1. Safety System Migration: The Fieldbus Advantage Big Changes Ahead

2. Presenters Larry O’Brien Global Marketing Manager Fieldbus Foundation

3. Introduction Changing Landscape of Safety Safety System Migration Wave is Coming Fieldbus for Process Safety? End User Pilot Program SIF Project and Specification Updates Are we Ever Going to see SIF Products? The Human Side Common Misconceptions

4. The Safety Challenge More severe and high profile plant incidents have plagued the process industries Bad actors have been ordered to revamp their “safety culture” Even companies with a good safety culture must be vigilant There is a pressing need to modernize the process safety infrastructure

5. Regulatory Environment Heats Up Major industry incidents are contributing to tighter legislative and regulatory environment. BOEMRE Strengthens Offshore Inspections Program Increased Civil Penalties NRC Rethinking Safety Requirements after Fukushima Disaster API 560 for Fired Heaters

6. Developing a Safety Culture “The fish rots from the head down” – if upper level management does not consider safety to be a top priority, it will not trickle down to the rest of the organization. Safety culture means doing “the right thing at the right time in response to normal and emergency situations.“ – From International Maritime Organization

7. The Business Value of Safety  Hard for many end users to justify safety system modernization  Not always easy for people to make the connection between safety and profit  Increasing time between turnarounds: 7-10 years in refining, online proof testing is needed  Plants have to be more flexible and adaptive, this presents a greater safety challenge  Fewer and less trained personnel  Unplanned Downtime accounts for $20 billion in the North American process industries

8. Safety Systems: The Monster Under the Bed? Users don’t normally like to deal with SISs Conventional safety systems are meant to lay dormant until they are needed Upgrade is a hassle, leave it alone as long as possible Upgrade projects are administrative- intensive, not “self actualizing” – John R. Somehow the legacy installed base has to be dealt with Can fieldbus make you love your safety system?

9. The Process Safety Modernization Conundrum Users are dealing with a huge installed base of process automation systems that are reaching the end of their useful life Most of these systems are older than 20 years according to ARC research In addition to these, there is a large installed base of process safety systems Safety system modernization is a completely different approach and has its own unique set of regulatory requirements The process safety system installed base profile is much older, comprised of older technology (relay based systems)

10. How big is the Installed Base? ARC Advisory Group says $65 billion for DCS alone. The overall market for process safety system is much smaller than DCS. Even if the aging installed base of safety systems is just 12 percent that of DCSs, it still amounts to $8 billion worldwide. The value of replacement is much higher due to the increased need for system engineering services and services related to regulatory compliance. Image Courtesy of AXESS.sk

11. Differences Between DCS Migration and Safety System Migration The state of many older installed relay based systems has been described as “Brittle” No such thing as phased modernization, it’s all or nothing Instruments and valves replaced at the same time Regulatory compliance, ISA 84, IEC 61508, IEC 61511 Must follow the safety lifecycle as outlined in these standards

12. Old Approaches Versus New Most safety systems are overspecified Old approach was just to buy a SIL 3 safety system and call it good Now we have to follow a new set of standards that call for a more careful evaluation of the safety lifecycle, LOPA This means less SIL 3 controls, more SIL 2

13. IEC 61511 Lifecycle Elements Perform Hazard and Risk Analysis: Determine hazards and hazardous events, the sequence of events leading to a hazardous condition, the associated process risks, the requirements of risk reduction, and the safety functions required. Allocate Safety Functions to Protection Layers: Check the available layers of protection. Allocate safety functions to protection layers and safety systems. Specify Requirements for Safety System: If tolerable risk is still out of limit, then specify the requirements for each safety system and respective safety integrity levels (SIL).

14. Foundation Fieldbus Safety Instrumented Functions (SIF) Foundation Fieldbus SIF –FOUNDATION Fieldbus is a all-digital communications protocol for the process industry –Can check the health of I/O and field devices –The system can incorporate sensor validation and environmental condition monitoring –It is a cost effective alternative to traditional field wiring –Provides network diagnostics, “The Black Channel” –Has recently been beta tested successfully –Pilot projects underway

15. FF-SIF Summary H1 Communication (Black Channel) is unchanged. SIF protocol detects network faults and appropriate action is taken. New SIF Function Blocks (AI, DO, DI, Write Lock). Function Block diagnostics detect application faults and appropriate action is taken.

16. Black Channel

17. Why FF-SIF? Improved Safety: SIF will allow for improved device self- diagnostics that will detect dangerous failures…reducing the number of dangerous undetected failures. Improved Operability: SIF device configuration will allow a valve to trip-on-demand-only and provide new device self- diagnostics…reducing the number of process interruptions due to nuisance trips. Reduced Cost: Improved configuration and installation flexibility offered by SIF will reduce safety system cost via asset management tools and multi-drop architecture.

18. Improved Safety Diagnostic data from devices can help eliminate process incidents It can also help you determine if your process assets are ready to protect you should the need arise (partial stroke testing, online proof testing) Fieldbus offers the best device self-diagnostics, which can be used to detect dangerous failures Reduce the number of failures Advanced network diagnostics in black channel approach reduces risk of communication failure

19. Why We Need Better Field Diagnostics for Process Safety Systems Source: Hydrocarbon Processing

20. F OUNDATION for SIF Reduces PFD Chevron's Analysis Shows that FF-SIF Greatly Reduces Potential Probable Failure on Demand Compared to Conventional Safety Systems

21. Improved Operability Valve trip-on-demand-only: “Trip-on-demand only systems utilize redundant and diverse communications and embedded logic in safety critical field devices to recognize and trip only on true demand signal and to fail-steady when internal failures of the device or the communications network are detected.” New device self-diagnostics Reduced nuisance trips increase unplanned downtime

22. FF-SIF Partial Stroke Testing Online partial stroke testing through HMI F OUNDATION -fieldbus based safety valves can provide much faster response times for status information compared to other networks F OUNDATION -fieldbus based safety valves provide easier integration of higher tier diagnostic information into the host system.

23. Single Version of the Truth You know you are getting a true measurement, no digital to analog conversion Persistent data storage: audit trail and reporting Data is timestamped F OUNDATION Fieldbus devices can indicate data quality -- whether signals communicating setpoints, PVs, etc. have good, bad or uncertain quality.

24. Reduced Cost Smaller Footprint: how much room do you have in your control building to migrate your old relay based safety system to a modern safety system? Marshalling cabinets Overall less hardware Eliminating HART multiplexers reduces complexity With digital positioners, no solenoids or limit switches Reduced wiring and terminations

25. SIF Application Examples & Response Times

26. FF-SIF Can Coexist within Conventional Safety Systems

27. A Solid, End User Driven Development History Working Team –ABB Instrumentation –Emerson Process Management –Fieldbus Foundation –HIMA –Honeywell SMS bv –Invensys/Triconex –Kellogg Brown & Root –Metso Automation –Rotork Control Systems –Saudi Aramco –Shell Global Solutions –Smar –Softing –TÜV Rheinland –Yokogawa Reviewers & Advisors –ABB –E.I. DuPont –Emerson Process Management –ExxonMobil Research & Engineering –Fieldbus Foundation –Invensys –Rockwell Automation –Shell Global Solutions –Yokogawa

28. Logic Solver Level SIF Protocol Valve Pres H1 Network BIFFI Emerson Westlock Yamatake Emerson HIMA Honeywell Invensys - Triconex Yokogawa Magnetrol Siemens Milltronics ABB E+H Smar Yokogawa Moore MTL P+F Logic Solver Engineering Workstation Asset Management Basic Process Control System End User Demonstration Sites BP – Gelsenkirchen, Germany – Honeywell Logic Solver Chevron – Houston, TX – Emerson Logic Solver Saudi Aramco – Dhahran – Triconex Logic Solver and Yokogawa Logic Solver Shell Global Solutions – Amsterdam – HIMA Logic Solver Other Providers Fieldbus Diagnostics Risknowlogy RuggedCom Softing TÜV Rheinland TÜV SÜD Temp Smar End User Demonstration in May 2008

30. Aramco’s Justification

31. BP’s Justification FOUNDATION SIF technology is universal, simple and efficient One platform supporting FOUNDATION fieldbus and FOUNDATION SIF One system to learn, operate and maintain One scalable fault- tolerant network

32. BP’s Justification Lowest total cost of ownership Lowest initial cost to get started – scalable to plantwide network Integrated asset data available on all levels of the infrastructure Enter data once Proven in use Mix and match F OUNDATION fieldbus and F OUNDATION for SIF Can be introduced in existing fieldbus infrastructure without additional hardware

33. Shell’s Justification Benefits in operational phase Reliability and availability aspects Diagnostics and self-checks Control-in-the-field option Throughput and quality aspects Accurate control, less variability Operations aspects Support for reduced manning Support for remote operations

34. Demanded by End Users to gain benefits of H1 in Safety Instrumented Functions Technical Specification Development Project Approved by BOD in October 2002 TÜV Protocol Type Approval including SIL 3 in December 2005 Marketing Demonstration Approved by BOD in October 2005 Marketing Demonstration Press Day completed May 2008 SIF_AI and Interoperability Test System released in 2008 SIF_DO and Interoperability Test System released in 2010 Pilot projects underway at Shell and Saudi Aramco 2009 - 2011 SIF Registered Products Expected 2013 Timeline

35. Shell Project & Technology has decided that FF-SIF will be specified for use on a Nederlandse Aardolie Maatschappij (NAM) project in the Netherlands. This is the first of a number of identical projects expected to utilize the technology. Shell is in discussions with several leading automation suppliers for commitments on the logic solver. When the instrument scope is complete, Shell is expecting the various device vendors to provide safety-approved products for the initial installations. The Shell Project & Technology Group Process Automation Control and Optimization (PACO) will monitor the development together with our NAM project organization. Shell Project & Technology is anxious to see industry progress in the area of FF-SIF implementation. End User Pilot Projects: Shell

36. Saudi Aramco successfully launched two FF-SIF pilot projects and plans have been initiated to install working FF-SIF systems within operating oil and gas facilities. A project is planned for the Juaymah gas plant in Saudi Arabia in late 2010. Saudi Aramco expects FF-SIF installation at the Juaymah gas plant to show how the use of fieldbus communications results in lower costs due to reduced hardwired I/O to the safety logic solver, as well as enhanced local testing and diagnostic capabilities. A second FF-SIF installation is planned with emergency isolation valves with automated functional testing and diagnostics. This configuration will replace existing emergency isolation valves with new valve bodies and pneumatic valve actuators fitted with FF-SIF smart valve controllers. After these smaller pilot projects are complete, Saudi Aramco plans expanded deployment of FF-SIF technology in order to exploit its benefits on larger, mega scale projects. End User Pilot Projects: Saudi Aramco

37. FF-SIF Specification Updates AUSTIN, Texas, Dec. 7, 2010 — The Fieldbus Foundation today announced that updated device development solutions for its Foundation Fieldbus for Safety Instrumented Functions (FF-SIF) technology are now available. The new release includes the FF- SIF Technical Specification, Foundation for SIF Interoperability Test Kit (SIF ITK), and DD Library. These solutions support development of interoperable fieldbus devices intended for use in industrial plant SIF applications.

38. FF-SIF Specification Updates The latest Foundation for SIF Technical Specification defines analog input (AI) blocks for SIF devices. FF-SIF Function Block Specification now addresses discrete output (DO) blocks, which is a major enhancement required for deployment of a complete fieldbus-based safety system. The updated specification package also includes the SIF Device ITK Profile, offering an easy way to map SIF field device requirements to existing SIF ITK versions. The Foundation DD Library includes standard Device Description Language (DDL) code for SIF blocks.

39. So Where are the Products? Products are being used in pilot installations right now Products must go through certification process with exida, TÜV or other similar organization This is a time consuming process, then they go to the Foundation We are ready to test and register products with new ITK! We expect first wave of products in 2012

40. The Human Side Different approach,different work processes from 4- 20mA Must use plant asset management system capabilities like AMS Buy in and involvement in earliest stages of the project is critical Training is critical Fieldbus Foundation has resources for that

41. Conclusions FF-SIF Works, has been given type approval by TÜV, and is suitable for many SIF applications FF-SIF is not an all or nothing proposition, it can coexist with conventional analog system FF-SIF provides superior safety system diagnostics and addresses the leading causes of safety system failure FF-SIF provides a great value for those wishing to modernize their old safety systems

42. Questions?