A Consultant perspective on FoundationTM Fieldbus on FPSO ... · 2 Singapore FPSO Seminar - 21...

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A Consultant perspective on FoundationTM Fieldbus on FPSO

Arasu ThanigaiBusiness Development Manager

Pepperl+Fuchs pte Ltd

Presented on Behalf of EPC companies

Courtesy – P+F, Technip, JGC, Samsung, Bechtel

2Singapore FPSO Seminar - 21 August 2009

Challenges and advantages

• FPSO Overview

• Difference between FPSO and non-FPSO applications

• Why Foundation Fieldbus System?

• Benefits from using FOUNDATION Fieldbus

• The Design of a Fieldbus application

FPSO PROJECT ACTIVITY OVERVIEW

MARKET OVERVIEW

PROJECT OVERVIEW

MARKET SEEING CURRENT RECORD DEMAND

Difference between FPSO and non-FPSO applications

• No major differences

• Components must be selected accordingly

• Marine certification must be checked for system components such as Power Conditioners, field devices, Control system, and the even the cables

• Components ( especially Fieldbus devices, and other accessories) must be chosen in order not to increase the net weight of the platform

Marine certifications

• All the system components must be certified for marine applications ( corrosive effects, vibration etc)

• Some examples of the marine certification agencies are – Det Norske Veritas (DnV) – American Bureau of Shipping (ABS)– Bureau Veritas (BV) – Llyod’s Register of Shipping – Germanischer Lloyd (GL)– Registro Italiano Navale Group (RINA)

• Example of the marine certificate – system components

• Marine certificate – for the cable

• The cable flame resistant and flame retardant cable will withstand very high temperature incase of any flames/fires and the system signals should be still maintained until few 100 degs.

• More info from cable manufacturers

• Similarly Marine certification must be checked for field devices and other system componets.

Why Foundation Fieldbus System?

• Increased Availability - Real time information of the plant health

• Reduced Capex - Reduced cabling, Easy installation, fast commissioning, Plug and Play, self documentation.

• Reduced Operational and Maintenance expenditure–Imbedded predictive intelligence & diagnostics at all levels.

Why Foundation Fieldbus System?

• Easy Integration with Business Enterprise–Seamless flow of information information –Open Standards (OPC)

• Utilizing Foundation fieldbus reduces cycle time– Engineering– Start-up & Commissioning

• Reduced Driving exposure and Hostile environment

Benefits from using FOUNDATION Fieldbus

• Installation completed on time

• Cutover completed ahead of schedule

• ROI was less than 18 months

• Better process control

• Increased productivity

Fieldbus Conventional

191 instruments 191 instruments24,000 feet of wire 1,500,000 feet of wire22 homeruns 191 homeruns

Costs: Costs:Wire - $18,400 Wire - $301,000Wiring blocks – $19,100 Junction Boxes - ?Connectors – $17,400 Marshalling - ?Miscellaneous – $7300 Miscellaneous - ?TOTAL - $62,200 TOTAL - > $301,000

• Less equipment and wiring – more signals• Qty of segments 103• Qty of devices 512• Qty of instrument signals 970*

• Example - LNG Project:• Many signals are multiplexed, using Temperature

and Digital Multiplexers and• Digital Valve Controllers

• 458 multiplexed signals – where are the savings?• (if the same conventional functionality is required)• Wiring• Terminations• Inspection• Loop Check• Instrument Cost• Material Handling• Data sheets• Instrument Index• Loop Diagrams

Fieldbus Design

• Project Standards

• Develop Project Standards• Collect and integrate the relevant standards• Research Existing Standards (Client’s/Engineer’s)• Research Knowledgebases• Develop Project Standards

• Result : Fieldbus Specification is generated which consists of all the project requirements

Fieldbus Design

• Project Documents – Deliverables

• P&ID Hookup Drawings• Control Narratives Wiring Diagrams• Instrument Index Alarm Strategy• Function Block Index HMI Graphics• Instrument Specifications SAT Procedures• Instrument Datasheets Purchase Requisitions• Network Drawings Purchase Specifications• Control Strategy Drawings Contrast Specifications• Segment Design• Function Block Datasheets• Location Drawings• FAT Procedures

Fieldbus Design

• Segment Design Considerations

• Control Loops on same segment– Transmitters– Valves

• Power requirements• Virtual Control Relationships• Risk

Fieldbus Design

• System Architecture

• The Host• – DCS or PLC or a Combination• Network Considerations

- Regulatory Control (Analog Control)– Control Backbone – Proprietary or Open (HSE)– Discretes– Drives

Fieldbus Design

• System Architecture

• Control-in-the-Field or Control-in-the-Host– Fast, deterministic, tighter control– No need to access the Host– Single loop integrity– Fewer components and more reliable– More scalable

• Discrete/Hybrid/Batch Processing– PLC– DCS– Flexible Function Blocks

Fieldbus Design

• Physical Layer – The Foundation

– Power Supplies– Power Conditioners– Terminators– Field Junction Blocks– Surge Suppressors– Spur Short Circuit Protection– IS Considerations– Cables– Connectors– Grounding

Design Consideration

• Fieldbus Reliability issues– Spur short circuit– Power supply failures– Surges– Others

• Spur Shorts– short circuit in one of the device or in its spur

cable disable– the segment– (new instrument installation, service of device,

water logging)– The potential problem can be overcome by using

current– limiter between the trunk cable and spur cable

• Trunk Cable protection

• If trunk cables cut, then the power to the field is lost• Trunk cable vulnerability is something that is also a

problem• in traditional DCS systems Trunk cable needs to be• protected in a conduit or sturdy cable tray which must be

according to the international wiring regulation regardless of trunk type.

• Lightning Surges

• There is no protection against a direct lightning strike

• The ground potential difference can travel over the cable and break down the electrical isolation of Fieldbus devices

• The general rule is that if the a horizontal distance between devices of greater than 70 to 100m or vertical separation greater than 10 to 30m, lightning surge protection should be used

• Proper Grounding methods should be used for effective surge protection of the platform.

Zone 1

Zone 0/1

IS applications

Ex ia(FISCO + Entity)

FieldBarrier

16..32V

230VAC

Fieldbus Power Hub

• Increasing availability of the physical layer

• Even after ensuring the DCS redundancy, Power supply redundancy, surge protection, Proper cable installation etc, other man made disturbances could affect the availability of the system.

• E.g. loose wires, water ingress, faulty devices, EMC/RFI interference

• Needs dedicated advanced diagnostics tools to locate and troubleshoot the issues

• What are the parameters to be checked

Segment voltage, Segment currentSegment noise (low freq, high freq.)Segment signal levelSegment signal jitterInstrument signal levelInstrument signal jitterIndividual Instrument noiseFieldbus terminationSegment earth fault (imbalance)Device communicationCommunication faultsCable degradation (trending

Control the physical layer

• Supervision and diagnostics– Measurements, Trending, Alarming

• Part of the Power Hub• Online and in real-time

with remote access– from the control room and – via Internet

• Simple-to-use DTMs– Color-coded status indicators– Built-in oscilloscope forgreatest detail

– Commissioning– Operation– Troubleshooting

Save time during commissioning

• Cable checkout– Accurate voltage level– Proper termination– Isolation to ground

• Accelarated field device validation– Signal quality and strength– Jitter

• Automatically generatedocumentation

per device and segment …

Reliable operation – increased uptime

• Snapshot establishes baseline• Configurable alarming• Longterm trending• Predicts data availability• Enables proactive maintenance

Communication hasn‘t failed yet …

Targeted Troubleshooting

• Fastest time to repair• Remote access for

– Maintenance planning– Assistance by fieldbus expert

• Oscilloscope function– Various triggers– Visual signal inspection

• Pinpoints trouble spot

Fieldbus Design

• System Acceptance– Factory Acceptance Tests– Interoperability tests are key

• Engineering Workstation interoperability• Device interoperability – all device types• Network components

– Segment operation – all typical segments– Graphics

– Module Acceptance Tests– Network validation• Noise – Watch out for Frequency Drives• Electrical characteristics• Grounding– System Functional Tests

Project Example

• SMOE Platform– PETRONAS Cahricali

DCS – Rockwell

Power supply - Pepperl+Fuchs High Power trunk concept

Field Junction Box – GRP (P+F)

Field devices – Rosemount , Flowserve, Yokogawa and ABB

Project Example

• SMOE Platform– PETRONAS Cahricali– Power conditioner redundant

Project Example

• SMOE Platform– PETRONAS Cahricali– Rockwell DCS

Project Example

– Field junction box

Conclusion

As it is evident compared to other instrumentation techniques, Foundation Fieldbus offers substantial overall cost saving and makes the maintenance simpler, it becomes the de facto standard for any Process Industry particularly on FPSO applications.