Building Foundation to Meet Future Challengesftp.gongkong.com/UploadFile/datum/2010-9/...Building Foundation to Meet Future Challenges Jasbir Singh Vice President (Instrument) Field

Instrumentation with Field Bus Technology:

Building Foundation to Meet Future

Challenges

Jasbir Singh

Vice President (Instrument)

Field Bus: A Way Forward>>>>

Slide No. 2

Device Management

Diagnostics Server

Conventional System Fieldbus Control System

PID

Diag

AI

AOAI

Control Output

MV

Plant Operation

& Control

Full Digital Communication

Automatic

Alarm Notification

from Device

Intelligent Device

BENEFIT FORM FIELD BUS

New Technology to achieve high

quality, low cost and expendibilty

Optimize operation by improving

control model precision

Improve process safety / stability by

more process information

Predictive maintenance based on

device diagnose data

Acquire field information to improve

process capability


Slide No. 3

Why Field bus ?

What gain ?


Slide No. 4

Increase

Return on

Capital investment

Low Capital

Investment

Reliable Project

Documentation

Reduce Maintenance

costs

The Business Perspective – How can we

survive in the competitive world………..Fast Commissioning

& Startup Reduce cost of

poor

quality

Improve predictability


Slide No. 5

Increase ROI

Reduced

Project Capital

Installation &

Commissioning

Cost,

Spares

Inventory /

Addition of new

Device at every point

of time

Reduced

Feed stocks

Energy and Utilities

Maintenance

waste

Abnormal Events

Low grade product

Penalties

Increase Productivity

Increased

Yield

Product

Consistency

New product

Equipment Capacity

Equip. Efficiency

Reduction of losses

Reduced

Unscheduled Downtime

Small stoppages

Scheduled Shutdowns

Duration

variability

Increase RevenueReduce Costs

Reduce Capital Increase Profitability

Markets Served

>1,000,000 devices

Over 12,000 Systems


http://www.bechtel.com/Briefs/0704/CSPC.htm

http://www.findarticles.com/p/articles/mi_qa3829/is_200502/ai_n11849534

http://www.fieldbus.org/EndUserSupport/Installations/

2006

Revenues

2006 Revenue

%

2011 Revenue 2011 Revenue

%

CAGR

FOUNDATION

Fieldbus566.6 68.1% 1,714.2 75.2% 24.8%

Profibus PA 263.8 31.7% 564.1 24.7% 16.4%

Other 1.3 0.2% 1.5 0.1% 3.6%

Total 831.7 100.0% 2,279.8 100.0% 22.3%

Figures in Million $

Total Shipments of Fieldbus Solutions for Process

Industries by Communication Protocol

Global

NA

27%

LA

5%

AP

24%

EMEA

44%

Market Distribution


Market Distribution

Oil & Gas

17%

Refining

15%

Chemical

23%

Petrochemical

10%

Pharmaceutical

3%

Food & Beverage

4%

Pulp & Paper

5%

Electric Power

10%

Mining & Metals

3%

Water & Waste

Water

4%

Other

6%

Industry


More than just a digital replacement for 4-20mA technology.

Supplier neutral and standards-based. Provides end users with a common framework to implement and manage strategies for operational excellence.

FOUNDATION technology is a unified infrastructure.

•Manages data, communication, plant assets, and plant events.

•Provides highly distributed control functionality and interoperability between devices and subsystems.

The scope of FOUNDATION technology really makes it a process automation

infrastructure… one of the most advanced and scalable available.

An Automation Infrastructure

• Field Bus: A Way Forward>>>>

Extensive Block Model

Common Data

Common Time

Determinism

Publish and Subscribe

High availability

Standards Based Control Network

Network Management.

FOUNDATION technology incorporates all aspects of a Managed

Infrastructure.

Attributes Of A Managed Infrastructure


FOUNDATION™ SIF Technology DemonstrationBackground

– Fieldbus Foundation’s Safety Instrumented Function (SIF)

technology fulfills the requirements of the IEC 61508 standard up

to and including SIL 3

– With the TÜV Type Approval, FOUNDATION fieldbus provides a

solution for SIFs in a wide range of plant applications

– FOUNDATION SIF specifications enable manufacturers to build

fieldbus devices in compliance with IEC 61508

– Third-party test agencies such as TÜV will certify that devices

are suitable for use in SIS applications

– End-users can choose SIF devices meeting the requirements of

IEC 61511 from multiple suppliers, instead of being restricted to

a proprietary safety system platform


Participants

FOUNDATION™ SIF Technology

Demonstration

Overview

– FOUNDATION SIF technology demonstration sites include:

• Chevron Houston, Texas, USA

• Saudi Aramco Dhahran, Saudi Arabia

• BP Gelsenkirchen, Germany

• Shell Global Solutions Amsterdam, The Netherlands

FOUNDATION™ SIF Technology Demonstration


Demo Description

– Enhanced diagnostics through a

fully integrated asset management

system

– Less testing of final elements – able

to take credit for real demand as test

– Smart testing/diagnostic and online

testing/partial stroke testing

– Early detection of dangerous

device failures

– Less spurious trips






System Topology:


Test Cases

– Level Transmitter

• High level trip

• Low level trip (pump protection)

• Measurement validation comparison (level radar device vs.

DP level device) DCS

• Dry probe diagnostic alarm

– Temperature Transmitter

• Low temperature alarm/trip

• Loss of temperature element with voting (1 out of 1 voting)



Support of business processes, production

management, asset management and

enterprise level applications.

Provides enhanced capabilities for tracking,

tracing, validation, and regulatory compliance

for safety, continuous and batch/hybrid

process applications.

FOUNDATION technology provides a high degree of business intelligence at the

infrastructural level through publish/subscribe technology.

Business Intelligence


FOUNDATION™ SIF Technology Demonstration:

Impact of FOUNDATION Device Diagnostics


FOUNDATION™ SIF Technology Demonstration:

Conclusions (Cont’d)

– FOUNDATION fieldbus provides an excellent diagnostics

platform to achieve optimized asset management

– Ongoing GSES test program (including FOUNDATION SIF)

focuses on diagnostics for process interfaces and valve

positioners

– Diagnostic information is a “must” to move from predictive to

condition-based maintenance to

enable cost reductions and process availability improvements


High Speed Ethernet (HSE) - The key to scalability.

Provides a mechanism to connect multiple H1

segments without gateways.

All of the functions that are available on H1 are

also available on HSE.

FOUNDATION systems can be expanded without the

need to shut down the process.

Devices can be added or swapped “hot”, and the

technology supports online firmware downloads and

upgrades.

FOUNDATION technology offers unlimited scalability, and can be implemented in

the smallest to the largest process automation systems.

The openness of FOUNDATION technology and its non-reliance on a particular

operating system or supplier platform make it easy to adopt new standards.


OPC UA

Production Management &Web Access

Intelligent Field Instruments &

Valves

HSE

Plant AssetManagement, Visualization,

Alarm Management

Foundation Fieldbus H1

Pervasive EDDL & Function

Block Structure

FF Wireless Specification

Drives, PLCs, Analytical

FB

FB

FB

Safety Instrumented

Systems

LinkActive

Scheduler

System & Network

Management

OPC UA

Production Management &Web Access

Intelligent Field Instruments &

Valves

HSE

Plant AssetManagement, Visualization,

Alarm Management

Foundation Fieldbus H1

Pervasive EDDL & Function

Block Structure

FF Wireless Specification

Drives, PLCs, Analytical

FBFB

FBFB

FBFBFB

Safety Instrumented

Systems

LinkActive

Scheduler

System & Network

Management

An Automation Infrastructure for Automation Excellence



Slide No. 25

2.3 million barrel /day Nanhi

30,000 FF devices and commissioned in 2005. Field bus foundation used for entire plant automation

TENCO Refinery Russia


ConocoPhilips YERP Refinery Saudi Arabia


Refineries on FF:


Refineries on FF:

Petro Rebigh Saudi Arabia



325,000 barrel /day Mississippi

300,000 barrel /day Mississippi

260,000 barrel /day California

225,000 barrel /day California

45,000 barrel /day Salt lake

52,000 barrel /day Canada

210,000 barrel /day UK

54,000 barrel /day Hawaii

112,000 barrel /day South Africa

Chevron Refineries under going FF:


Emerson to Digitally Automate China's Largest Integrated

Refining/Petrochemical Facility:

EPM has been selected to digitally automate the Fujian

Refining and Ethylene Joint Venture Project in Quanzhou City,

Fujian Province, China. It is the largest integrated refining and

petrochemicals project ever undertaken in China. Project

startup is expected by 2009.

EPM will serve as the Main Instrument and Controls Contractor

(MICC) on the project, and will install its PlantWeb. The PlantWeb

installation will include eight DeltaV, AMS, safety instrumented

system (SIS), fire and gas systems, Rosemount pressure and

temperature transmitters, plus Fisher digital valve controllers, all

utilizing FOUNDATION fieldbus, HART, OPC and Modbus

communication technologies, and delivering information to a real-

time database.


Emerson to Digitally Automate China's Largest Integrated

Refining/Petrochemical Facility:

The project will expand the existing refinery at Quanzhou, Fujian

Province, from 80,000 barrels per day to 240,000 barrels per day.

The upgraded refinery will primarily refine and process sour Arabian

crude. In addition, new petrochemical facilities will be constructed,

including an 800,000 tons-per-year ethylene steam cracker, an

800,000 tons-per-year polyethylene unit, a 400,000 tons-per-year

polypropylene unit, and an aromatics complex to produce

700,000 tons per year of paraxylene. A 300,000-tons crude berth and

associated utilities will also be built.


CUSTOMER EMERSON PROJECTS

Indian Oil Corp Ltd Vadodara 9000 devices (Field Barrier)

Reliance Life Sciences Mumbai12500 devices (Field Barrier)

SRF LIMITED4900 devices (Field Barrier)

Andhra Sugars Limited4400 devices (Field Barrier)

NAGRUJUNA AGRICHEM LIMITED4000 devices (Field Barrier)

Shiram Vinyl & Chemical Industries3700 devices (Field Barrier)

Indian Oil Corp Ltd Barauni3300 devices (Field Barrier)

JOHNSON MATTHEY CHEMICALS INDIA PVT LTD 3000 devices (Field Barrier)

Aquapharm Chemical Co. Pvt. Ltd. 2400 devices (Field Barrier)

Continental Carbon India Limited2350 devices (Field Barrier)

DSM Anti - Infective India Limited Tabla2000 devices (Field Barrier)

ATUL LTD1950 devices (Field Barrier)

Cheminova India Limiited1900 devices (Field Barrier)

SRF Ltd.1500 devices (Field Barrier)


CUSTOMER EMERSON PROJECTS

Vinati Organics Ltd1500 devices (Field Barrier)

GODREJ INDUSTRIES LTD1500 devices (Field Barrier)

Bayer Ltd. 1450 devices (Field Barrier)

Jocil Limited 1300 devices (Field Barrier)

Bharat Petroleum Corporation Ltd.,1200 devices (Field Barrier)

DSM Anti - Infective India Limited1200 devices (Field Barrier)

Shriram Fertilizers and Chemicals Limited 1200 devices (Field Barrier)

NAGRUJUNA AGRICHEM LIMITED 1100 devices (Field Barrier)

Bayer Bilag 1000 devices (Field Barrier)

Novartis Enterprises Ltd 800 devices (Field Barrier)

JUBILANT ORGANOSYS 700 devices (Field Barrier)

BPCL Kochi Refineries 700 devices (Field Barrier)


Yokogawa awarded for Package Order to Supply Control

Systems for Petrochemical Complex in Singapore:

Yokogawa has received a package order from Shell Eastern

Petroleum (Pte) Ltd (SEPL) to supply control systems for the

Shell Eastern Petrochemicals Complex (SEPC) in Singapore.

At the SEPC, SEPL is constructing a new petrochemical plant

that will annually produce 800 thousand tons of ethylene and

750 thousand tons of mono-ethylene glycol and upgrading an

existing petroleum refinery with a refining capacity of 500

thousand bpd. Yokogawa shall deliver the control systems using the

latest FOUNDATION fieldbus technology for these upgrade and

expansion projects by December 2008. The delivered systems

will include the CS 3000, ProSafe-RS, Exaquantum (PIMS)

and EJX.


Yokogawa awarded as main system supplier for ESSAR refinery

expansion project:

Yokogawa secure the order as Main Automation Contractor &

supplier of DCS, ESD and F&G system for Essar refinery

expansion from 10.5 to 34 MMTPA. Yokogawa shall deliver the

control systems using the latest FOUNDATION field bus technology

for this expansion projects by December 2009. The Overall system

supply will include the CS 3000 VP, ProSafe-RS ESD & F&G.


CUSTOMER YOKOGAWA PROJECTS

ACC LIMITED - CHAIBASA 32 segment and 250 devices (FISCO PS)

SAINT GOBAIN GLASS INDIA LTD 32 segment and 250 devices (FISCO PS)

MRPL ISOM UNIT 68 segment and 600 devices (FNICO PS)

THE ANDHRA SUGARS LIMITED 25 segment and 200 devices (FISCO PS)

CONSOLIDATED CONTRACTORS CO.OMAN LL 25 segment and 200 devices (FISCO PS)

JUBILANT ORGANOSYS LTD 28 segment and 200 devices (Field Barrier)

ONGC C2/C3/C4 136 segment and 400 devices (Field Barrier)

GUJARAT NARMADA VALLEY FERTILIZERS 12 segment and 100 devices (FISCO PS)

HINDUSTAN ORGANIC CHEMICALS LTD.-

RASAYANI

90 segment and 400 devices (Field Barrier)

SYNGENTA INDIA LTD, 123 segment and 1000 devices (Field Barrier)

SERVALAKSHMI PAPER PVT LTD 150 segment and 1000 devices (Field Barrier)

BHARAT OMAN REFINERY LIMITED 1428 segment and 6000+ devices (Field Barrier & FISCO PS)

IOCL PANIPAT MSQ PROJECT 140 segment and 1000 devices (Field Barrier)

HPCL MITTAL ENERGY LIMITED 2240 segment and 11000+ devices (Field Barrier)

ESSAR OIL LIMITED 400 segment and 4000+ devices (Field Barrier)

MANGALORE REFINERY & PETROCHEMICALS

LIMITED-PHASE III EXPANSION

4176 segment and 16500+ devices (FNICO)


Honeywell’s 2007 Users Group Americas Symposium:

The Honeywell 2007 Users' Group Americas Symposium was

held June 10-14th in Phoenix at the Arizona Resort and Spa. A

record attendance of over 1,700 people from around the world

participated in the event that included a general session on

industry innovations and advancements, technology and

solutions update sessions, industry break out sessions, and an

exposition demonstrating key Honeywell products, solutions,

and services. Honeywell is also attracting a lot of recognition

for their innovative highly integrated POMS and Experion PKS

Batch Control System solution for the Pharmaceutical industry.

In ARC’s view, the new system comes closest to meeting a full

implementation of the ISA 88 batch standard.


Honeywell secure $ 4.7 million automation project of

cement plant in west Virginia with FF:

• Qatar Shell Improves Efficiency of GTL Plant

Honeywell was selected by Qatar Shell GTL Ltd. to design and

implement the integrated process automation system for the

Pearl Gas to Liquids (GTL) plant. This includes installation

of the Experion Process Knowledge System (PKS) Release

300, with FOUNDATION fieldbus communication, to tie

together all critical subsystems in the plant.

With the integrated automation platform, Qatar Shell GTL Ltd.

will be able to efficiently control GTL operations from

production at the platforms, to processing at the on-shore

plant, to shipping of the finished product.


Slide No. 37

Customer Honeywell Projects

HPCL, Mumbai LOBS ( C300 Controllers, FF – Field Barriers ) – FF I/O– 2000

HPCL, Mumbai FCCU ( C300 Controllers, FF- Field Barriers/FISCO) – FF I/O – 1300

BPCL-Kochi NHT CCR ( C300 + FF ( Field Barriers ) – FF I/O – 1700

IOCL-Baroda VGO ( C300 Controllers + FF – Field Barriers ) – FF I/O – 1200

Chemplast PVC ( C300 Controllers + FF – Megablock ) – FF I/O - 600

IOCL-Haldia SRU ( C300 Controllers + FF – FISCO ) – FF I/O - 1400

MRPL,

Mangalore

CDU I ( C300 Controllers + FF – HPT ) – FF I/O - 200

OMPL Aromatics ( C300 Controllers + FF – HPT / FISCO ) – FF I/O - 4500

OPAL Petrochemical ( C300 Controllers + FF – Field Barriers ) – FF I/O - 6000

IOCL,

Paradeep

Grass Root Refinery ( C300 Controllers + FF – Field Barriers)- FFI/O - 16000


Slide No. 38

INVENSYS IS THE SYSTEM SUUPLIER FOR RELIENCE

REFINERY EXPANSION:Invensys is the Main automation contractor and system supplier for

upcoming refinery and polypropylene plant. The refinery capacity is doubled

to 62.5 MMTPA with current expansion. This is state of art plant with fully

automated and Foundation Field bus system in most of the control loops.

The plant FF system is commissioned with advance diagnostic module from

MTL. Reliance award Invensys first refinery full automation i.e. DCS,

ESD,TAS,OFFSITES and Field Instruments like Transmitters. Based on past

experience having Invensys system in Old refinery , Reliance extend all the

full automation portfolio of Invensys to new refinery. Reliance uses Invensys

Solutions like Enterprise Control system, Online Optimization package and

their major New project like KGD6 also Invensys solutions are selected.

JERP Expansion total Solution are extended in the same system with all new

technology implemented while maintaining all old Hardware.

.


ABB system and Asset Master: a New Comprehensive

Field Device Management and Optimization Solution:

ABB introduced Asset Master, a new software solution that

helps user to meet these objectives, as well as providing

traditional set-up tools for instrumentation configuration and

calibration.

ABB system used state of art plant operation on Profibus

DP for high precision Fibre production in Thailand using

multiple protocol for information exchange with other

systems.


CUSTOMER ABB PROJECTS

Tata Steel, Sinter Plant 3000 IO on Profibus, 250 FF Devices, 7OS

Reliance Patalganga, Conitnuous Polymerisation

Plant - 7 4500 IO, 1ES/OS+5OS, FF, IM

Reliance Hazira, Conitnuous Polymerisation Plant - 104400 IO, 1ES/OS+5OS, FF, IM

Reliance Hazira, Conitnuous Polymerisation Plant - 116600 IO, 1ES/OS+5OS, FF, IM

JVSL, Bellary, Sinter PlantSinter Plant 3000 IO on Profibus, 250 FF Devices, 7OS

JSPL, Raigarh, Sinter Plant 3000 IO on Profibus, 250 FF Devices, 7OS

TISCO, Jamshedpur, Sinter Plant No 4 3000 IO on Profibus, 250 FF Devices, 7OS

JSPL, Raigarh, Coke Oven 800 IO on Profibus, 250 FF Devices 2 OS

JSW, Bellary, Sinter Plant #2 3000 IO on FFH1 and Profibus, 7OS

ONGC, Offshore Exploration Site (175 Locations) 7500 FF Devices on 850 FF H1 segments

ITC Bhadrachalam, Paper Plant

4500 IO on Profibus, 12 OS, 1000 FF

Devices

SRF, Speciality Chemical 600 Ios on Profibus 120 FF Devices

JSW, Bellary, Sinter Plant #4 3000 IO on Profibus, 250 FF Devices, 7OS


Slide No. 41

MIS / PIM

(Existing Plant)

ETHERNET

BUS

HART

PROCESS FIELD BUS

Optic

FibreTCP IP

Device Net

Remote I/O

New Extension

EWSPRM /

AMSHIS HIS

Mod Bus

OmROn

Touch

Panels

Remote I / O


Reduction in Terminations 40%

Reduction in I/O Cards 60%

Reduction in Panel Space 50%

Reduction in # Transmitters (multi variable) 10%

Reduction in erection hardware 40%

Reduction in Installation & commissioning time 50%

Reduction in Home run wiring 40%

Reduction due to remote diagnostics > 50%

Reduction in time to add new device 70%

Reduction in Calibration time 70%

Increase in Device cost 10 %


Slide No. 43

DESCRIPTION ANALOG INSTRUMENTS FF DEVICES

Control Valve calibration

3 Hrs. 15 Min

Transmitter calibration 1.5 Hrs. 15 Min

Termination checking 30 min 5 Min

Loop Checking 3 ~ 4 Hrs. 20 Min

Special tool required for Calibration

Yes, loop validator, ma source, hand tools

From DCS / Hand Held communicator

Device calibration & parameterization

Calibration at Field / workshop On line from HOST (DCS)

Detection of Defect Mostly physical inspection at different level is required

From DCS Automatically Generated

Maintenance / calibration History

To be entered Manually Automatically captured & stored in DCS

Skill up Training No special training Additional Training needed

General advantages:


Operations

Loop

Device

Drift

µP

Externalinfluence

Electronics

DefectiveSensor

Drift

Level 2

Level 3

Three- Level Diagnostics Module

- “Abnormality Analysis”

Field Bus: A Way Forward>>>>Enterprise Network

Operations

Loop

Device

Communication

& Networking

Level 4

Drift

µP

Externalinfluence

Electronics

Defective

Sensor Drift

FF SensorsLevel 1

Level 2

Level 3

FF AccessoriesLevel 1A

Four – Level FF Management Module

- “Abnormality Analysis”


Slide No. 46

Output to valve

Over a period of time,

control valve packing

requires tightening

depending on the

packing material and

wear and tear in order

to avoid fugitive

emissions

Valve diagnostics

Hunting


Slide No. 47

Overall Plant Information:


Loop Level Diagnosis:


Slide No. 49

Loop Level Diagnosis: Overview status


Reduction of plant devices due to availability of multivariable devices

Specific Information shall be available at different level (Top management, Engineer & shop floor)

Control at on wire is possible for majority of loops

Audit trail available for maintenance

Need based Maintenance and spare planning shall be possible

Advance process control shall be possible with multiple data in structured form

Trouble shooting and its recovery is easy

Jasbir Singh

[email protected]

09825318147

mailto:[email protected]

Documents

Building Foundation to Meet Future Challengesftp.gongkong.com/UploadFile/datum/2010-9/...Building Foundation to Meet Future Challenges Jasbir Singh Vice President (Instrument) Field