Malaysia End-User Seminar11 November 20091

Building PETRONAS Capability Through Fieldbus Testing

ZULKARNAIN DARUSPrincipal Engineer

Group Technology SolutionsPETRONAS

Malaysia End-User Seminar11 November 20092

INTRODUCTION

• FOUNDATION Fieldbus (FF) is 10+ years in the market but utilization in PETRONAS is low.

• Installation based in PETRONAS:– PPMSB: 1500 + 200 = 1700+ devices– PFK: 200+ devices– NPK: 800+ devices– Carigali:

• SUPG-B: 290+• SUJT-C: <100• SUDP-A: 200+

• GTS believes that FF can bring– Cost savings– Online asset proactive / preventive maintenance

• BAJT-H • KNPG-B• KNJT-C etc

Malaysia End-User Seminar11 November 20093

CURRENT ISSUES WITH FIELDBUS IN PETRONAS

• Level of competency for O&M personnel– Different tools– System software competency required

• Hardware issues– Field barrier failure– H1 card failure– Device drop out for no apparent reason

• To address these issues and start building PETRONAS capability in fieldbus system, GTS and UTP collaborated and…

Malaysia End-User Seminar11 November 20094

UTP FOUNDATION FIELDBUS LAB

• Lab was set up in Aug 2008

• Officially launched by Rector of Universiti Tekonologi PETRONAS (UTP) in Nov 2008

Field instrument rack: 25+ devices

Host stations

Host controllers: 4 systems

Malaysia End-User Seminar11 November 20095

PARTICIPATING VENDORS

POWER

HUB

DEVICES

HOST

Malaysia End-User Seminar11 November 20096

FIELDBUS SYSTEM ARCHITECTURE IN UTP

P+F Power Conditioner

EWS AMS

MTL Power Conditioner

ROSEMOUNT YOKOGAWA

P+FFOXBORO

HONEYWELLE+H

FISHER

YOKOGAWAFOXBORO HONEYWELL

EWS EWS EWS PRM

EMERSON

• 2 segments of 300m and 500m type A cable

• Field barrier from MTL and P+F

}

Malaysia End-User Seminar11 November 20097

DELIVERABLES AND ASPIRATIONS

• A report on results from interoperability testing that will serve

as reference for FF in PETRONAS.

• A revised PTS on FF system.

• Working group who are well-versed on all aspects of FF system

• A test facility to verify fieldbus host interoperability and provide

user guidelines for each Host.

• Training and skill certification facility within 2 – 3 years for

engineers and UTP students on FF system.

• A test platform for R&D activities for UTP especially in areas of

Instrumentation & Control and Control Strategies.

Malaysia End-User Seminar11 November 20098

TEST DONE SO FAR…

Basic Test (Sept 08 – May 09)

• Findings– Problem with block instantiation leads to commissioning problem

– Field device communicator can’t communicate with all devices

– Wizards to perform some tasks may not necessarily available

– Not all system can restore device original configuration automatically

– In trouble if address of device inadvertently changed to out-of-scanned

range

– Some devices are polarity sensitive

Malaysia End-User Seminar11 November 20099

NEXT TEST TO BE COMPLETED…

Stress Test• Fully loaded segment

• Failure recovery

• Cable constraint: using other industrial standard instrument

cable

• Control in field including tuning

• Segment design tool

• Back up LAS

• etc

Malaysia End-User Seminar11 November 200910

FIELDBUS CERTIFICATION PROGRAM

• Intended for PETRONAS staff

• Staff shall be certified before they can work with Fieldbus system in

PETRONAS

• Training to be conducted by UTP

• Typical syllabus:– Comparison between fieldbus and conventional 4-20mA– System architecture– How to design fieldbus segment– Safety concept– Device communication layer– DD, LAS and macrocycle– Maintenance and troubleshooting

• Intention to open course to public in 5 years time

Malaysia End-User Seminar11 November 200911

Distinctive

Com

petitive

Financial Year

• A testing facility that will be used to verify

other Hosts and devices’

interoperability based on PETRONAS

standard and provide user guidance

Base

• A future training and skill certification facility

within 2 – 3 years for engineers and UTP

students who will be working on fieldbus

system

• A test platform for R&D activities for UTP

especially in areas of Instrumentation &

Control and Control Strategies

A PETRONAS Technical Standard on Foundation Fieldbus

system

Working group who are well-versed on the

fieldbus system in term of operation and

maintenance

2009/2010 2010/2011 2011/2012

Diagnostic capability enables real-time asset management, simplifying routine maintenance and supporting predictive maintenance

2012/20132008/2009

DEVELOP TECHNICAL

GOVERNANCE.

FOCUS ON GROUP

COMPENTENCY

UNFOLD & ACQUIRE

ADVANCED DIAGNOSTIC FEATURES

TRAINING CENTER FOR FIELDBUS TECHNOLOGY

FIT-FOR-PURPOSE TESTING FACILITY

Stress test validates the accuracy of systemic specifics, through simulation of variables for robustness in process automation

VALUE ADDING PLATFORM FOR R&D

A report on results from interoperability

testing that will be the reference for

Foundation Fieldbus system in PETRONAS

Continuous testing to stress fieldbus

system and explore its diagnostic

capability

Conduct Basic Test and Extended Test (basic operation and exploratory test) on all Hosts Completed

FOUNDATION FIELDBUS TESTING ROADMAP

Malaysia End-User Seminar11 November 200912

www.fieldbus.org