Post on 11-May-2020
transcript
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
Field Bus: A Way Forward>>>>
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
Field Bus: A Way Forward>>>>
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
Field Bus: A Way Forward>>>>
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
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
Field Bus: A Way Forward>>>>
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
Field Bus: A Way Forward>>>>
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
Field Bus: A Way Forward>>>>
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
FOUNDATION™ SIF Technology Demonstration
Field Bus: A Way Forward>>>>
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)
FOUNDATION™ SIF Technology Demonstration
Field Bus: A Way Forward>>>>
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
Field Bus: A Way Forward>>>>
FOUNDATION™ SIF Technology Demonstration:
Impact of FOUNDATION Device Diagnostics
Field Bus: A Way Forward>>>>
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
Field Bus: A Way Forward>>>>
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.
Field Bus: A Way Forward>>>>
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
Field Bus: A Way Forward>>>>
Field Bus: A Way Forward>>>>
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
45,000 FF devices and commissioned in 2006. Field bus foundation used for entire plant automation
ConocoPhilips YERP Refinery Saudi Arabia
25,000 FF devices and commissioned in 2006. Field bus foundation used for entire plant automation
Refineries on FF:
Field Bus: A Way Forward>>>>
Refineries on FF:
Petro Rebigh Saudi Arabia
30,000 FF devices and commissioned in 2006. Field bus foundation used for entire plant automation
Field Bus: A Way Forward>>>>
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:
Field Bus: A Way Forward>>>>
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.
Field Bus: A Way Forward>>>>
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.
Field Bus: A Way Forward>>>>
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)
Field Bus: A Way Forward>>>>
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)
Field Bus: A Way Forward>>>>
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.
Field Bus: A Way Forward>>>>
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.
Field Bus: A Way Forward>>>>
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)
Field Bus: A Way Forward>>>>
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.
Field Bus: A Way Forward>>>>
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.
Field Bus: A Way Forward>>>>
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
Field Bus: A Way Forward>>>>
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.
.
Field Bus: A Way Forward>>>>
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.
Field Bus: A Way Forward>>>>
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
Field Bus: A Way Forward>>>>
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
Field Bus: A Way Forward>>>>
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 %
Field Bus: A Way Forward>>>>
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:
Field Bus: A Way Forward>>>>
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”
Field Bus: A Way Forward>>>>
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
Field Bus: A Way Forward>>>>
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