Dr. Norbert Kuschnerus, Bayer Technology Services, Page 1 Fieldbus Foundation – European General Assembly 2008 Fieldbus User´s Experiences, Requirements and Expectations

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 2 Content 1. Introduction A short fieldbus-history in the light of user statements 2. Requirements The essential properties of a successful fieldbus solution 3. User Experiences 10 years of fieldbus use in a nutshell 4. The Path forward Fieldbus as an empowering technology

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 3 Introduction A short fieldbus-history, in the light of user statements Source: presentation of Dr. Pfleger (BASF) at the NAMUR General Meeting : The further increasing use of digital technology in field devices combined with more intelligence in the field generates a need for more complex communication, which cannot be implemented with today´s technology. An obvious technical solution is the use of a fieldbus.

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 4 Introduction A short fieldbus-history, in the light of user statements Source: presentation of G. Rehn (Bayer Technology Services) at the NAMUR General Meeting 2001) 2001: Today we know, that the combination of fieldbus and intelligent field devices is the key technology for the implementation of modern asset management for devices and plants. We are still at the beginning of the use of fieldbus as a means for communication between field device and control system.

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 5 Introduction A short fieldbus-history, in the light of user statements Source: presentation of M. Pelz/S. Seintsch (Clariant/BIS Prozesstechnik) at the NAMUR General Meeting 2005) The end of the road is not reached yet 2005:

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 6 Introduction A short fieldbus-history, in the light of user statements Source: presentation of M. Pelz (Clariant) at the NAMUR General Meeting 2007 Moderne Feldgeräte werden immer komplexer, benötigen hierfür eine komfortable/zentrale Bedienung Moderne Feldgeräte werden immer komplexer, benötigen hierfür eine komfortable/zentrale Bedienung Die heutige zentrale Gerätekommunikation ermöglicht eine effiziente Instandhaltung, erfordert jedoch noch einen zu hohen Aufwand im Bereich der Geräteintegration Die heutige zentrale Gerätekommunikation ermöglicht eine effiziente Instandhaltung, erfordert jedoch noch einen zu hohen Aufwand im Bereich der Geräteintegration Die zentrale Gerätekommunikation von morgen soll eine stabile Plattform für moderne IH-Strategien, MES, Gerätediagnose, ASM, bilden, ohne Mehraufwand und mit langfristiger Investitionssicherheit! Die zentrale Gerätekommunikation von morgen soll eine stabile Plattform für moderne IH-Strategien, MES, Gerätediagnose, ASM, bilden, ohne Mehraufwand und mit langfristiger Investitionssicherheit! The selection of field devices must no longer be dominated by issues of device integration, it must rather be governed by the properties of the device itself. 2007:

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 7 Introduction A short fieldbus-history, in the light of user statements Moderne Feldgeräte werden immer komplexer, benötigen hierfür eine komfortable/zentrale Bedienung Moderne Feldgeräte werden immer komplexer, benötigen hierfür eine komfortable/zentrale Bedienung Die heutige zentrale Gerätekommunikation ermöglicht eine effiziente Instandhaltung, erfordert jedoch noch einen zu hohen Aufwand im Bereich der Geräteintegration Die heutige zentrale Gerätekommunikation ermöglicht eine effiziente Instandhaltung, erfordert jedoch noch einen zu hohen Aufwand im Bereich der Geräteintegration Die zentrale Gerätekommunikation von morgen soll eine stabile Plattform für moderne IH-Strategien, MES, Gerätediagnose, ASM, bilden, ohne Mehraufwand und mit langfristiger Investitionssicherheit! Die zentrale Gerätekommunikation von morgen soll eine stabile Plattform für moderne IH-Strategien, MES, Gerätediagnose, ASM, bilden, ohne Mehraufwand und mit langfristiger Investitionssicherheit! 20 years our engineers have been bothered with integrating field devices into the automation system. We should rather be able to select the devices according to their suitability for the process application. 2007:

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 8 Requirements Fundamental User Requirements: Reliability of fieldbus installations matches that of conventional installations Explosion Protection application as simple as for conventional installations Commissioning and startup problem-free as in conventional installations Interoperability and interchangeability ressemble that of conventional installations Life time support available like for conventional installations Fundamental User Requirements: Reliability of fieldbus installations matches that of conventional installations Explosion Protection application as simple as for conventional installations Commissioning and startup problem-free as in conventional installations Interoperability and interchangeability comparable to conventional installations Life time support available like for conventional installations

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 9 Requirements Extended User Requirements: Lower life-time costs than conventional installations Enhanced diagnostic support for field devices compared to conventional installations Fieldbus for Safety Applications Fieldbus as an enabling technology -for new automation solutions, that helps increase the plant performance: asset management systems advanced process control systems performance monitoring systems -to increase operator knowledge about process and plant.

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 10 Experiences Planning, installation and commissioning of the basic functionality do not pose a problem. Once a fieldbus installation is running, it has a good availability. Fieldbus has made possible the desired integration of the different systems (PCS, Asset Management, configuration) and devices.

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 11 Experiences Replacement of devices and extensions of the system can be a problem, due to this tight integration (both Hardware and Software). Each component in these integrated systems has its own software version. Updating a software module frequently causes problems. Due to the complexity of the technology there have been reliability problems. Today we do not have long term experiences with the operation and maintenance of these integrated systems.

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 12 The Path forward The two keys to a fieldbus success-story: 1.Make sure, that end users can rely on fieldbus technology (i.e. remove users current reservations to implement fieldbus systems) 2. Develop vendor independent functionality, that helps users to increase the performance of their plants.

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 13 The Path forward 1.Make sure, that end users can rely on fieldbus technology Make fieldbus design, installation and maintenance as simple as for conventional mA installations Solve the various problems still associated with fieldbus technology

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 14 The Path forward 2. Develop vendor independent functionality, that helps users to increase the performance of their plants. Use fieldbus to provide support for: Engineering and startup phase of the plant (e.g. startup monitor with additional information) Automation equipment diagnostics and maintenance Management of the plant assets Operation of the plant Advanced process control Increased operator knowledge about process and plant

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 15 The Path forward 2. Develop vendor independent functionality, that helps users to increase the performance of their plants. Use fieldbus to provide support for: Operational Excellence

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 16 The Path forward Performance plant utilisation product yield product quality availability safety ability to deliver costs consumption of energy and raw materials inventory labor utilisation capital investment automation technology is the basis for success Source: Bayer Technology Services GmbH

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 17 The Path forward Plan Source Commission Operate / MaintainRetire Plant Asset Management Optimize :  product yield  plant availability, plant lifetime  EAM: Enterprise Asset Management  CALM: Collaborative Asset Lifecycle Management Source: presentation of Dr. Gote at the NAMUR General Meeting 2006 Plant Asset Management supports the longest phase of the lifecycle

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 18 The Path forward reserve of wear-out reliability plant performance NE 107 ?  NE 91 Source: presentation of Dr. Gote at the NAMUR General Meeting 2006 Aspects of Asset Management

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 19 The Path forward Source: Bayer Technology Services GmbH P T L F Monitoring of process and plants Monitoring of Units F PR T PR T HC V HC Diagnostic of intelligent field devices and machines In-Process S-A-L *) Monitoring L Asset Management for Production Support Aspects of Asset Management *) Sensor-Actuator-Loop

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 20 The Path forward Source: Bayer Group Diagnostic of intelligent field devices and machines Installation 2003 Documentation for 2002 nicht complete

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 21 The Path forward Liste of control loops with status information List of suppressed control loops Details for selected control loops Diagnostic information Source: Dr. Dünnebier, Bayer Technology Services GmbH Controller Performance Monitoring

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 22 The Path forward Source: presentation of Dr. J. Kiesbauer, Samson AG Valve Diagnostics

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 23 The Path forward Performance and Asset Monitoring Current energy consumption? Fouling of condensor? Efficiency of collumn? Efficiency factor and status of pump? Conversion and yield of reaction? Quality of control? Measured value OK? Operating efficiency of plant / unit? Source: Dr. Klatt, Bayer Technology Services GmbH

Fieldbus Foundation – European General Assembly 2008 Dr. Norbert Kuschnerus, Bayer Technology Services, Page 24 Conclusion Although fieldbus technology today is reliable and usable, there is still room for improvement. Especially the problem of software versions in a tightly integrated environment needs to be solved to remove users current reservations to implement fieldbus systems. Future developments of fieldbus functionality and solutions for device integration should make available the full potential of fieldbus technology. It is crucial for the success of fieldbus technology, that vendor independent solutions become available, that are easy to engineer and that support the manufacturers in achieving operational excellence.