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Fieldbus Foundation Safety System Demo at Shell Global Solutions Amsterdam is a Success

The introduction of a fieldbus-based safety system, otherwise known as Foundation Fieldbus Safety Instrumented Functions (FF-SIF), was one of the most anticipated events in the world of process automation this year.  ARC was fortunate enough to be able to attend the successful first demonstration of the system at Shell Global Solutions in Amsterdam on May 20th.  It was obvious from the beginning of the event that FF-SIF is going to have a tremendous amount of end user support.  Aside from the Shell representatives, there were several users from companies, such as Chevron, Saudi Aramco, BP, Exxon Mobil, and many others.

It is very clear that the end users want this technology and are striving to include FF-SIS systems in their project specifications.  Peter Eigenraam from Shell stated that they would probably be specifying FF-SIF systems for their new projects starting in 2011.  According to Peter, “FF-SIF is a logical extension and a follow-up to fieldbus for process applications”.  In addition to the demo in Amsterdam that served as the primary media event, other FF-SIF systems were being tested simultaneously at Chevron in Houston, Saudi Aramco in Dhahran, and BP in Germany.

A Multivendor System

The demo system itself was comprised of products from several vendors.  The actual safety system was provided by HIMA, while Yokogawa provided the basic process control system and plant asset management software.  Field instrumentation was provided by ABB, Endress+Hauser, Magnetrol, Siemens, and Smar.  Valves were provided by Emerson, Metso Automation, and Westlock.  Other suppliers included, RuggedCom and Softing.  The demos running at Aramco, Chevron, and BP included other systems and products from all of the major process automation suppliers.  Other supplier representatives on hand at the demo included people from Honeywell, Invensys, Moore Hawk, Biffi, MTL, Topworx, Azbil (Yamatake), Dresser Industries, MTL, Pepperl + Fuchs, and Risknowlogy.

Demo Highlights the Value of Predictive Diagnostics in SIS

The demonstration of the system itself provided a glimpse into the primary value proposition of FF-SIS – the advanced diagnostics functions.  There was some palpable tension in the air as the system itself was demonstrated live, but everything was executed flawlessly.  Functions demonstrated included high and low level trips, partial stroke testing of valves, and a partial stroke test that was interrupted by the ESD.  The last example showed that even in the middle of a partial stroke test the ESD could successfully take over and shut down the system during an abnormal situation.  Two out of three (2oo3) voting was demonstrated using Yokogawa, Smar, and E+H devices.  The system also reacted successfully to a loss of temperature probe, and the system reacted successfully to a measurement validation alarm and a diagnostic alarm generated from a dry probe on a Magnetrol level device.

Rich Timoney, President of Fieldbus Foundation, put it nicely when he stated that the difference between an FF-SIF system and a conventional emergency shutdown system is the same as doing a forensic analysis on a patient after he is dead versus performing proactive diagnosis to address problems before death occurs.  Advanced diagnostics ensure that many issues can be addressed proactively before the ESD needs to step in and do its job.

A Standards-Based Solution

Foundation Fieldbus has always adhered to the international standard, and the SIF is no exception.  The FF SIS protocol meets the IEC 61508 standard for functional safety systems up to SIL 3, and allows users to build safety systems that adhere to the IEC 61511 standard for functional safety in the process industries.  The protocol has already received TÜV approval, and suppliers are going to start submitting their products for TÜV approval over the next year.  This means that we should see actual products that are certified by TÜV available commercially some time in 2010, with implementation on large projects probably in 2011, as Shell indicated.

Moving Ahead

Aside from product development and approval, future developments from the Fieldbus Foundation and member companies include developing best practices and guidelines for FF-SIF implementation, quantifying the reduction in total cost of ownership, and quantifying reduced installation costs associated with the technology.  The Fieldbus Foundation also has to go through the process of testing devices from suppliers when they are available to ensure that they meet FF specifications (the Foundation “check mark” that everyone is familiar with).

ARC expects that adoption and implementation of FF-SIF systems should be accelerated by the fact that many end users are specifying FF-based systems and devices for their large grassroots projects today, so we will not have the same gradual bell curve of acceptance that we saw in the early days of fieldbus.  Many systems integrators have also shied away from implementing fieldbus systems, because safety systems account for a large portion of the I/O on major projects.  With an FF-SIS system available, it will be increasingly difficult to make that argument.

ARC also sees a lot of potential for FF-SIF in existing facilities.  There are a number of older safety systems installed in plants today that will require upgrading, just as there are a large number of ageing basic process control systems.  Availability of FF-SIF and its promise of reduced spurious trips, advanced diagnostics, reduced lifecycle and operational costs, and compatibility with existing hardware infrastructures, could provide many end users with the impetus to convert to these systems more rapidly.  The large amount of end user support around the Amsterdam demo is a strong indicator that FF-SIS has a strong future.