Sustainability through Process Field Networks

S t i bilit Th h PS t i bilit Th h PSustainability Through Process Field Networks

Sustainability Through Process Field Networks

Wil ChinResearch Director

ARC Advisory [email protected]@ARCweb.com

Diverse Communication Technologies Diverse Communication Technologies

Supervisory

Control PROFInetPROFInet

ORK

LEV

EL

HSE

I/ODP, PAN

ETW

O

Device

TYPE OF CONTROL

H1

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Machinery ProcessTYPE OF CONTROL

2009 Process Field Network Survival Guide2009 Process Field Network Survival Guide

New and Brownfield: E t d M d i ti & R iExtend –Modernization & Repair Measured Field Investments Invest in Value InitiatesInvest in Value InitiatesMore Productivity with LessUse Existing InfrastructureUse Existing Infrastructure Networks Provide Access to Information

Use Economical Field Networks to Access Intelligence - Reduce Operational and

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Maintenance Cost

Plant Asset Management Growth ($Millions)Plant Asset Management Growth ($Millions)

Total Shipments of PAMCAGR=10 8%

24062500

3000

CAGR=10.8%

1443.81571

17231910

2138

1500

2000

500

1000

1500

0

500

2006 2007 2008 2009 2010 2011

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Achievable PAM Benefits Achievable PAM Benefits

O&G, Chemical, Petrochemical, Power IndustriesIndustries• Removed 183 of overtime hours • Reduced monthly work orders by 8%

Improved planned work mix to 40%• Improved planned work mix to 40%• Saved $800k in 6 months• Saved $200 device in commissioning and installation

R d d h k t ti b 30%• Reduced checkout time by 30%• Increase production by 4-10%• Reduced unplanned shutdown by 9%

d d l b 20%• Reduced total maintenance cost by 20%• Reduced valve maintenance by 50%

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Worldwide Installed Base of Field DevicesField Devices - Press, Temp, Flow, Level, Valve Positioners, AnalyticalWorldwide Installed Base of Field DevicesField Devices - Press, Temp, Flow, Level, Valve Positioners, Analytical

58 Million Installed Devices in 2007

Smart Non - Smart

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Process Field CommunicationsProcess Field Communications

N l 24 illi HART d iNearly 24 million HART devices are installed in process plants around the globegHART communication protocol is a low cost solution for 2009 economic h llchallenges

Foundation Fieldbus & Profibus Continues to be the protocol of choiceContinues to be the protocol of choice for “Greenfield” capital projects

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Why HART?Why HART?

Low Risk SolutionL C t S l tiLow Cost SolutionAvailability of ProductsAlready Halfway There Use Existing FieldAlready Halfway There- Use Existing Field DevicesProven Value Enables PAM of Field DevicesWireless HART Standard

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WirelessHARTWirelessHART

Built on the HART StandardsBackward compatibleBackward compatibleDelivers benefits to users independent of the age of control systemsEnables transition to a predictive maintenance strategy to:• Lower operating and maintenance costLower operating and maintenance cost• Increase plant availability• Help in regulatory compliance

HART certified devices by May 2009HART certified devices by May, 2009

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WirelessHART ApplicationsWirelessHART Applications

Capture device and process information via PAM solution Communicate installed base of existing HART device diagnostics using a wireless adapterdevice diagnostics using a wireless adapterDeploy measurement previously not cost-effective Simplify installation and commissioning • Uses the same HART tools

l d• Minimal training required

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Wireless Field Device PenetrationWireless Field Device Penetration

15%

5%

10%

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Success “HART Plant of The Year”Success “HART Plant of The Year”

PDVSA near Barcelona, Venezuela248 000 b l d fi248,000 barrel per day refinery7.5°API FeedstockProduces Synthetic CrudeProduces Synthetic Crude5,000 Field Devices tied to DCSMultiple Field Device SuppliersMultiple Field Device SuppliersEmerson AMS PAM SystemHoneywell DCSyOther Suppliers: Dresser Masoneilan, Endress +Hauser, General Monitors, Saab, Control logic

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Award Presentation PhotosAward Presentation Photos

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ResultsResults

Increased Wrench Time by 10%Increased Wrench Time by 10%• Optimized Maintenance • Predictive Maintenance• Predictive Maintenance• Traceable Calibration Records

Allows the Workforce to do More With Less

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ResultsResults

60% reduction of Lost Profit Opportunities (LPO) caused by field device faultsReduced “Bad Actors” by 95%Reduced Bad Actors by 95%• Reducing Random Failures

Reduced LPO by $70 m in 2-yearsReduced LPO by $70 m in 2 years

Strong Case for Field Networks in Good and Bad Economies

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Good and Bad Economies

FDT Enables Information Access FDT Enables Information Access

Configuration Optimization PAM ReliabilityConfiguration Optimization PAM ReliabilitySupported Protocols

Process IndustryFDT Process IndustryFDT

HART

Foundation Fieldbus

CIP (DeviceNet/IP, CompoNet)

Interbus Process IndustryFDTDiscrete Industry

Hybrid Industry

Process IndustryFDTDiscrete Industry

Hybrid Industry

Interbus

IO-Link

Modbus SL/TCP

Profibus DP/PA

Profinet I/O

ProfibusDevices

SensorBuses

Devices

Foundation FieldbusDevices

HARTDevices

ProfibusDevices

SensorBuses

Devices

Foundation FieldbusDevices

HARTDevices

ProfibusDevices

SensorBuses

Devices

Foundation FieldbusDevices

HARTDevices

Profinet I/O

Pending Protocols

CANopen

FDT Enables Interoperability Regardless of Industry, Protocol, and Application

SERCOS III

AS-I

EtherCAT

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Visit FDT in the Innovation Showcase

Thank You.Thank You.For more information, contact the author at

[email protected] or visit our web pages atwww arcweb com

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