Sustainability: Process Field Networks
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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
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Diverse Communication Technologies Diverse Communication Technologies
Supervisory
Control PROFInetPROFInet
ORK
LEV
EL
HSE
I/ODP, PAN
ETW
O
Device
TYPE OF CONTROL
H1
2© ARC Advisory Group
Machinery ProcessTYPE OF CONTROL
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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
3© ARC Advisory Group
Maintenance Cost
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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
4© ARC Advisory Group
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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
6© ARC Advisory Group
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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
14© ARC Advisory Group
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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
15© ARC Advisory Group
Good and Bad Economies
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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
16© ARC Advisory Group
Visit FDT in the Innovation Showcase
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Thank You.Thank You.For more information, contact the author at
[email protected] or visit our web pages atwww arcweb com
17© ARC Advisory Group
www.arcweb.com