Cooper Industries: Confidential F OUNDATION Fieldbus™ - Practical Success Stories Phil Saward, Product Manager

Introduction  Topics What is Fieldbus? Comparison with existing 4-20mA installations Typical field network F OUNDATION TM fieldbus in the Pharmaceutical industry When should Fieldbus be considered? Why use Foundation Fieldbus? Design, installation and commissioning Operation and maintenance  Economic benefits  Technical benefits

Fieldbus system niches

How is fieldbus different from 4-20mA? 4-20mA Power Supply fieldbus Power Supply In 4-20mA circuits, the power supply, field device and input card are connected in series. In a Fieldbus system, the power supply, field devices and input card are connected in parallel. Input card

Safe area Typical Fieldbus installation Redundant, isolated Fieldbus power conditioner Field wiring hub with spur short-circuit protection F OUNDATION Fieldbus Devices FIELD CONTROL ROOM Fieldbus control system (DCS)

Fieldbus Today

F OUNDATION fieldbus TM in Pharmaceuticals  Installed base worldwide (published by Fieldbus Foundation, 2008): >10,000 systems >700,000 field instruments  Diverse adoption: 9 of the top 10 oil & gas companies 24 of the top 25 pharmaceutical manufacturers 23 of the top 25 chemical producers 15 of the top 20 pulp & paper companies 10 of the top 20 food & beverage companies  ARC Advisory Group: “…powerful value proposition for fieldbus in the hybrid industries-namely, food & beverage and pharmaceutical, particularly when it comes to easing the process of validation and regulatory compliance and the integration of batch procedural operations with continuous processes. The function block structure of Foundation technology lends itself to these processes very well.”

Market Distribution Global Industry

Example FF applications in Europe OperatorLocationControl System Novo NordiskBagsvaerd, DenmarkEmerson AstraZenecaGartuna, SwedenEmerson NovartisBasel, SwitzerlandEmerson NovartisGrimsby, UKEmerson Sanofi AventisAramon, FranceEmerson Biogal Rt.Debrecen, HungaryYokogawa Glaxo SmithKlineCork, EireEmerson GenzymeBelgiumEmerson

When should fieldbus be considered?  ‘Green Field’ Facility  Facility Upgrade New unit operation  Process Automation Focus ≥ 60% of sensors are analogue  Existing cabling infrastructure is overloaded

Why use F OUNDATION fieldbus TM ?  Integrated digital architecture  “Future proof” Sensors can be field upgraded with new features  Economic savings Different incentives at each stage of a facility life cycle: Capital/Construction Commissioning Operations, maintenance Reduced infrastructure

Re-using Installed Cables Three existing 4-20 mA Pairs J-Box TT Fieldbus devices Three existing pairs, one used for fieldbus J-Box

ReplaceOperations & MaintenanceEngineering, Construction, & Commissioning/Start-up Economic Life Cycle Cash Flow Analog fieldbus Time

Engineering, Construction & Start-up Time startup Cash Flow Reduce implementation risk and cost Engage in FEED stage Sooner and faster start-up

Termination count FT FCV TT Field PT Junction Box Marsh Cab I.S. Barrier I/O Assembly Conventional analog termination Fieldbus termination (also included in conventional termination count) Marshalling done in Junction Box with Fieldbus so Marsh Cab is optional Totals:75 Analog 34 Fieldbus 4 pr 1 pr

Engineering - Network Loading  Number of devices per network segment mA per transmitter mA per valve  Segment Length Defined by Fieldbus standard function of number of devices Segment topology  Voltage Calculations 9 volt minimum at field device design for 12 volts  Bus Bandwidth Balance cycle time against number of devices Function of host control system  Virtual Communication Resources Required for communication between devices and host

Operations & Maintenance Cash Flow Higher sustained production with minimize costs Faster time-to profit Safer operation Fewer unscheduled outages Shorter scheduled outage Longer duration to scheduled outage

Measurement accuracy IS InterfaceI/O card PV = 392.8mb 12.83mAPV = 393.1mb12.87mA IS InterfaceH1 I/O card PV = 392.8mb Field JB + marshalling 12.86mA PV = 392.8mb Leakage + noise Conversion error 4-20mA Fieldbus

Diagnostics save wasted maintenance 63% of instrument maintenance labour results in no action taken: waste of resources 35% 28% 20% 6% 4% Shell Global Solutions

Fieldbus Project Costs  Estimated Project Savings Materials and Field Devices Some increase Installation Labour Savings up to 50% Commissioning: Significant savings up to 60%  Overall Capital Savings of 25–30% However savings will only be realized if the project is planned as a fieldbus project.

Foundation System Architecture  Scheduled Determinism Highly Reliable Performance  Automatic Addressing ‘Plug and Play’  Functional Communication Peer to Peer – More Powerful Publisher/Subscriber – Higher Performance  Alarms and Events Time Stamped, Auditable Records  Firmware Download Reduced Risk of Obsolescence  Rigorous Testing – Host & Device

Questions