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December 2004— Vol. 5, No. 11 Welcome to the 60th issue of Fieldbus Facts Online, a monthly electronic newsletter and your link to the latest news, trends, and applications related to FOUNDATION fieldbus and the Fieldbus Foundation. Besides this latest web-based edition, previous issues are also accessible here. Fieldbus Facts Online is sponsored by the Fieldbus Foundation (FF, Austin, TX) and its members. The foundation is an international, not-for-profit corporation—consisting of more than 200 leading process and manufacturing automation companies and end-users worldwide—dedicated to providing the industry with the "Freedom to Choose" and the "Power to Integrate." For more news and information about registered FOUNDATION fieldbus products, click here. PLEASE NOTE: If you know someone, who might be interested in receiving Fieldbus Facts, via e-mail please send them this link: www.controleng.com/subscribe.asp
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HIGHLIGHTS FROM THIS ISSUE BP fieldbus demo project makes progress BNG achieves instrumentation self-certification Fieldbus end user/integrator seminar scheduled 2005 fieldbus training schedule now available 2005 general assembly slated for Vienna ABB System 800xA slated for offshore project Emerson automates level measurement at Esso refinery E+H: HSE opens backbone to every fieldbus Texas board recognizes skill standards Hawke TrunkGuard receives FM approval Use care when selecting an automation partner Smar challenges users to re-think role of field instruments Softing offers economical way to get on the bus Yamatake releases control valve maintenance system Yokogawa enhances its asset management software MTL introduces process junction boxes Fieldbus launches 'User's Corner' New! 'User's Corner' BP fieldbus demo project makes progress
The BP manufacturing project brings together many aspects of FOUNDATION fieldbus technology in a comprehensive and totally functional production environment and is supported by leading automation equipment suppliers. Comprehensive system and supplier-designed implementations form the basis of this in-depth effort, where the advanced capabilities of FOUNDATION fieldbus for critical process control exemplify the best technology solution available. According to BP personnel at the Lima facility, the project continues to make excellent progress. Component testing and verification of components was recently completed at the Lee College Fieldbus Center in Baytown, Texas. The system will begin live operation in May 2005. Read Fieldbus Facts Online for regular updates on the BP fieldbus project in the coming months, or click here for more information.
BNG achieves instrumentation self-certification
In 2001, BNG installed a FOUNDATION fieldbus-based Yokogawa control system on a filter test rig containing a Centum CS3000 host and devices from Endress+Hauser, ABB, Emerson Process Management, Smar, Valtek, and Yokogawa. This plant started up in 2002 and proved to be an exceptionally reliable multi-vendor installation. The group conducted a radiation hardness test as part of their self-certification process. Following internal reviews, it decided to donate the test results to the Fieldbus Foundation. Because of the risk involved in operating nuclear plants, this acceptance of FOUNDATION technology confirms its robustness and maturity. BNG intends to use FOUNDATION fieldbus for future automation projects. BNG is active in nuclear waste treatment and nuclear plant decommissioning, and also provides services to the entire nuclear industry. For more information, please visit the BNG Web site.
Fieldbus end user/integrator seminar scheduled
The one-day event is designed for those seeking to learn more about FOUNDATION fieldbus and consists of a basic-moderate-level training workshop that reviews fieldbus terminology, device requirements, segment design, host requirements, software configuration, documentation, and site installation guidelines. End-user case studies, an update on what's new with the technology, and a safety discussion will be presented in the afternoon. Attendees will have a chance to speak with fieldbus professionals and ask technical questions during the panel discussion. End users, engineers, and integrators will benefit from the seminar. All attendees will receive a CD containing application guidelines, the end user case studies, and much more. Controls manufacturers will be on-hand with tabletop exhibits displaying the latest fieldbus equipment. Fieldbus Foundation staff also will be available to answer questions. Click here to sign up today to attend this event.
2005 fieldbus training schedule now available The Fieldbus Foundation's 2005 fieldbus workshop schedule is now available. The course schedule includes:
Fieldbus Overview is a basic introduction to FOUNDATION technology using a working fieldbus system. Topics covered include: fieldbus concepts, wiring, basic messaging, function blocks, and applications. Anyone interested in FOUNDATION fieldbus from an application standpoint, from end users to marketing professionals and application engineers, would benefit from attending. Advanced Technical Workshop provides in-depth coverage of FOUNDATION fieldbus, including demonstrations of a working fieldbus system. Topics covered include: physical layer, data link layer, fieldbus access sub layer, network management, system management, configuration, fieldbus message specification, and development of FF function blocks. The course is intended for device developers, test engineers, and those needing a detailed knowledge of FOUNDATION fieldbus. Prerequisite: Fieldbus Overview. Device Description Workshop provides an understanding of how to write interoperable Device Descriptions (DDs) using Device Description Language (DDL), standard function blocks, and transducer blocks. Also covered is DD development for a fieldbus device using a PC-based "tokenizer" development tool. This course is intended for those writing interoperable DDs. Register before the early registration deadline and receive a 15% discount. Don't miss out—sign-up to attend these valuable courses today! Click here to download a pdf with more information and a registration form.
2005 general assembly slated for Vienna
Attendees can expect to come away from this event polished on fieldbus installation updates, technology advancements, and more. Tabletop displays of major automation and control industry manufacturers will show the newest devices and host systems available. End users will present real-life stories on plant integration. FOUNDATION fieldbus workshops for manufacturers, end users, and contractors will focus on "Plant Wide Integration, H1 + HSE." All attendees are invited to attend a welcome reception the evening of the 23rd to meet and mingle with industry professionals and listen to keynote speeches from Richard Timoney, Fieldbus Foundation president; John Berra, president of the board of directors; an important European manufacturer; and a senior executive from a prominent end user. Fieldbus Foundation has seen astounding growth throughout the years. It now has more than 5,000 systems integrated with over 400,000 devices. ARC reports that fieldbus is the chosen technology by the end user. It accounts for most installations and is the preferred technology for future integrations. Fieldbus Foundation predicts system and device installations will double by 2006. Join us for the annual Fieldbus Foundation General Assembly and find out why FOUNDATION Fieldbus technology has the industry talking. Click here for more information.
ABB System 800xA slated for offshore project
The ABB solution will help PEMEX increase offshore production capacity at their four drilling platforms. ICA Fluor chose ABB because of their extensive offshore experience, ability to successfully deliver within the customer's time schedule, and full range of systems and services that meet technical compliance requirements for this project. Another important factor was the company's ability to expand the system and integrate with future products and technologies. System 800xA's integration capability extends beyond traditional automation systems to achieve the productivity gains necessary to succeed in today's business markets. The system integrates essential process control with production management, safety systems, smart instrumentation, smart drives and motor control, robotics, information management, asset optimization, and documentation. Its unique engineering environment manages one set of consistent data for single-point entry, single-point change, and re-use across the plant. Click here to learn more.
Emerson automates level measurement at Esso refinery
The existing solution of differential pressure manometers with oil filled capillaries had been installed in the 1960s. Because the site required the measurement system to have a local indicator and be separate from the main level measurement system, Esso evaluated replacement using similar manometer technology, as well as alternatives. A FOUNDATION fieldbus-based solution was judged the alternative that could bring cost and functional benefits, and also serve to test this new technology. The Emerson PlantWeb solution was no more costly than a manometer system because of the unique capabilities of the 3051S transmitters and FOUNDATION fieldbus digital communications. For more information, click here to visit the Emerson Web site.
E+H: HSE opens backbone to every fieldbus
ControlCare SFC162 is registered and approved as a Class 42.2a device according to CTK/HTK certification standards defined by the Fieldbus Foundation. Technically, it comprises a Linking Device with four FF H1 channels and one Ethernet 100 Mbits/s port with HSE-based protocol. Its control capability supports standard and custom FF Function Blocks types, including Hybrid Function Blocks, according to Flexible Function Block (FFB) technology. ControlCare SFC173 is a certified Profibus Class I Master (DPV1). Technically, it includes a FOUNDATION fieldbus HSE/Profibus DP gateway with one Profibus DP/PA channel and one Ethernet 100 Mbits/s port with HSE-based protocol. It has the same control capability as its FOUNDATION fieldbus counterpart. It also supports Profibus Profile for HART, which means that remote I/O supporting HART protocol can be directly connected to HART Master/Clients through the HSE/Profibus DP Gateway. HSE and ControlCare give users open information exchange between field, control, and enterprise management levels. Click here to visit the Endress Web site.
Texas board recognizes skill standards
The project began more than two years ago when the National Education Goals Panel identified a growing deficiency in the education of instrumentation workers. The revised standards give educators and trainers a blue print for program development. Institutions will be able to adapt their curriculum to meet current industry needs and standards, and in turn provide skilled workers to Texas employers. Fieldbus Center and the Industrial Technology Advisory Committee (ITAC) will now move to have the program nationally recognized. The Fieldbus Center at Lee College was established in 2000 with a three-year grant from the National Science Foundation to provide education on emerging technologies in the field of control systems. The Center develops programs for teaching fieldbus and process control systems maintenance, creates and maintains an applied research center, and develops multi-craft curricula for fieldbus and industrial networking technologies. It accomplishes these goals through collaboration with more than 50 partners. For information on the Fieldbus Center, click here.
Hawke TrunkGuard receives FM approval
Hawke's TrunkGuard technology (switching off faulty spurs rather than "current-limiting," and patented automatic segment termination eliminating installation errors) is now available for use on both sides of the Atlantic. The TG200 Series is manufactured in 4-, 8- and 10-way forms, with a variety of field enclosure and cable gland options. Hawke also offers a stainless steel junction box pre-configured to connect 20 spurs via two segments, specifically for retrofit applications. Hawke manufactures all of the component parts for fieldbus device couplers, cable glands, electronic modules, and field enclosures to provide end users and systems integrators what they need on any project anywhere in the world. Hawke International sales offices are in Manchester (EU-MEA), Houston (Americas), and Singapore (Asia Pacific). Click here to visit the Hawke Web site.
Use care when selecting an automation partner
Procuring a knowledgeable workforce to execute and support a project is one of the most critical challenges to achieving a successful fieldbus project. Customer and supplier should work together to define overall project requirements, perform field surveys, and mutually develop the fieldbus segment layout for the plant. As key users of fieldbus information, maintenance and operations personnel must be involved from the beginning. Be sure to consider the automation supplier's industry experience and ability to deliver a proven fieldbus platform. Especially important are practices used for fieldbus deployment, established industry expertise, and consulting services. Does the supplier have the resources to deliver the project on schedule and on-budget and use registered devices and systems that meet all the criteria set forth by the Fieldbus Foundation? A qualified automation supplier supports and endorses partner products. Honeywell's PKS Advantage™ program offers a non-exclusive environment where the best automation solutions suppliers collaborate to develop and deliver truly open solutions. PKS Advantage participants use open communications protocols to distribute data and information throughout the system. Click here to read more about the PKS Advantage program.
Smar challenges users to re-think role of field instruments 
Few suppliers or end users question the benefits of FOUNDATION fieldbus. However, some common misconceptions stand in the way of the technology realizing its full potential. It is wise to understand these issues when selecting a fieldbus-based control system. FOUNDATION fieldbus brings an open standard to bus technology and provides open methods for a process automation system in the most distributed architecture possible. Unfortunately, some applied fieldbus systems still resemble a traditional, proprietary architecture, with controls concentrated in one or several controllers. These systems do incorporate FOUNDATION fieldbus H1 for field-level networks, and the networks use interoperable field instruments for measuring and sensing. They may even be configured to generate diagnostic alarms. But, that is all they are configured to do. A centralized fieldbus implementation plays little or no part in true process automation. A central controller still handles automation functions, with measurements from the H1 device network polled using the standard FOUNDATION protocol. And control outputs are still written to valves and output devices from the same central location. Users get the wrong impression of FOUNDATION fieldbus when they just replace traditional 4-20 mA loops with a digital, interoperable H1 bus. The time has come to re-think the role of field instruments in a typical process automation architecture. With FOUNDATION fieldbus, the functional divide between a centralized DCS and field devices no longer exists. Each new device connected to a fieldbus control system provides additional resources that should be exploited to the fullest. Visit the Smar Web site to learn more.
Softing offers economical way to get on the bus
FBK is small enough to be integrated into most existing device housings. The connection point is between the HART modulator and the device hardware. Because the hardware is ready-to-use, no costs are incurred for fieldbus physical layer testing. The board is fully designed to the specifications of the Fieldbus Foundation and comes ready for all necessary conformance testing. Ready-made templates can be customized to provide unique features to an application-specific device. Existing HART device commands are mapped right through to the H1 side. The kit also handles essential user-defined commands. The costs of building the required Device Description files are included in the kit. In terms of physical bus characteristics, both FOUNDATION fieldbus and Profibus PA use the H1 standard according to IEC 61158-2. The necessary function blocks are also very similar, making it only a small step to get a new fieldbus device to work with both technologies. For more information, visit the Softing Web site.
Yamatake releases control valve maintenance system
The system lets users visualize control valve health and provides maintenance advisory information. Its real-time condition monitoring and advisory alarm function helps reduce breakdown maintenance and total CV overhaul costs. CV health alarms generate maintenance requests to minimize unexpected control valve failures. Important control valve and safety-related information can be monitored in real -time with the CV Stick Slip diagnostic function, which statistically monitors CV hysterics. Valstaff also provides remote calibration of control valves through an auto set-up function in the AVP300 Series smart valve positioner. Yamatake's AVP 300 Series smart valve positioner has operated in the field for more than a decade. More than 100,000 are installed (including in conventional 4-20 mA environments). Users may upgrade conventional 4-20 mA AVP 300s to HART or FOUNDATION fieldbus communication environments. Learn more about Valstaff on the Yamatake Web site.
Yokogawa enhances its asset management software
PRM lets users remotely access devices that have the field communication capability and intelligence of FOUNDATION fieldbus. It integrates FOUNDATION fieldbus technologies with others, such as HART, providing the benefits of FF while protecting existing investment strategies. PRM supports advanced capabilities that offer information and centralized management of parameters and the intelligence provided by devices. Demand for lower total cost of ownership for measurement, automation, and information systems, and the need for optimum operation, has driven the development of PRM enhancements. These include advanced diagnosis and calibration data management functions. With a "documenting calibrator interface," users can upload field gathered data to the PRM database. PRM takes advantage of "smart" devices and advanced diagnostics so that maintenance staffs can understand which devices truly need maintenance by operation—not only by schedule. Dependence on large maintenance systems is costly. Use of automated maintenance can significantly reduce costs. The interactivity of FOUNDATION fieldbus lets instruments be monitored online and data communicated to other entities in the enterprise. PRM's interface to computerized maintenance management systems (CMMS) gives customers a major advantage toward meeting their plant device maintenance needs. For more information about PRM, click here to visit the Yokogawa Web site.
MTL introduces process junction boxes
Process JBs benefit from MTL's experience with the SECCO and Nanhai projects, the world's 2 largest fieldbus projects installed thus far. On both projects, engineering costs were significantly reduced by the approval of the Process JBs. The Process JB product range is suitable for Zone2/Division 2, Zone 1/Division 1 intrinsically safe, and Zone 1 increased safety applications. Process JB enclosures offer space for cable terminations and a choice of cable gland types to meet exacting process industry requirements. Product range includes painted stainless steel, carbon loaded polyester, and polished stainless steel. Process JBs are available now. Click here to download a complete data sheet.
Fieldbus launches 'User's Corner' Fieldbus Foundation recently announced the creation of the "User's Corner." Part of Fieldbus Forums, the User's Corner is a convenient, Web-based interface to the latest FOUNDATION fieldbus end-user stories, successes and references. Now, end users can post and receive valuable information from the forum site, allowing the community to gain knowledge from their counterparts. There is no better place than this new forum to find answers to your questions on installation stories, benefits, savings, and more. Ian Verhappen, director of ICE-Pros Inc. and chairman of the Fieldbus Foundation End-User Advisory Council stated "this User's Corner forum is an excellent addition to Fieldbus Forums because the venue lets end users share their insights in greater detail, allowing a broader knowledge base around the world." By establishing the User's Corner, the Fieldbus Foundation continues its tradition of openly sharing knowledge and experiences related to Fieldbus technology. This searchable knowledge-base community is open to members and nonmembers. Anyone who has experiences with the technology is welcome. The stories will have an end user focus and will not be host-oriented unless the host content greatly contributed to the overall project. Shell Deer Park, TX, a leadership installation, has been selected for this inaugural launch of the User's Corner for December 2004. Click here to read the Shell Deer Park story. Click here to register for Fieldbus Forums.
Shell Deer Park, TX, posts their experiences with FOUNDATION fieldbus in the User's Corner: Predictive maintenance Shell Deer Park Refinery—Cat Cracker location. We found several fieldbus transmitters issuing communication failure diagnostics. Upon investigation, it was discovered that an error in installation had left loose conduit plugs on transmitters, allowing thermocycling to introduce water vapor into the transmitters. The problem was discovered before there was any impact to operations from failed transmitters. Foundation Fieldbus technology impact: Eliminated potential loss of product. Cost savings: Estimated in a range between $3M-$50M. Click here for more information.
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The BP fieldbus demo continues to make progress. The Lima, OH, Butanediol (BDO) manufacturing project, is a "live," world-scale chemical production plant that safely handles substances in a continuous process. As part of the technology demonstration project, new system integration techniques are being demonstrated using FOUNDATION fieldbus.
A partnership between the British Nuclear Group (BNG) and Yokogawa has helped BNG realize self-certification of instrumentation for use in nuclear industry applications. BNG, a business group of BNFL plc in the United Kingdom, described the achievement at a recent Fieldbus Foundation European End-user Council meeting in Antwerp, Belgium.
Make time to attend the first Fieldbus Foundation seminar of the new year and learn what's new with FOUNDATION fieldbus technology. The seminar will take place on January 28 in Downey, CA (greater LA area), and will be hosted by the Energy Resource Center, a training center for petrochemical companies.
EPC (engineering, procurement, construction) contractor ICA Fluor/Industria Del Hierro (ICA Fluor) has selected ABB's IndustrialIT Extended Automation System 800xA to automate PEMEX's offshore drilling platforms, located at the Ku-Maloob-Zaap field in Sonda de Campeche, Mexico. The $4.5 million project includes System 800xA with redundant AC800M controllers, Plantguard Systems for emergency shutdown and fire and gas systems, FOUNDATION fieldbus technology, safety transmitters, and Totalflow computers. The order also includes project management, engineering, design, construction, training, test, commissioning, and start-up.
Emerson Process Management's replacement of independent level measurement equipment on seven spherical propane and butane storage tanks at the Esso refinery at Slagen in Norway, is achieving installation savings and integrating the measurement solutions with the refinery network at no extra cost. Emerson supplied 
Because an open Ethernet backbone lets every subsystem be integrated into a control system without proprietary interfaces, Endress+Hauser chose FOUNDATION fieldbus HSE for its ControlCare field-based control platform. The ControlCare SFC162 Bridge/Linking Device and ControlCare SFC173 HSE/Profibus DP Gateway are tailored to connect to FOUNDATION fieldbus H1 and Profibus DP/PA networks.
Texas Skill Standards Board recently recognized the industrial instrumentation and controls technician skill standards developed through a Lee College Fieldbus Center project. The effort was funded in part by a National Science Foundation grant.
FM has granted Non-Incendive (Class I Division 2 Groups ABCD) approval for Hawke's TG200 Series Device Coupler. The device has also received Sira approval as Non-Incendive Ex nA[nL] IIC for Zone 2 in European applications.
Choosing a knowledgeable, experienced, and supportive automation partner is the key to implementing a successful FOUNDATION fieldbus project—and to reaping all the benefits that fieldbus has to offer.
Softing's Fieldbus Kit (FBK) is an off-the-shelf, proven solution for rapidly developing FOUNDATION fieldbus H1 field devices for Intrinsically Safe (IS) and non-IS environments. Used in conjunction with an existing HART slave device, it creates a complete fieldbus product.
Valstaff, an advanced control valve maintenance support system, released by Yamatake Corp., is based on more than 70 years control valve manufacturing and field maintenance service experience. It is available with either HART communication or FOUNDATION fieldbus with the AVP300 Series smart valve positioner.
Yokogawa recently enhanced its Plant Resource Manager (PRM), powerful, value-added asset management software that integrates and manages maintenance information from field instruments, monitors online conditions, and records historical data.
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