FIELDBUS IN ONGC C2C3 PLANT

Agenda - FF Technology Conference

GNFC, Bharuch4th F b 2011on 4th February, 2011

PMC : Foster Wheeler Energy

EPC T E i i I di Li it d

MITHUN BISWAS

EPC : Toyo Engineering India Limited

DCS Vendor : Yokogawa India Limited

Plant Location : Dahej Gujarat

AEE(I)

ONGC

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Plant Location : Dahej, Gujarat

FIELDBUS IN ONGCFIELDBUS IN ONGC• In C2 C3 Plant ONGC has first conceptualized and implemented Fieldbus• In C2‐C3 Plant ONGC has first conceptualized and implemented Fieldbus 

both for open and closed loops. 

• ONGC has embarked upon a project for – “Enterprise wide SCADA system for production and Drilling facilities” . The scope of this project is to capture data from both off‐shore and on‐shore assets which covers 157capture data from both off shore and on shore assets which covers 157 offshore platforms ,10 offshore rigs, 247 nos onshore installations , interconnecting pipeline , 5 on shore process plants and 65 onshore rigs. As per strategy adopted , all new additional devices has been opted for h f f l l h lhaving FF interface except for some typical applications where special type of instruments have been necessary and the manufacturers are yet to develop models with FF interface

• Also in Rajamundry ONGC G1 project fieldbus installation is in progress

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C2-C3 PLANT, ONGC

ONGC h t C2 C3 d C4 t ti l t t D h j G j t C2 C3 & C4 ill b t t d f thONGC has set up a C2, C3 and C4 extraction plant at Dahej, Gujarat. C2‐C3 & C4 will be extracted from therich LNG Petronet LNG Ltd. imports at Dahej in Gujarat from Qatar. These compounds would then be fed intoa petrochemical plant OPAL to manufacture polymers. Recovery of these valuable products from feedLNG is attractive as lean LNG after recovery of these components still has the similar value in

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y pterms of heat content.In this plant 90% of the process loops are in Fieldbus.

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SYSTEM CONFIGURATIONSYSTEM CONFIGURATION

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Fieldbus Infrastructure for ONGC C2C3Fieldbus Infrastructure for ONGC C2C3

YOKOGAWA HOST

FIELDBARRIERS FIELDBUS TERMINATORPOWER

SUPPLYJUNCTION

BOX

SURGE PROTECTOR

PROCESSINTERFACE

FIELDBUS

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FIELDBUS DEVICES

Fieldbus Infrastructure for ONGC C2C3

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R d d FF P S lRedundant FF Power SupplyThe Power Hub:

– Enclosed Motherboard – Passive Power Conditioning– CREST Technology for safe operation even under fault gy p

conditions– Fault output via diagnostic module (Basic or Advanced)– Redundant or non redundant board versions

– Host connection via system cable available– Segment protection against host spur faults– High efficiency (85%)High efficiency (85%)– Fully galvanically isolated– 30V / 500mA Output for maximum number of

field devices

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Isolation Switch Terminator

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PRM(PLANT RESOURCE MANAGER)

PRM employs FOUNDATION™ fieldbus technology to transform i t f l k i l d it i tmaintenance from manual work mainly done on site into 

information technology‐based device management that can be performed remotely and automatically. With FOUNDATION™ fieldbus PRM can acquire information such as the device ID devicefieldbus, PRM can acquire information such as the device ID, device parameters, and self‐diagnostics information, in addition to measured data. This wealth of information is used for administration and supervision of assets such as field devices and also for remoteand supervision of assets such as field devices, and also for remote automated inspections.

PRM supports the FOUNDATION™ fieldbus HART PROFIBUSPRM supports the FOUNDATION™ fieldbus, HART, PROFIBUS, and ISA100.11a communications protocols, ensuring an extensive range of devices to choose from. PRM fully embraces an open, rich, and intuitive access to intelligent field devicesand intuitive access to intelligent field devices.

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Fieldbus Design with Segment CheckerFieldbus Design with Segment Checker

I fi ldb t ll th t d d iIn a fieldbus segment all the connected devices are interdependentThe layout of a segment is a complex calculation withThe layout of a segment is a complex calculation with various variables:

Number of connected devicesImpedances of the devicesImpedances of the devicesCable lengths and typeFieldbus signal level

f l (l h k f )Type of topology (line, tree, chicken‐foot...)

FieldConnex Segment Checker automates segment calculationcalculationMany device libraries approved by popular manufacturers

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Where FF Technology is not considered by ONGC 

1. Emergency Shutdown Systems.2. Fire & gas Control systems. 3 Fast loops like Compressor Controls.( Anti Surge )4 Various packages like Heaters Compressors4. Various packages like Heaters, Compressors.5. Analyzer Systems6. Custody Transfer Metering y g7. Truck Loading Package

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PROBLEMS FACED WITH FIELDBUSPROBLEMS FACED WITH FIELDBUS

1 I l ti f i di id l i t t i ti l b i1. Isolation  of  individual instrument in a particular barrier.

2. IOP in the faceplate of instruments .The problem is solved by2. IOP in the faceplate of instruments .The problem is solved by restarting of instrument power.

3 S i d i hi h i d i h i3. Sometimes device which is connected with communicator does not show in the live list  whereas other devices are available.

4. O/S mode problem comes regularly in instrument  due to some software issues in PRMsome software issues in PRM

5.      Calibrator for FF devices

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Carbon Footprint Reduction in C2‐C3 Plant ,Dahej

Material %Reduction

% Reduction inCarbon Footprint

Factsp

CABLE 90 90 30965m Fieldbus cable used. ConventionalInstrumentation will require aroundInstrumentation will require around309000m of cable.

TERMINATION 25 25

I/O Card 43 43 34 cards required for 1632 I/O in Fieldbus.Whereas conventional system will require60 cards

System/MarshallingCabinet

83 83 1 Marshalling cabinet for 1632 I/Owhereas 6 Marshalling cabinet will beused for the same no of I/O forCabinet used for the same no. of I/O forconventional system.

I.S Barrier 92 92 1 barrier in Fieldbus against 12 barriers inconventional for 12 instruments.

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