not say so. This is quite a devices are more expensive than conventional devices. normal production plant. Our field test is a pro- With increasing production numbers the prices will duction plant, too. It is categorized in a lower risc drop significantly. Here some more savings are possi- class, but it operates with fieldbus. Two more pro- ble. But, as already mentioned, savings are not the pri- jects are in the planning stage. mary goal of fieldbus. In the beginning the devices will Dr. Eckert: Do the results of the study “Fieldbus become more expensive, because they will incorporate and Remote I/O System comparison” (FuRIOS) more features. It is utopical to expect that the produc- have any positive influence on your decisions for ers will create these new tools free of charge. future fieldbus projects? Dr. Eckert: One major argument for the fieldbus H. van Rijt: FuRIOS has no influence. Already are the diagnosis functionalities. What is your two years ago we created a comprehensive cost judgement regarding the tools which are current- model and built a laboratory with two fieldbuses ly available? FuRIOS Fieldbus and Remote I/O System Comparison

F. van Laak: Basically one cannot really speak of Dr. Eckert: Do the planners of new plants take diagnosis yet. Most often it is just a check on failures. these new posibilites into consideration? But the field devices became more stable during the F. van Laak: No, and that is not to be expected. last decades, the failure rates are very small. The goal Aachen and Cologne have not been built in one day, is to combine the diagnosis with the process itself. too. I hope that the planners understand why the field- Temperature verification of the specific transmitter is bus technology is so essential. Of courxe, not all possi- already offered by many producers. This is a start, at bilities are available immediately. It simply needs time. least, with the temperature transmitters. Really inter- The fieldbus offers the progress in our field of expertise. esting is the monitoring of the thermo element in regard to long-term accuracy. Ideally calibration Dr. Eckert: In your opinion, will Remote I/O sys- would not be necessary any more! tems vanish completely from the market?

H. van Rijt: One more application of modern F. van Laak: DSM still affords the luxurity to think diagnosis is the Blocked Line Detection. With this of new technologies. We are not the only, but among the pressure transmitter sends an alarm signal if the first companies who try to use the fieldbus technol- the duct is closed or blocked. These tools are ogy. There will be always users who are not brave already available, but currently only with enough or who are not at all thinking of fieldbus. Foundation Fieldbus devices. Profibus will cer- These will stay with Remote I/O. tainly follow, but the basic requirement for all Dr. Eckert: Consequently you do not deem diagnostic functions is the fieldbus. One more Aventis as very brave because they will start advantage is the automated fault signalling. working on a big fieldbus plant? When using HART we have to contact the trans- mitter each time and ask for the diagnosis data. H. van Rijt: For these people who know what they talk about it is not a very brave step. For F. van Laak: With fieldbus we have nothing like that outsiders it may look like a jump into cold water. to do. These informations come automatically since But for people who have the appropriate exper- they are included in every cyclic data exchange. tise and who know where the problems might be H. van Rijt: Such functions need more processor hidden this is not really a question. capacity and more energy which the 4 to 20 mA Dr. Eckert: With Foundation Fieldbus the plant technology simply cannot deliver. If the proces- design is slightly different than with Profibus sors get faster by the factor ten than they will because of the structure and functionality of the have the same frequency as a microwave device. Control System. Major elements are device power Nowadays a PC has a 2.4 GHz processor, over the bus, power conditioners and fieldbus microwave devices have 24 GHz. High-perfor- barriers. How essential are these for economic mance processors need more energy, and ulti- efficiency of a plant. mately this says everything. The conventional technology simply has reached its limits. F. van Laak: Without these components the design would be straightaway catastrophic, even without tak- Dr. Eckert: Apart from the diagnosis, which fur- ing the plant reliability into account. The new fieldbus ther functionalities do you see as necessary, being components allow a much more simple structure and the users of these new devices? reduce the fault-sensitive elements significantly.

F. van Laak: In my opinion the development of multi- Dr. Eckert: FuRIOS draws the conclusion that variable and multi-sensor devices will pick up speed, intrinsically safe fieldbus barriers are not eco- triggered by the fieldbus. With theses devices the inter- nomical. In your opinion: is the version in ferences in the process can be reduced. In principle increased safety sufficient? each flange is a weak point. Less flanges mean less risk. Even the EU authorities are working on the min- F. van Laak: We as NAMUR requested the possibili- imization of potential leakages. ty to connect the devices intrinsically safe. But there is FuRIOS Fieldbus and Remote I/O System Comparison no reason why a main cable should be intrinsically Dr. Eckert: Have you already connected compo- safe. Is a compressor in the plant intrinsically safe? nents from different suppliers in your practical Why than has the fieldbus to be it? How often do we experience? work on a main cable? Never! We have to work where the devices are connected. Once the main cable is F. van Laak: We did some testing. The possible sav- installed it will be there for 25 years, at least. ings are, in view of the complete project, only peanuts. Incendently the version in increased safety is cheaper, This is the reason why I keep saying that power sup- too. But the driving force is reliability, and this is ply, conditioner and fieldbus barriers are one system. much more important for me. The Power Conditioners Together with the appropriate fieldbus cables this will have no electronics. So this cannot break and block a be a solid, coherent solution. complete segment. Reliability simply is a better argu- Dr. Eckert: ment than price. Will fieldbus be successful? F. van Laak: Fieldbus in itself is only the means. It is Dr. Eckert: In respect of the mentioned all about the devices and their functionalities. In five relieability : Should the various fieldbus compo- years from now we will speak quite differently about nents be available from one single source? the fieldbus than we do today and the conventional F. van Laak: We as user would wish that. The system technology will not play a significant role any more. of fieldbus powering, conditioner and fieldbus barrier One can fight against new technologies, but the can varied only inside tight limits. Most problems are progress cannot be stopped. created from the power supply. Due to reliability we want as few active components on the trunk as possi- ble. Consequently no active conditioner. A resistor or a coil are hardy ever defect. The weak points are transis- tors and integrated circuits. The other side of the medal is the missing galvanic isolation with a passive conditioner. This isolation works as a kind of “dirt fil- ter”, for dirt coming from the power supply. For dis- turbances coupled onto the trunk even a galvanic iso- lation has no use. The power supply unit needs to have a appropriately high quality. DSM uses only pas- sive conditioners. At the moment only two suppliers offer powerful devices with 1 Amp or more.

H. van Rijt: Looking at the hardware-side not all devices have the same quality for the bus connec- tion. The snsitivity for disturbances or for varia- tions in the amplitude are different. All devices meet the respective standards more or less, but not all of them in the same way. Unfortunately the differences in quality are rather big. A bad fieldbus power feed module might create prob- lems with low-quality fieldbus devices. With high-quality fieldbus devices the power supply is less critical. Seen from the pure technical point of view it is possible to use components from differ- ent producers. But I think it is sensible to have the complete system from one supplier. Here the supplier can guarantee for the full communica- tion chain. Our preferred system would be one designed for maximum interoperability of all the system components. FuRIOS 2 Fieldbus and Remote I/O System Comparison

From theory to practical operation Aventis builds pharmaceutical production plant based on FuRIOS Study

Two years ago Aventis Pharma Deutschland and Infraserv Höchst Technik conducted the FuRIOS study (Fieldbus and Remote I/O System Comparison) in order to evaluate the cost/benefit aspects of fieldbus tech- nology and to increase its acceptance in the process industry. This system comparison convinced the producer of pharmaceuticals and soon after publication of the study Aventis started to turn these theoretical considera- tions into real practice. The Ketek plant is the first automated production plant which follows the recommendations of FuRIOS.

FieldConnex® from Pepperl+Fuchs in the Ketek tank farm: The new plant for pharmaceutical agents pro- Bodo Bartscheit, project manager Process C&I at duces several stages of the new antibiotic Ketek Aventis. Not without some pride, since the com- for treatment of acute respiratory infections. The plete project was under the full responsibility of instrumentation of the plant is based completely the team. In order to optimize the coordination on fieldbus technology, which makes it one of the with the engineering company his colleague most modern of its kind. The only exceptions are Harald Hauch, project manager automation, the safety oriented applications and a few acted as interface between plant operator and ser- remaining conventional signals. The cost for the vice companies. For the creation of commission- Process C&I are about 12 million Euro. The plant ing and installation procedures as well as is divided in 200 Profibus PA segments with a training of personnel Aventis took the specialists total of 1.600 Profibus PA field devices. Two pro- of Infraserv Höchst Technik on board, thus taking duction lines comprise 15 device types of seven advantage of the experienced team which had different manufacturers, all of them working fully already been involved in conducting the FuRIOS interoperable. The control system is supplied by study. ABB. The complete fieldbus installation for FuRIOS is a classical evaluation which took a real device connections in explosion hazardous areas plant, working on Remote I/O technology, and follows the fieldbus barrier concept and is real- projected it 1:1 to fieldbus technology – with ized by means of the FieldConnex system of absolutely identical requirements. With the Ketek Pepperl+Fuchs. project Aventis followed these prerequisites and „Ketek is one of the largest projects of our project designed topology and instrumentation accor- team. In some areas of engineering and construc- dingly. “Maybe we designed 1:1.01 on fieldbus. tion we have been supported by Siemens“, says But in general the design work went as usual“, FuRIOS 2 Fieldbus and Remote I/O System Comparison says Dr. Thomas Tauchnitz, former manager of had to do a lot of things several times, since there technology and projects at Aventis agents. Many were modifications and adaptations ongoing all of the advantages of digital technology can only the time“, explains Sven Seintsch of Infraserv take effect if the planner uses the new possibili- Höchst Technik. Changes during the planning ties in an intelligent way. But here the practical process are daily business in pharma projects. “In experience is missing. „The engineering teams that respect the advantage of fieldbus has to be still follow the conventional technology since estimated even higher since the user gets much they know all its nooks and crannies. One uses more flexible”, says Dietz. “The first plant his leeways only after a certain experience is showed how this reduced project time can be gained“, knows Manfred Dietz, head of the test used sensible. Detailed planning of Process C&I laboratory at Infraserv Höchst Technik. This can start later, is installed later in the plant and counts especially regarding the application of thus saves a lot on modifications since the pro- multivariable devices which had not been consi- duction process is already stable“, confirms dered in FuRIOS. “At 10 out of 2,000 measuring Bartscheit. The logical consequence: the plant can points we used the functionalities of multivari- go into operation earlier and this means money able devices. Here we go one step further than in the pocket. FuRIOS“, explains Bartscheit. At no time any of the hardware problems endan- gered the faster commissioning. The Profibus New technology means rethinking software worked without problems, too. The All team members underestimated the demand same the project members could not state for the on training. One point which is unfavourable for FDT/DTM software (see box). “The commissio- fieldbus only at the first glance since the demand ning of the Profibus lines went without problems is much higher with Remote I/O technology. in terms of the hardware. As an average it took With Remote I/O Systems new field devices and only one day for 30 devices. One more advan- new operation philosophies show up all the time tage, compared to older times, is that marshalling and the personnel has to be trained anew for each faults do not occur”, Seintsch sums it up. This is project. „Somebody fit on Profibus is fit. It is one seen as a real success by the fieldbus experts. single learning process only”, confirms Dietz. Bartscheit: „Ultimately a lot of apprehensions “With each technology change the initial trai- proved wrong and we searched for problems nings take the most effort since one has to start at which simply did not exist.“ zero.” The manager of the test laboratory knows Once the teething problems are solved and the what he is talking about since he and his team users are familiar with the new technology, its conducted all Profibus training sessions during benefit will be increased even more. Realization this project. of the many chances offered by fieldbus technolo- Everybody has to learn the new technology – gy requires a certain experience. “At the moment installation personnel, planner, engineers and everybody is happy when the bus is working”, managers. “In order to take full advantage of the says Seintsch. “Aspects such as process optimiza- fieldbus benefits everybody has to know what tion, diagnosis and maintenance are still some this technology can do and what not”, says Dietz, way out. Only after the technology is established and Tauchnitz adds: “Every trainee learns how to the user will start to pay attention to the mass of connect 4 mA … 20 mA in his first year. How to additional information he gets for free by the connect Profibus PA? This we had to work out, bus.” In the expert’s opinion the discussion on write down and teach to every employee.” The added value of fieldbus is just starting. specialists are sure: this was a good investment All concur in one more point: The new Profibus for the Profibus newcomers. Dietz: „Companies plant confirms the predication of FuRIOS regar- can save on trainings, but this will backfire du- ding faster commissioning and more simple ring operational maintenance.“ installation. Fieldbus technology and fieldbus barrier concept have definitely proven their suit- Time is money ability for daily use, and this gets around. At pre- The experiences of this pilot project show that sent there are two major projects and one smaller there is savings potential in commissioning. “We one with fieldbus technology in Industriepark FuRIOS 2 Fieldbus and Remote I/O System Comparison

Höchst at Frankfurt, Germany. Furthermore there fieldbus-fan Tauchnitz. „People who are not are many more ongoing projects at other loca- brave enough by now cannot be helped. At this tions of the former Höchst company. “The time is location there will be no new plant designed ripe for digital technology. If we want to get out without fieldbus, this is certain!” of this antiquated 4 mA ... 20 mA device techno- logy we desperately need the fieldbus“, says Dr. Christine Eckert, journalist

FDT/DTM Project scope FuRIOS and the considerations regarding Ketek are Control system ABB Melodie focused on the theme of fieldbus only. The study did 11 process near components, DCS‘s not cover field device engineering and therefore does 22 Profibus DP segments not give any assessment on its advantages or disad- 250 Drives and Converters vantages. For the first time, the integration of the 200 Profibus PA segments 15 different device types was done directly in the 1600 Profibus PA devices control system. The project team decided to use the 1230 Transducers, FDT/DTM Technology as integration tool. Since 160 Positioners this technology is rather new it raised several ques- 190 Valve Boxes, tions all through the project. It required a lot of 20 Sensor Boxes persistence and competence of all involved persons to 15 different device types manufactured by ABB, master these obstacles. At first glance this seems to Endress+Hauser, Krohne, Knick, be contradictory to the statement ‘fieldbus is ready Pepperl+Fuchs, Samson, Vega for practical use’. However, at a closer look one sees 50 Segment Couplers Pepperl+Fuchs SK2 that device engineering is a completely different 470 Fieldbus Barriers Pepperl+Fuchs FieldBarrier subject, independent of fieldbus. Field device engineering FDT/DTM technology in Control System FuRIOS 2 Fieldbus and Remote I/O System Comparison

Opinions

Dr. Volker Oestreich Richard Timoney Managing Director Profibus User Organisation President and CEO of the Fieldbus Foundation Previously, processing Foundation™ fieldbus industry has taken a uses the performance capa- somewhat tentative appro- bilities of the intelligence ach towards fieldbus tech- distributed throughout the nology and insisted on field devices to increase proof of problem-free ope- plant performance. It is ration. The background to particularly suitable for this lies, on the one hand, use in mission-critical in the long plant lifetime of applications where data typically 20-30 years and, transmission and the high on the other hand, in the reliability of single-loop high risks and hazard integrity are required. Two potential inherent to such concrete examples clearly equipment. In the meantime, however, the advantages demonstrate the great savings potential which can of the technology are undisputed and fieldbus techno- be exploited with this digital technology. Unplanned logy is finding increasingly wide acceptance and process shutdowns represent the largest individual application. Just last year, fieldbus technology achie- source of lost profits. This downtime, which is particu- ved an important breakthrough thanks to successful larly harmful in continuous process operations, is con- installations in full-scale operations and due to siderably reduced due to the modern diagnostic func- various NAMUR recommendations. The experience tions of fieldbus technology. A manufacturer can also reports of different users at the latest annual general obtain enormous benefits from this technology with meeting of the association of users of process control regard to high maintenance costs with the use of pre- technology, in my opinion, were a red-letter day for dictive maintenance processes which enable intelligent fieldbus technology. Of course, as the Managing management of essential physical plant assets and Director of the Profibus Nutzerorganisation (PNO), which lead to a large reduction in operating costs. I was particularly delighted with the explicit praise These costs really do offer plenty of opportunities for given to Profibus PA. Initially, the advantages of field- savings. In a study conducted by Dow Chemical, it bus technology were seen to lie in cabling and was discovered that 63 percent of trips to the field by engineering aspects. However, the real added value - maintenance staff were either for routine checks or no provided by new diagnosis possibilities and improved problem existed at all. Additionally, in a similar study, asset management which has a positive effect on life- it was found that 86 percent of maintenance is reactive cycle costs – will only become fully apparent during (too late) or preventative (unnecessary) whereas, with the coming years of plant operation. I assume that in a predictive/proactive approach, best practice is 40 future there will be a small number of new plants only percent. The number of process plants which are put- which are set up without fieldbus systems. There are ting their faith in this technology is increasing year by also many good reasons for installing this new techno- year. Worldwide, there are already more than 400,000 logy when existing plants are refittet. With Profibus fieldbus devices and 5,000 hosts systems installed in DP and PA, on the basis of one standard communica- plants. Currently, key industries such as petroleum tion protocol, Profibus represents the key to successful and natural gas, chemicals, pharmaceuticals, hybrid applications. Worldwide, it is the only fieldbus utility supplies, paper manufacturing as well as consu- which can master discrete and continuous or batch mer goods manufacturing are constructing new large applications equally effectively. Profibus offers the installations all over the world where this technology processing and manufacturing industry a comprehen- is integrated. In Europe too, particularly in countries sive automation concept for all stages from inbound such as Russia, Poland and Germany, the technology logistics through production to outbound logistics. is becoming state-of-the-art – as the results of a recent study by the ARC Advisory Group have proved: So, whether modernization or new installation, big or small, Foundation fieldbus is the technology of choice. FuRIOS 2 Fieldbus and Remote I/O System Comparison

Opinions

Martin Schwibach Marc Van Pelt speaker of the NAMUR Working Group 2.6 ‘Fieldbusses’ Vice President – Europe, Middle East & Africa Operations Fieldbus technology is Fieldbus Foundation mature enough for practi- On top of the classical cal use although there is, savings on cabling and the for example, a certain investment costs reduction requirement for develop- fieldbus opens, due to its ment work regarding field diagnosis functions, the device integration and implementation of diagno- possibility of reducing stics. However, now that maintenance costs. This the first fieldbus installa- makes it an important con- tions have successfully tributor to plant efficiency. started working, the user The Foundation Fieldbus should find it much easier Technology offers predic- to make a decision in favor tive and even proactive of this technology. maintenance functions Nevertheless, the question: „fieldbus yes or no?“ which go far beyond purely reactive maintenance and manifests itself for every new plant. The central con- generate enormous advantages for the running plant. cern is always economic efficiency. As well as the advantages regarding installation costs, fieldbus tech- This intelligence, which has been available for a long nology also offers considerable added value, for exam- time in office communication, can now be used ple, with diagnostics and device parameterization, not consistently in the field, too. For example, there are to forget the savings potential in maintenance costs. devices who „report themselves sick“ before they lose The decisive factor are the overall life cycle costs their functionality and cause an unplanned process which will become an increasingly prominent factor in shutdown. Particularly with critical applications, avai- future. It goes without saying, that the additional lability and safety are essential or, to put it bluntly, an benefits have to be quantifiable in hard cash for the idle cracker is a very costly cracker. company operating the plant. Realistically, such favo- Apparently, these are convincing arguments since all rable decisions will only be made when the implemen- new large scale projects in China and the Middle East tation of the technology ultimately results in a positive effect on price or quality of the produced product. In will be equipped with Foundation Fieldbus addition, the future use of fieldbusses depends on Technology. Since about two years now, fieldbus tech- various peripheral conditions – among others on the nology has really started to proliferate. Certainly one region where investments are taking place. Aspects reason is the new topology with fieldbus barriers such as wage costs and the know-how of the employ- which, due to higher power in the field, allow to con- ees play a vital role in the decision for the new techno- nect many more devices per segment in ex-zones. The logy. Therefore, the economic advantages must be cal- users in Europe accept and favor this structure becau- culated differently outside of Europe. Digital commu- se there are no longer any power limitations and the nication technology is much richer in solution possibi- advantages of fieldbus technology can be realized to lities compared to analog technology, creates a plat- their full effect. Similarly in the Middle East, where form for new ideas and applications and is important for the further development of automation technology plant complexes with 50,000 to 100,000 field devices in general. Due to the long live span of processing are in planning, there is a clear tendency in favor of plants the challenge in the process industry lies in a this solution. Many of the initial teething troubles of constant awareness for the long term performance fieldbus technology have been overcome in the mean- capacity of the implemented solutions and products. time. Large international companies are playing an important pioneering role in introducing this new technology and, like Shell for example, are actively promoting it. At this stage, users are clearly deciding in favor of fieldbus technology. The ratio of fieldbus plants compared to conventional applications will continually grow over the next five to ten years. FuRIOS 2 Fieldbus and Remote I/O System Comparison

Opinions

Ian Verhappen, Dr. Joachim Zobel Chairman of the End User Advisory Council (EUAC) of the Senior Automation Engineer at Novartis Pharma Fieldbus Foundation Fieldbus technology has Today, really everything is been an intensive concern becoming digitally connec- of mine since the year ted – even buildings – and I 2000. At this time, we were think it’s high time for the building a pilot plant for processing industry to start the company Hoffman la following this trend. Roche with 30 Profibus PA Fieldbus systems are pro- viding users with much devices in order to make more information and richer in-depth analyses of the data. You simply know practical working suitabili- whether something is hap- ty of the fieldbus technolo- pening or not. However, the gy. This pilot plant also most important benefit is gave us the opportunity of the increased reliability. For example, as well as accu- examining and also evaluating the technically feasible rate process variables, I get a status signal every time wiring philosophies. Here, the system with fieldbus and all kinds of maintenance information that I am able barriers was clearly superior in comparison to a seg- to use. But the information quality is not very good if ment completely intrinsically safe. Due to the higher my network isn’t working satisfactorily. The network is supply power, at one hand, more devices can be con- a very important and critical part of the system. nected per segment – which clearly leads to cost Therefore, users in Europe are increasingly relying on a reductions. On the other hand, the electrical current topology with fieldbarriers for the bus to bus connec- per connection is limited at the barrier which means tion. People here in North America are at least talking that a short-circuit at one device does not immediately about this. However, I think the fieldbus barrier con- put down the whole segment. Using the barrier princi- cept is a goal which will be achieved as users in North ple also requires the least rethinking by the mainte- America move from the traditional class division to the nance personnel because they can work on each zone concept. The zone concept is now accepted in device individually as they have always done Canada and the United States and has been included in without unintentionally influencing other fieldbus the National Electrical Code (NEC). Therefore, especial- devices. The hardware is no problem and one reaches ly for new plants, there is great potential for the zones new limitations only with the increasing data volume concept because the amount of energy that is available per device and thus the increasing cycle time on the down the signal wire is significantly higher. Engineers bus. There were some difficulties starting up the pilot though are often conservative and they still prefer to plant, however, due to the experience gained here, the stay with the traditional explosion-proof classification. subsequent large-scale project, a continuous process It’s an education process and it’s important to explain Vitamin E plant, was commissioned relatively prob- why the zones concept – as well as being safe - helps to lem-free. With all the projects to date, whether save money. Also, with fieldbarriers, FISCO and for Roche or Novartis, whether with Profibus PA or FNICO there is a great increase in flexibility. I always with Foundation Fieldbus, only small problems and try to encourage people to use the zone approach. One some teething troubles occurred, however these could client is already planning this into his new project. be solved relatively simply. Up to date, there is no After one or two plants are working well, others should general strategy at Novartis Pharmaceuticals stating quickly “jump on board” as well. In future, we’ll have whether fieldbus technology should be used or not. even a tighter integration with the different levels of the The senior engineers and the plant operation decide control system. Right now, it’s good to have full inter- this themselves for each new project separately. It operability proven by fieldbus check marks. The next has been clearly recognized though, that depending topic to tackle is: how do we get the devices working on the type of plant, fieldbus technology offers deci- better with the hosts and the hosts working better with sive advantages. With continuous processes, the management and enterprise resource planning sys- emphasis is placed on diagnosis and maintenance. For tems? With fieldbus, we have got all this marvellous pharmaceutical plants, the most important factor is information with its huge potential. Now, people sim- auditability. Thus, new considerations are in progress ply have to learn how to use it. since fieldbus technology is a valid alternative for newly installed plants. Things are looking good for the fieldbus! The fieldbus is finding its wings The first experiences at a pharmaceutical plant of Aventis

Aventis Pharma Deutschland of the sanofi-aventis Group is constructing two new production lines, based on fieldbus technology, for two preliminary sub- stances of the novel antibiotic Ketek for treatment of acute respiratory infec- tions. The engineering group of Aventis single-handedly managed the project and implemented the automation with the support of Siemens as their general engineering consultant. "The greatest challenge of all was to retrofit a running production plant", says Bodo Bartscheit, the process control project manager of Aventis. As a part of the project the test laboratory of Infraserv Höchst Technik was assigned to commission the fieldbus technology. The Ketek plant is one of the first plants to be set up based on the “Fieldbus and Remote I/O System Comparison” (FuRIOS) study.

At the general assembly of the “Asso- sive laboratory tests performed by ciation of Users of Process Control Infraserv Höchst Technik formed an Technology” NAMUR in Lahnstein, important basis for reaching a decision Germany, at the beginning of November on the new fieldbus plant of Aventis 2004, Sven Seintsch, by representing all located the industrial estate ‘Industrie- participants in the project, drew a first park Höchst’ near Frankfurt, Germany. conclusion about how the FuRIOS has been put into practice. Mr. Seintsch is a Fieldbus in action member of staff of the Infraserv test la- The current implementation uses Profi- boratory as well as IGR (Industrial bus PA. However, according to FuRIOS, Practices Interest Group) expert consul- Foundation Fieldbus H1 could be used tant for fieldbus technology and member equally good. At first, Aventis and of the NAMUR fieldbus working group. Infraserv Höchst Technik built a test seg- Two years prior, Dr. Thomas Tauchnitz, ment under laboratory conditions to head of technology and projects at check the technology thoroughly and to Aventis Pharma Deutschland, had intro- eliminate potential problems in advance. duced the FuRIOS study to the same Within this pilot project the complex auditorium. The aim of the analysis was experimental set-up has proven extreme- a study of feasibility as well as cost-be- ly useful in many ways. One of the nefit aspects of the fieldbus from the major targets was the development of a user’s point of view. The results of the commissioning strategy, in order to test system comparison as well as the exten- the communication between the different ment since it is not yet at it were for the experts of Aventis and its prime”, comments Infraserv Höchst Technik, future pro- Seintsch and continues: jects at the Frankfurt location would be “Maybe you do not always equipped with fieldbus exclusively. have to be among the However, solutions for long-term sup- first". As this technology port, a guaranteed downward compati- for device integration is a bility and software maintenance must relatively new kind of be optimized on the part of the manu- technology, the Ketek facturers. One step has been taken in the plant posed a learning right direction, several projects current- curve for both users and ly in planning or installation phases manufacturers. “FuRIOS confirm the increasing acceptance of has predicted teething fieldbus technology in the chemical and problems during the first pharmaceutical industry. Maybe the project and, indeed, prob- expectation manufacturers have had for lems cropped up. many years will finally be fulfilled - the However, they mainly breakthrough of fieldbus technology in occurred during device the process industry. ® FieldConnex from Pepperl+Fuchs in the Ketek tank farm integration which was not components and to train the installation in the scope of the system comparison companies on using the new device tech- study", explains Seintsch. One thing is nology. crystal clear: The start-up problems with Fieldbus barrier it is! With the exception of the safety related device integration has nothing to do The breakthrough regarding device con- signals, which were still wired conven- with fieldbus. In conjunction with the nection methods were the fieldbus barri- tionally, all process instrumentation com- device manufacturers and the Infraserv ers. This was one of the conclusions of the munication is working on fieldbus. The test laboratory, Aventis had to overcome working group 2.6 ‘Fieldbus’ at the 2004 plant consists of 11 process-near compo- several obstacles. But now it is almost NAMUR general assembly. Fieldbus barriers nents with 22 Profibus DP segments, to done. Today all of the devices except play a major role in all three experience which 250 motors and transverters are one are operating smoothly and the pro- reports presented by DSM, Infraserv/ connected. The two new production lines ject responsible persons are confident Aventis and Novartis. Back in 2000, before comprise a total of 200 Profibus PA seg- that they will also overcome this last the fieldbus barriers were broadly avail- able, only few devices could be operated ments with 1,600 Profibus PA devices. hurdle. at one segment, whether Profibus PA or The conventional intrinsically safe valves Clear path for Profibus PA Foundation Fieldbus H1, if the fieldbus lay- and their end position signalling are out was of the conventional kind with the "We can already say today that the coupled to the bus by 190 Valve Boxes, barrier in the control room. With today’s and 20 Sensor Boxes read the intrinsically Ketek project confirms the FuRIOS typical topology, which the NAMUR work- safe binary switch signals. 50 Segment study in regard to faster commissioning ing group recommends as "best practice", Couplers provide a faultless transmission and easy installation", says Seintsch. the installation is based on fieldbus barri- of signals between Profibus DP and PA The basic general conditions: a different ers, since they reduce wiring, planning and segments. The modular Segment way of thinking during planning and installation costs and thus are the main Coupler’s Power Link Modules supply installation as well as qualified and spe- contributors to the operating efficiency of high current to the Profibus PA segments cially trained personnel. It is also clear the technology. The fieldbus barrier’s out- put lines guarantee higher flexibility, more which then is distributed to the indivi- that fieldbus technology alleviates the devices per Profibus segment and increase dual field devices by 470 fieldbus barri- confirmation of intrinsic safety by using the FISCO model. This way, instead of of plant availability. The outputs of the ers from Pepperl+Fuchs. With the given fieldbus barriers are individually short-cir- calculations filling up folders, only a Zone 1 topology, the use of fieldbus bar- cuit current limited and intrinsically safe riers is a decisive criterion for operation few parameters are to be documented. according to both Entity and FISCO – efficiency. Typically, 12 devices are con- The life cycle costs, however, cannot be another advantage when planning or nected to four fieldbus barriers per seg- compared to the study yet, as they will operating fieldbus plants, as this makes the ment and approximately 60 to 70 field become apparent during long-term fieldbus suitable for all currently available devices to one Segment Coupler. Thus operation only. Also for confirmation of devices. Furthermore, the fieldbus barriers Aventis does not use all the connection FuRIOS’s expectations on additional enable the disconnection and exchange of points of the fieldbus barriers and leaves benefits of fieldbus technology in regard the devices during operation and thus facilitate service and maintenance. approx. 20 % spares to extend the pro- to maintenance and diagnostics a cer- duction lines later without rewiring. The tain amount of patience and time is plant integrates 15 different device types required, too. of multiple vendors like ABB, Endress+ All participants in the project are asking Hauser, Krohne, Knick, Pepperl+Fuchs, the manufacturers for a redundant cou- Dr. rer. nat. Christine Eckert Samson and Vega. Plant commissioning pler, higher output current for the Journalist was done directly in the DCS system, Profibus PA lines and additional types Communication for science and technology using a FDT/DTM (Field Device Tool / of field devices in two-conductor tech- Tel. +49 6151/272771 [email protected] Device Type Manager) based integration nology. A definite "yes" for fieldbus by ▲ Contact tool. all users of process automation techno- logy could possibly speed up the deve- Pepperl+Fuchs GmbH Tel. +49 621/776-0 The FDT/DTM problem lopment of new components. At least, it [email protected] "Generally speaking, the FDT/DTM tech- would be an unambiguous signal for www.pepperl-fuchs.com nology is good and the manufacturers the manufacturers that it pays off to should continue to follow its develop- continue investing in this technology. If Fit for the future With fieldbus technology Clariant keeps all options open (pre-print from CHEManager no. 07.05)

verything takes its time, espe- cially in the processing industry. EConsequently the enthusiasm for fieldbus technology is rather limi- ted outside the sworn group of field- bus fans. But the whole branch of the industry closely monitors the perfor- mance of the first projects. It certain- ly looks as if the new fieldbus plant at Clariant could push the thinking process some more in the direction of digital technology. Even after long considerations Thomas Eichhorn and Michael Pelz, process control engineers at the department HPP, Division Pigments & Additives of Clariant, could find no significant argument against fieldbus technolo- gy. The secret of success lies in clever- ly contrived preparations and in the decision not to use any of the techni- cal sophistications for the first use of tons per year and produces red DPP pig- „It was obvious that there had to be fieldbus technology. If one approa- ments such as Hostaperm ROT D2G 70. some money spent on trainings, due to ches the fieldbus rather conservative- These are mainly used in automobile and the change of the control system”, ly it works almost without any prob- synthetics industries as well as in heavy- explains Eichhorn. „However, in the case lems from the very beginning. Thus duty paints. The plant is partitioned in of fieldbus it took only three days in the Clariant, producer of a multitude of 20 Profibus DP and 47 Profibus PA seg- Infraserv Höchst Technik test lab, so the chemicals, is up-to-date in terms of ments and comprises a total of 1,160 expenditure was rather limited.“ For the Process C&I points, of which 553 are basic training on Profibus technology a plant technology and can fully bene- connected to Profibus PA. Besides the Siemens PCS 7 version 6 was available. fit from future technological improve- vendor of the control system, Siemens, The same system controls the new pig- ments. and Pepperl+Fuchs as the supplier of the ment plant. “The best way to get solid The endusers in the chemical and phar- fieldbus installation technology the knowledge is „learning by doing“, Pelz maceutical industry are full of curiosity, device manufacturer list reads like the is convinced. The Clariant Engineering „Who is who“ of measurement instru- Team Rhein-Main carefully planned the asking Eichhorn and Pelz rather bluntly mentation. A total of 326 Profibus PA whole project and strove to avoid prob- at every opportunity: How is the field- field devices of different types and lems from the very beginning. The IGR bus technology in your new Rubin plant manufacturers are installed. The field test laboratory was tasked to run a test performing? Well, it works fantastic. devices were integrated by using setup. Four field devices were connected However, the engineers at Clariant have Electronic Device Descriptions (EDDs), to the control system, following the not always been so confident. “Our due to the control system. High-Power Trunk Concept of department really spent a lot of brain- Pepperl+Fuchs. „More was not necessary power on what might occur“, says Pelz. Cleverly planned since we had sent one sample of each But nothing dramatic happened. The During the design of the Rubin plant’s field device type to the vendor of the tiny problems which popped up had fieldbus network the team of Clariant’s control system beforehand. So we could been solved immediately by Clariant and Control C&I project manager Markus be sure that device integration was a the respective manufacturer. “If I use the Henninger used the experiences of the piece of cake once Siemens had the con- technology conventionally and without Infraserv Höchst Technik test laboratory trollers up and running”, explains highlights such as diagnosis, the fieldbus as well as in-house fieldbus experts. Eichhorn. is something which works fine and I can Simultaneously a new tool for documen- use it easily“, explains Pelz, and tation of the complete fieldbus system Dead on target, thanks to fieldbus Eichhorn adds: “Clariant did a good was developed, jointly with the compa- This precautions soon proved to be very thing to turn down the expectations a ny GAT (Gesellschaft für Automati- advantageous since the time schedule bit. Thus even our very first application sierungstechnik). Due to the experts one was extremely tight. “The engineering of Profibus works wonderful.“ This first does not need powerful CAD design was still under way as the plant was major fieldbus plant of Clariant, located software when applying fieldbus. An already in construction”, remembers in the Industriepark Höchst near Access data base solution provides only Eichhorn. Clariant did not want to spe- Frankfurt, Germany, had been planned these dates which are really needed by culate on the benefit of the fieldbus’ and installed by Clariant’s engineering the technicians. This saves paper and faster commissioning „With convention- group. Following an intensive prepara- money. And it significantly reduces the al technology, due to its longer I/O tion phase it took a construction period effort for documentation of the indivi- checks, we would have had major time of about 17 months before the plant was dual measuring points during planning problems”, emphasizes Pelz. Since the commissioned mid of October 2004. This and operation maintenance phases. The installation schedule of the plant did not plant of Clariant’s department HPP, divi- commissioning was done by Clariant’s follow the layout of the Profibus seg- sion Pigments & Additives, at the cur- own operation crew, supported by ments each day new devices had to be rent stage has a capacity of several 100 Siemens in regard of the Control System. added to the various fieldbus lines and tested immediately. “Fieldbus technolo- switches and actuators to the box with- of the company is still in use. When gy opens some leeway to the commis- out excessive work-arounds. In the automating these plants, if ever, only sioning teams. Thus they could react meantime there is even a low-power sig- Remote I/O Systems could be used”, flexibly when the installation process got nal lamp available which can be connec- says Eichhorn. At any new plant the sit- stuck now and then“, says Eichhorn. So ted to the valve box. Now, for the first uation has to be evaluated anew, too. fieldbus technology proved extremely time, operation terminals and drives However, due to the successful Rubin helpful to meet the tight time schedule. on/off can be connected to Profibus PA. project, it seems Clariant will move more Ultimately Clariant managed to get the and more to fieldbus. This is supported plant up and running dead on time. First come first serve by today’s new projects. However, Pelz The next big bonus Clariant is expecting is confident: “In the next decades we Hand in Hand from fieldbus technology is diagnosis. will see conventional 4 mA … 20 mA The layout of the Rubin plant follows “We would have liked to use it right technology, Remote I/O and fieldbus the recommendations of the “Fieldbus away because we anticipate tremendous technology side by side.” and Remote I/O System Comparison” benefits on the workload. Shut-downs and maintenance intervals which could Christine Eckert FuRIOS. “The topology based on field- Journalist bus barriers is already perceived as the be planned in advance mean a gigantic step forward. This has nothing to do classical way, just two years after the Contacts: study”, Pelz knows. The appropriate with love of technology or weird ideas”, explains Pelz. Minimized and calculable fieldbus installation technology, such as Thomas Eichhorn plant shut-downs means big money in Segment Couplers and FieldBarriers for Dipl.-Ing. Thomas device connection in explosion hazar- the pocket. However, Clariant took the Eichhorn is opera- dous areas, is supplied by the company hard decision not to use fieldbus diagno- tions engineer at the Pepperl+Fuchs, based in Mannheim, sis at the Rubin plant: at one hand field RUBIN plant in the Germany. As prescribed in FuRIOS, devices and control systems supporting department HPP of Clariant went completely without the respective functionalities are just Clariant GmbH. Remote I/O systems and collects almost now coming to market, on the other all digital signals by fieldbus. Several hand a unified regulation for diagnosis reasons, such as spare parts reduction, is missing. The latter is perceived as Clariant GmbH minimization of device types and uni- much more serious. “We sincerely hope Div. Pigments&Additives, Department HPP fied installation and operation, led to the that the diagnosis topic is moving on. Industriepark Höchst, Building D787 decision to use one type of valve box This was one of our reasons to decide for D-65926 Frankfurt am Main only. The idea: One digital interface fieldbus. The NAMUR recommendation Office Phone: +49 (0) 69 305-12561 which can be used, channel by channel, NE 107 or the GMA directive 2650 Office Fax: +49 (0) 69 305-89696 either for valve monitoring or as digital should help standardization along”, says E-Mail: [email protected] input/output. “All participants believed Pelz. Then diagnosis would come free of in this principle. In practical use a few charge with the next control system Michael Pelz problems arose since we took the box update. With each device change or Dipl.-Ing. Michael beyond its limits”, Pelz realizes. In order plant modification diagnosis would be Pelz is operations engineer and main to discontinue the lead breakage control implemented in further sections of the contact for fieldbus for the input connections one additional plant. Pelz: „Advanced diagnosis is only in the department termination module was necessary. possible with fieldbus.“ HPP of Clariant “There was a learning curve at The future can start GmbH. Pepperl+Fuchs, too. But it was a superb Which technology is used where at cooperation and a fantastic support Clariant? This is depending on type and which resulted in a modified valve box“, Clariant GmbH size of the plant in question, environ- says Eichhorn and Pelz emphasizes: Div. Pigments&Additives, Department HPP mental conditions as well as the region „This is meant absolutely positive. The Industriepark Höchst, Building D787 in which the investment takes place. initial problems had been evaluated in D-65926 Frankfurt am Main “Some of our plants are significantly joint teams and the result is a new Office Phone: +49 (0) 69 305-29494 older than 40 years, and sometimes valve/digital interface box.” Now it is Office Fax: +49 (0) 69 305-86681 instrumentation from the founding years E-Mail: [email protected] possible to connect fixtures, individual

Fieldbus Barrier Technology in practical use Operate and Observe

The applicability of the FuRIOS Study Thomas Kasten, Pepperl+Fuchs

Translation of the german original article ‘Die Anwendbarkeit der FuRIOS Studie’, published in atp Automatisierungstechnische Praxis 03/2003, page 51-54

„Fieldbus is here, it could be put to use“. To verify this hypothesis the NAMUR published the „FuRIOS“ project which analyses the cost/bene- fit aspects of the possible application of a fieldbus system. The following article discusses the possi- bilities of a practice-oriented transfer of this study’s results using the example of a comprehensive Fieldbus Installation System already available on the market. The advantages of a complete system consisting of components designed for maximum interoperability as well as the practical benefits of specific technical features of some of these components are presented. Finally some perspectives are given regarding the transferability of the study’s results to meet the requirements of different Process Techniques.

“FuRIOS” is an abbreviation of the german wording for that a further savings potential for fieldbus technology “Fieldbus and Remote I/O System Comparison” which relative to Remote I/O systems is confirmed by the FuRIOS stands for an examination of a plant automation project study. The concrete results of the FuRIOS study indicated using fieldbus technology from the point of view of the potential savings of EUR 338.00 per process control point user. or, depending on the engineering tools applied, between The study considers both the investment phase and the 3.6% and 4.2% of the overall process control point costs. wider outlook towards later operation of the plant. Special Naturally, these values cannot be generalized for all appli- emphasis has been given to real-live boundary conditions cations, since a real, existing pharmaceutical production which are as close as possible to those typical of a pharma- plant has been considered. However, the application of the ceutical/chemical production plant. The study has been car- knowledge gained and the basic principles formulated in ried out by Aventis Pharma Deutschland and Infraserv the FuRIOS study would surely lead to significant savings Höchst, in collaboration with nine manufacturers. The for other process automated production plants, too. Yet results have been presented at the NAMUR general assem- more impressive would be the savings when looking at a bly in November 2002 and elaborated in detail in the atp direct transition from conventional point-to-point cabling magazine in December 2002. to fieldbus technology. If one considers the investment NAMUR is the association of users of process control tech- costs alone, then the sensors and actuators with fieldbus nology. Its working group 2.6 “Fieldbusses” determines capability are typically somewhat more expensive than their

Figure 1: Fieldbus topology of the investigated plant. Source: lecture by Dr. Tauchnitz at the NAMUR general assembly – november 2002 Figure 2: Topology according to the FuRIOS recommendation, with FieldConnex™

atp 45 (2003) Heft 3 51 Operate and Observe

nected devices should be avoided. FieldConnex™ offers the possibility to follow this recommendation from the FuRIOS project as close as possible. By means of appropri- ate Installation System components a relatively high supply current is fed to the field devices via the fieldbus. The basis for this is the power supply concept of combined „increased safety“ and „intrinsic safety“. The fieldbus sig- nals are converted by coupling devices from the RS485 physics of the PROFIBUS DP to the IEC 61158-2 (MBP, Manchester Bus Powered) physics of PROFIBUS PA. The supply current is likewise coupled by the segment coupler into the PROFIBUS PA and transferred via a suitable cable in explosion protection category Ex e to a point as close as Figure 3: Modular Segment Coupler SK2 possible to the field devices. This is where the fieldbus junc- counterparts in the customary technology or when using tion boxes are installed to branch the main cable to the HART. However, if one applies a general analysis to the field individual field devices. In the FieldBarrier™ version these devices and the interface level combined, then the savings junction boxes carry out the conversion of the PROFIBUS PA are more than 11 %. This is due to the complete elimina- into the „intrinsically safe“ protection category Ex i tion of the instrumentation level of the Remote I/O system. (PROFIBUS MBP-IS) for connecting the devices located in With regard to the control system, the cost of the fieldbus Ex-Zone 1 or 0. So-called segment couplers or DP/PA-Links master cards cannot be compared in general with the costs convert the signals, which are transferred from the control of the conventional I/O cards. Here the specific topology of system via PROFIBUS DP with up to 12 Mbit/s, to the trans- the plant, the number of channels and the channel costs fer rate of 31.25 kBit/s of PROFIBUS PA. FieldConnex™ play too large a role. In the FuRIOS project the master cards offers the segment coupler SK2. Its modular concept had no influence, because here Remote I/O systems have enables the construction of up to 20 PROFIBUS PA seg- been compared with fieldbus systems and accordingly the ments, to which several field devices can be connected process control system was already designed for PROFIBUS. On the other hand, on the transition from conventional wiring to fieldbus these considerations are very likely to have a part to play! The principal savings on the move to fieldbus technology are clearly in the communication sys- tem, which links the control system with the field devices. The basis for the realisation of the advantages of a fieldbus communication system is a thoroughgoing and universal application of the fieldbus technology. The investigations of the FuRIOS project showed that a combination of field- bus and Remote I/O is not an economic proposition. Only a clear fieldbus topology and a fully-fledged application of the fieldbus barrier technology will allow to take advantage of the functional benefits of fieldbus – capable devices as well as of the savings in cost provided by the connection technique. With FieldConnex™ Pepperl+Fuchs presents a comprehensive system of fieldbus installation technology which meets the basic prerequisites of the FuRIOS study. All the elements which are necessary for communication between the fieldbus master card and the field devices are incorporated in the FieldConnex™ system. To what extent the utilized field devices are fieldbus-capable in itself is not a decisive factor, since via specific FieldConnex™ Fieldbus Process Interfaces conventional signals can also be linked into the bus communication. Depending on the plant structure and the necessary process control points the resulting topology for the fieldbus wiring can be arbitrarily complex. One of the essential results of the FuRIOS study is the recommendation that a clear structure of the topology Figure 4: Fieldbarrier™ with intrinsically safe connected field should be strived for and that mutual influence of the con- devices

52 45 (2003) Heft 3 atp Operate and Observe

until complete exhaustion of the address range provided by resistances are integrated in the Power Link modules of the the bus master. By appropriate assignment of the field segment coupler SK2; the FieldBarrier™ and the majority devices to the various segments it is possible to ensure that of the fieldbus junction boxes have integrated switchable the high data rate of PROFIBUS DP is optimally utilized for termination resistors as standard. However, if external ter- the PROFIBUS PA field devices. Since the conversion of data mination resistances are required, these are available in var- takes place transparently inside the SK2 the fieldbus mas- ious versions to screw in or to install on a standard mount- ter responds directly to each slave, quasi “through the seg- ing rail. ment coupler”. It is not always the case that all the necessary field devices Each slave has its individual bus address. Therefore the full are available with a PROFIBUS interface. For simple binary scope of 244 bytes of I/O data is available for each slave, signals a direct connection to the fieldbus is often not prac- without restriction. This functionality is particularly impor- ticable, because the bus address would be used inefficient- tant in respect to modern multi-variable field devices ly and the equipment of a simple sensor with a bus inter- which, in conjunction with an optimized fieldbus installa- face would not be acceptable for reasons of cost. In such tion, can contribute significantly to the reduction of invest- cases as well as for control of valves and monitoring of ment costs. The segment coupler SK2 itself does not have their end positions the Fieldbus Process Interfaces of the to be configured in the control system. High flexibility in FieldConnex™ System are used. They are connected via the layout of the fieldbus topology is assured by the mod- the intrinsically safe output of a FieldBarrier™ to PROFIBUS ularity of the FieldConnex™ segment coupler SK2. It com- PA and permit the transfer of up to four valve controls (See prises a gateway and up to 20 Power Link modules. Each Figure 4) or twelve binary signals via one bus address. In Power Link module opens and supplies a PROFIBUS PA seg- similar fashion, the conventional 4 – 20 mA signals and ment. These Power Link modules are currently available temperature signals can also be connected to the fieldbus with up to 400 mA of supply power. The supply of the by means of the modular MiniRIO system. modules and the communication with the common gate- Not to be forgotten are the actual connecting elements of way, which carries out the conversion of the fieldbus sig- a fieldbus installation: The cables. FieldConnex™ offers all nals, takes place via Power Rail mounting rails. the necessary cable types for the construction of the com- The high supply power provided by the Power Link module plete topology – from PROFIBUS DP through PROFIBUS PA for the respective PA segment is fed into the Ex Zone 1 via Ex e – and on to the cables for the intrinsically safe a suitable cable in the „increased safety“ protection cate- PROFIBUS PA. The intrinsically safe cables meet the require- gory Ex e. Here a fieldbus barrier distributes it to intrinsi- ments of FISCO. cally safe PROFIBUS PA (MBP-IS) lines. The FieldBarrier™ With the Ex e/Ex i power supply concept and the supplies up to four PA branch lines with 40 mA supply FieldConnex™ system components described above the power each.Since adequate supply power is available from optimum fieldbus installation for any application in process the Power Link module, a number of FieldBarriers™ can be technology can be designed. daisy-chained by continuing the Ex e trunk cable. Every In addition to the pure investment costs, „FuRIOS“ also FieldBarrier™ output is individually protected against short- provided an evaluation of the operating factors. It is seen circuit feedbacks. It is recommended to connect only one that a plant with fieldbus technology can be brought into field device per output. This ensures that a fault at one field operation significantly faster than a plant relying on device only affects that device and does not have an effect Remote I/O systems. The training requirements for operat- on neighbouring devices or, in the worst case, brings the ing personnel are less; more precise measurements enable whole fieldbus to a standstill. a higher product quality to be achieved and fault elimina- The technology of the FieldBarrier™ enables every intrinsi- tion is also faster because of the extensive diagnostic fea- cally safe output to be operated with up to 120 m of cable tures of the fieldbus devices. More difficult to evaluate are without a fieldbus termination resistor. This is a multiple of the factors relating to an asset management system opti- what is stated in the relevant standard. mized through the fieldbus technology and the future sav- In respect of the necessary equipotential bonding, the ings through the use of multi-variable devices. FieldBarrier™ enables a significant reduction in investment Even in engineering and installation phases FuRIOS identi- costs to be achieved. In the FieldBarrier™ the outputs are fies potential savings which could be realized through the galvanically isolated from the main fieldbus cable. application of a comprehensive installation system. In this Therefore it is not necessary to provide a safe equipotential context, FieldConnex™ offers a software tool for designing bonding throughout the whole plant. This creates signifi- the fieldbus segments simply and efficiently with cant savings not only in regard of the investment costs but FieldBarrier™, on top of the system components optimized also in regard of the long-term operation costs since a save for mutual operation. FuRIOS investigated only the appli- equipotential bonding is critical in respect of the contact cation of PROFIBUS but states explicitly that similar results resistances and hence in respect of ageing. are to be expected for FOUNDATION Fieldbus. The plant Each end of a bus segment must be terminated with a considered was a pharmaceutical – chemical production fieldbus termination resistance. Here also, FieldConnex™ operation, which has been generallydefined as Ex-zone 1. offers the simple and cost-reducing option: Appropriate Different framework conditions result in other require-

atp 45 (2003) Heft 3 53 Operate and Observe

ments on the components of the fieldbus installation sys- tem, of course. Accordingly FieldConnex™ offers many Dipl.-Wirtsch.-Ing. Thomas Kasten is responsi- ble for the product group FieldConnex™ in other system components in addition to the versions the Marketing Department of Pepperl+Fuchs described above, including comprehensive solutions for GmbH. Prior to that he held several positions FOUNDATION Fieldbus. The construction of a production outside of Germany, covering technical mar- keting and service. He is a member of the plant, which will employ the principles and the technology Marketing Working Group of the PROFIBUS postulated in the FuRIOS study, is planned by Aventis User Organisation and of the European Pharma for the year 2003. Marketing Council of the Fieldbus Foundation. Adresse: Pepperl +Fuchs GmbH, Bibliography: Process Automation Division, (1) Tauchnitz, T., Schmieder, W., Seintsch, S.: FuRIOS: Feldbus und Königsberger Allee 87, D-68307 Mannheim, Remote I/O – ein Systemvergleich. atp – Automatisierungs- Tel. +49 621 776 -1415, technische Praxis 44 (2002), Edition 12, pages 61-70 e-mail: tkasten@ de.pepperl-fuchs.com

54 45 (2003) Heft 3 atp Less handicaps in explosion hazardous areas

Practice-oriented Power Supply Concepts for fieldbus reduce previous limitations

The first practical experiences with the comprehensive use of fieldbus technology in major automated production plants have been presented at the 2004 general assembly of NAMUR, the Association of Users of Process Control Technology. The decisive factor for the positive appraisal was the utilization of modern power supply concepts which eli- minate fieldbus technology’s pre- vious limitations in explosion hazardous areas. High Power Trunk Concepts for Ex-zones 1 and 2 allow to get the optimum advantage of fieldbus technology while maintaining the benefits of explosion protection by means of energy limitation. Fig. 1: Fieldbus topology in line structure with trunk and spurs

fter long years of testing in the first plants. A good example is and theoretical analyses, the Ketek plant of Aventis Pharma A plant control by fieldbus Deutschland which produces two pre- technology is starting to liminary substances of the novel antibi- gain success in process automation. At otic Ketek by means of two production the NAMUR general assembly in lines comprising a total of 1,600 November 2004 several presentations PROFIBUS PA devices. Dipl.-Wirtsch.-Ing. Thomas described and positively appraised the Kasten is responsible for the product group FieldConnex® first practical experiences in using Basics of fieldbus use in explosion in the Marketing Department PROFIBUS PA as well as FOUNDA- hazardous environments of Pepperl+Fuchs GmbH. Prior TION Fieldbus H1 in major production to that he held several posi- What’s so special about this fieldbus tions outside of Germany, plants. A basic prerequisite for this covering technical marketing acceptance is the elimination of the barrier concept? To answer this ques- and service. He is a member of limitations which restricted the use of tion one has to consider the conditions the Marketing Working Group fieldbus technology in explosion haz- set in the fieldbus standard IEC 61158-2 of the PROFIBUS User Organisation and of the ardous environments up to now. This as well as the requirements of explo- European Marketing Council was achieved by the fieldbus barrier sion protection in Zone 1/Class I, Div. 1 of the Fieldbus Foundation. concept which had been evaluated the- by means of intrinsic safety according Contact oretically two years ago in the FuRIOS to IEC 60079-27. The fieldbus standard Tel. +49 621 776-2222 Study and now sees its practical use allows up to 32 devices at one segment [email protected] 27

and requires for each field device a mini- intrinsic safety is a rather complex cal- which elements of a fieldbus segment mum working voltage of 9 V DC and a culation when using the original Entity repair and maintenance work during minimum current consumption of 10 model. The Fieldbus Intrinsically Safe operation might be necessary. These mA. The digital communication signals Concept FISCO reduces this confirma- are the field devices and their connec- are transmitted in Manchester II enco- tion to the comparison of only a few tion lines which should consequently be ding by means of a ± 9 mA amplitude. parameters and allows the slightly high- installed in EEx i. The need for live All considerations are based on the ref- er power supply of 100 mA, however work at the passive wiring of trunk and erence fieldbus cable Type A, which is a paying for these advantages by fieldbus distribution modules is shielded twisted pair cable with con- increased requirements on the device extremely unlikely, these can be ductor cross-sections of 0.8 mm2 technology and reduced maximum total installed using the explosion protection (AWG18) and a loop resistance of 44 cable length. method ‘increased safety’ EEx e resp. Ohm/km. This cable transmits the digi- Div. 2 wiring methods. Thus the passive tal communication as well as the supply Advantages of the fieldbus wiring is not subjected to energy power for the field devices. In order to barrier concept limitation. State-of-the-art fieldbus bar- disconnect individual devices from the Starting point of the development of riers such as the FieldConnex® bus without impairing the operation of this concept was the evaluation at FieldBarrier are designed for connecting the other devices each one should be connected to one central main line (trunk) by means of individual drop lines. Fig. 1 shows such a recommended line structure with a trunk and several con- nection spurs. The term ‚Power Supply’ summa- rizes the specific fieldbus power supply units which are mandatory to combine the digital signal of the fieldbus host with the direct current for device supply. These Power Supplies are available in se- veral versions and various output current levels. Based hereon and the actual power consumption of the connected devices the maximum cable length of a fieldbus segment is calculated, keeping in mind that the device farthest away from the Power Supply has to meet the above mentioned minimum values. The maxi- mum total cable length of trunk plus all spurs is 1,900 m, according to IEC 61158-2. ‚Intrinsic Safety’ EEx i achieves the explosion protec- tion by limiting the energy in the segment so that a spark powerful enough to ignite the surrounding atmosphere can- not develop. This allows live work at the devices during operation without special safety precautions. The other side of the coin is a significant reduction of the supply cur- rent to 70 mA for EEx ia appli- cations which results in major limitations regarding cable length and possible number of devices. Consequently the fieldbus was not attractive for explosion hazardous environ- ments up to now. Furthermore the required confirmation of confirmation of intrinsic safety is reduced to the respective device and its connection line and can be conducted according to Entity as well as, simpli- fied, according to FISCO. Even more, now the max. cable length of 1,900 m as defined in IEC 61158-2 for non-Ex areas is possible in Zone 1, too, with full advantage of the max. spur length of 120 m. Protection against failures due to short-circuit or overvoltage The big advantage of fieldbus technolo- gy is the connection of several sensors and actuators to one and the same cable, whilst with conventional point- to-point wiring each device needs its individual cable to the process-near component in the safe area. Therefore a short-circuit would impair only that one device. With fieldbus, however, all devices at the segment would stop communicating. To prevent that each output of the FieldBarrier is short-cir- Fig. 2: Topology for Zone 1 according to the fieldbus barrier concept cuit current limited to 45 mA, only the faulty spur will go offline. Since the remaining devices in the segment keep communicating an easy and fast fault and daisy-chaining the trunk in EEx e, 1 A with FOUNDATION Fieldbus H1, localisation in the control system is can be installed in Zone 1 resp. in Class I, significantly more than under EEx i con- guaranteed. Furthermore each module Div. 2 with spurs reaching into Div. 1, ditions. Consequently this way of field- of the FieldConnex® system is protected and thus allow to lead a high supply bus wiring is often described as ‚High- against functional overvoltages. For power into the explosion hazardous Power Trunk Conzept’. The four out- enhanced protection, e.g. by imple- area. When using modern Power puts of the FieldBarrier deliver 40 mA menting a lightning protection zones Supplies such as the modules of the EEx ia IIC and thus allow the connec- concept according to IEC 61312-1, there FieldConnexTM system, this could be tion of intrinsically safe field devices are surge protection modules specifical- 400 mA with PROFIBUS PA and up to with all their advantages, see fig. 2. The ly optimized for fieldbus technology available.

High Power Trunk Concepts for Zone 2 / Class I, Div. 2 A fieldbus segment for Zone 2 can be designed similar to the fieldbus barrier concept. Since the requirements in regard to explosion protection are not as stringent FieldConnex® Segment Protectors are used instead of FieldBarriers (fig. 3). For the trunk the explosion protection method‚ non sparking’ EEx nA is applied and allows to lead high power into Zone 2. The Segment Protectors are certified accor- ding to EEx nA[L] and can be installed in Zone 2 / Class I, Div. 2. Each output is energy limited according to EEx nL IIC, the output current is 40 mA, the output voltage max. 31 V. Furthermore each output is individually short-circuit current limited to 45 mA. Field devices with appropriate certification for Zone 2 as well as intrinsically safe devices can be connected. The evaluation of the safety parameters Fig. 3: High Power Trunk concept for Zone 2 follows the Entity concept but is signifi- cantly simplified since each spur is cal- 29

ply power into explosion hazardous areas. On top of the above described function of merging digital fieldbus sig- nal and supply current modern Fieldbus Power Supplies offer far more features for optimization of fieldbus communication and plant availability. Modular designed Segment Couplers (fig. 4) convert the RS485 transmission physics of PROFIBUS DP to the IEC 61158-2 physics of PROFIBUS PA. Various Gateway Modules are available. To each Gateway several Power Link Modules can be connected, each one supplying one fieldbus segment with up to 400 mA. The Segment Coupler’s maximum configuration allows the design of 20 PA Segments according to ® Fig. 4: FieldConnex Segment Coupler with media redundant PROFIBUS DP the High-Power Trunk Concept with a connection and Power Link Modules for 2 PROFIBUS PA segments media redundant PROFIBUS DP con- nection to the Profibus master. The FieldConnex® Power Hub (fig. 5) is a culated individually. For the supply of devices. As the only benefit the confir- modular system, too, and allows the today’s typical intrinsically safe devices mation of the safety parameters by cal- connection of up to four FOUNDA- ® the FieldConnex Power Hub system culation can be omitted. In future the TION Fieldbus H1 segments to one offers modules with a voltage limitation requirements for these voltage limita- common motherboard. Several variants to max. 23 V. By means of Power Hub tions will dwindle since more and more with host-specific system connectors are modules limited to 17 V segments fol- field devices certified according to EEx available. Depending on the require- lowing the Fieldbus Non-Incendive nL with Ui > 32 V are appearing on ments on plant availability the mother- Concept FNICO according to IEC the market. Thus the voltage limitation boards can be equipped with single or 60079-27 Ed. 1 can be installed. FNICO of the Segment Protector is sufficient redundant electronic modules. The is an adaptation of FISCO to Zone 2, and the advantages of the High-Power novel CREST technology stabilizes the however today there are only a few Trunk Concept can be fully realized. fieldbus communication by minimizing FNICO certified field devices available Fieldbus Power Supplies the disturbances due to noise and sup- on the market. Furthermore the voltage pressing the resonances in the system. limitation reduces the possible total High-Power Trunk Concepts for Zone 1 Very high requirements on the isolation cable length and number of fieldbus and Zone 2 allow to transmit high sup- of fieldbus segments can be met by using modules with galvanic isolation. Diagnostic modules allow monitoring of various functional parameters of Power Hub and fieldbus segment. Furthermore some variants of the Power Hub feature a novel short-circuit current limitation of the connection line to the host. Perspective The first practical experiences with comprehensive fieldbus applications in major production plants are rather encouraging. The presentations at the NAMUR general assembly concluded with the statement: “Fieldbus is the right path to future”. However, the users still handed over a list of wishes to manufacturers and fieldbus organisa- tions which was gladly accepted. For example the fieldbus barrier concept, since a few month, is explicitly men- tioned in the official Application Guide of the Fieldbus Foundation. In the near future design and calculation of High- Power Trunk Concepts will be facilitat- ed by new tools such as the recently ® Fig. 5: FieldConnex® Power Hub on Motherboard for four FOUNDATION updated FieldConnex Segment Fieldbus H1 segments, redundant configuration Checker software tool. FOUNDATION FIELDBUS H1 HIGH-POWER TRUNK TOPOLOGIES High-Power Trunk Topologies for FOUNDATION Fieldbus H1 The FuRIOS study recommends the application of fieldbus technology all throughout process production plants. Only in this way the advantages of this future oriented technology can be realized to the fullest extend. The basis is a topology concept which neutralizes the previous limitations of fieldbus application in explosion hazardous areas. These High-Power Trunk Topologies can easily be designed by means of a comprehensive Fieldbus Installation System such as FieldConnex®. Furthermore FieldConnex® offers all modules and protection functionalities to ensure efficient plant operation with high availability over many years. The expe- riences from plants planned and put into operation based on these installation concepts confirm the expectations of FuRIOS. A High-Power Trunk Topology consists of several basic functional groups. The FieldConnex® System offers for each functionality the appropriate, interoperable modules.

Fieldbus Power Hub Fieldbus ■ Modular Power Supply System meeting the requirements of all applications and host systems Power ■ High output current and several voltages for maximum number of devices in various explosion protection concepts Supply ■ Sophisticated isolation, redundancy and diagnosis concepts guarantee optimum plant availability ■ Novel CREST technology minimizes signal distortions and ensures safe communication

Fieldbus Cables and Cord Sets Fieldbus ■ Fieldbus cable type A according to fieldbus installation guidelines for optimum signal transmission Signal ■ Safe operation due to variants for all environmental conditions Transmission ■ Versions with various plug connectors allow fast and fault-free installation

Junction Box Fieldbus ■ Simple, individual connection of field devices to the fieldbus segment Distribution ■ Quick and efficient fault localisation and rectification ■ High flexibility due to various connection types and sturdy housings for harsh environments

Segment Protector Fieldbus ■ Explosion protection in Zone 2 / Class I, Div. 2 by energy limitation of the outputs Distribution and ■ Increased plant reliability due to short-circuit and overload protection Energy Limitation ■ High flexibility due to various connection types and sturdy housings for harsh environments

FieldBarrier ■ Fieldbus Explosion protection in Zone 1 / Class I, Div. 1 by intrinsically safe outputs according to FISCO and Entity ■ Distribution and Increased plant reliability due to short-circuit and overload protection Intrinsic Safety ■ Various shielding options guarantee minimization of signal distortions ■ High flexibility due to various connection types and sturdy housings for harsh environments

Temperature Multi-Input, Valve Coupler, Fieldbus-Pneumatic Interface Fieldbus ■ Easy integration of almost all conventional signals into fieldbus communication Process ■ Power supply of the interfaces intrinsically safe via the fieldbus cable Interfaces ■ Integrated diagnostic functions for sensors and connection cables ■ Direct actuation of solenoid and pneumatic valves

Surge Protector Surge ■ Protection of fieldbus host and instrumentation against voltage surges and lightning strikes Protection ■ Variants for various environmental conditions and explosion protection concepts ■ Modular system with additional functionalities allow efficient plant operation

Segment Checker Design Software, Documentation, Services ■ Efficient planning of optimized fieldbus topologies by ‚Drag and Drop’ on Accessories, www.segmentchecker.com Tools ■ Comprehensive installation guidelines and detailed information on all FieldConnex® modules on www.fieldconnex.info ■ Consulting services and support with fieldbus projects and specific system solutions by your local Pepperl+Fuchs representative PROFIBUS PA HIGH-POWER TRUNK TOPOLOGIES High-Power Trunk Topologies for PROFIBUS PA The FuRIOS study recommends the application of fieldbus technology all throughout process production plants. Only in this way the advantages of this future oriented technology can be realized to the fullest extend. The basis is a topology concept which neutralizes the previous limitations of fieldbus application in explosion hazardous areas. These High-Power Trunk Topologies can easily be designed by means of a comprehensive Fieldbus Installation System such as FieldConnex®. Furthermore FieldConnex® offers all modules and protection functionalities to ensure efficient plant operation with high availability over many years. The experiences from plants planned and put into operation based on these installation concepts confirm the expectations of FuRIOS. A High-Power Trunk Topology consists of several basic func- tional groups. The FieldConnex® System offers for each functionality the appropriate, interoperable modules.

Segment Coupler Fieldbus ■ Adaptation of all PROFIBUS DP bit rates to PROFIBUS PA Power ■ High power output for maximum number of devices per segment Supply ■ Modular concept allows flexible plant design ■ Maximum safety due to galvanic isolation

Fieldbus Cables and Cord Sets Fieldbus ■ Fieldbus cable type A according to fieldbus installation guidelines for optimum signal transmission Signal ■ Safe operation due to variants for all environmental conditions Transmission ■ Versions with various plug connectors allow fast and fault-free installation

Junction Box ■ Simple, individual connection of field devices to the fieldbus segment Fieldbus ■ Quick and efficient fault localisation and rectification Distribution ■ High flexibility due to various connection types and sturdy housings for harsh environments

Fieldbus Segment Protector ■ Distribution and Explosion protection in Zone 2 / Class I, Div. 2 by energy limitation of the outputs ■ Energy Limitation Increased plant reliability due to short-circuit and overload protection ■ High flexibility due to various connection types and sturdy housings for harsh environments

FieldBarrier ■ Explosion protection in Zone 1 / Class I, Div. 1 by intrinsically safe outputs according to FISCO and Entity Fieldbus ■ Increased plant reliability due to short-circuit and overload protection Distribution and ■ Various shielding options guarantee minimization of signal distortions Intrinsic Safety ■ High flexibility due to various connection types and sturdy housings for harsh environments

Valve Coupler, Sensor Interface, Fieldbus-Pneumatic Interface, MiniRIO ■ Easy integration of almost all conventional signals into fieldbus communication Fieldbus ■ Power supply of most interfaces intrinsically safe via the fieldbus cable Process ■ Integrated diagnostic functions for sensors and connection cables Interfaces ■ Direct actuation of solenoid and pneumatic valves

Surge Protector ■ Protection of fieldbus host and instrumentation against voltage surges and lightning strikes Surge ■ Variants for various environmental conditions and explosion protection concepts Protection ■ Modular system with additional functionalities allow efficient plant operation

Segment Checker Design Software, Documentation, Services ■ Efficient planning of optimized fieldbus topologies by ‚Drag and Drop’ on www.segmentchecker.com Zubehör, ■ Comprehensive installation guidelines and detailed information on all FieldConnex® modules Hilfsmittel on www.fieldconnex.info ■ Consulting services and support with fieldbus projects and specific system solutions by your local Pepperl+Fuchs representative FAX answer to +49 621 / 776 1400 _ Please send to: or by e-mail: [email protected] Pepperl+Fuchs GmbH Product Marketing, Mr. Thomas Kasten

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