Field Bus Foundation : of-the-art Technology, Feasibility and Practicability

Transcription

1 Field Bus Foundation : State-of of-the-art Technology, Feasibility and Practicability Jasbir Singh Essar Oil Jamnagar jasbirsingh@essar.com 1

2 Essar Group - Mission To create enduring value for customers and stakeholders in core manufacturing and service businesses, through world-class operating standards, state-of-the-art technology and the positive attitude of our people 2

3 Businesses Essar Group Shipping Ports Steel Energy Power Communications Projects & Logistics Essar Steel Ltd 4.6 MTPA integrated steel plant Essar Steel (Hazira) 4 MTPA integrated steel plant (under implementation) Essar Steel Orissa 6 MTPA pellet plant (under implementation) Algoma Steel, Canada 4.0 MTPA integrated steel plant Minnesota Steel 6 MTPA pellet plant (planned) 1.4 billion tonne iron ore reserves Essar Oil 12.5 MTPA refinery complex Over 1,000 retail outlets Refinery expansion to 34 MTPA in two phases Exploration & Production Assets E&P rights in valuable oil & gas blocks in India and abroad Essar Power / Bhander Power 1,015 MW combined cycle Vadinar Power 125 MW co-generation; expanding to 1250 MW Essar Power MP 1,200 MW coal based (under implementation) Essar Power Gujarat 1,200 MW coal based (under implementation) Essar Power Jharkhand 1,200 MW coal based (under implementation) Vodafone Essar 60 million subscribers Essar Telecom Infrastructure 3,500 telecom towers operational; 20,000 planned by 2010 The MobileStore Over 1,300 outlets operational; 2,500 planned by 2010 Aegis - BPO 30,000 people in offices in the Philippines, Costa Rica, USA and India BPL Mobile More than 1.8 million subscribers Essar Shipping Fleet of 26 vessels, DWT of 1.49 mn Vadinar Oil Terminal Terminal facility of 32 MTPA Liquid Cargo Bulk Terminal Dry bulk port facilities Essar Oilfields A drilling company with 13 rigs Essar Logistics Owns and operates transshipment assets Essar Construction - Engineering - Fabrication - Construction Fully geared to execute turnkey EPC jobs in India and overseas Essar Offshore Subsea Expertise in marine construction Global Supplies (UAE) FZE Global procurement company Heavy Engineering Services PT Essar Indonesia 0.4 MTPA cold rolling complex Project Management Consultants Asia s largest equipment bank

4 Energy From Rig to Retail Essar Oil is a fully-integrated oil company of international standard and scale 4

5 Aligning Performance Improvement Opportunities with Business Objectives $$$ Field Bus Foundation provides the way to bridge the gap between business goals and specific Plant performance factors 5

6 Support of Engineering and Project Management Consultancy in Field Bus System: 1. Purchase Specification Data Sheets Technical note 2. Design Basis Standard Specification Design Guidelines Design Notes 3. Simple Safety guidelines / documentations 4. FAT Guidelines 5. Error Measurement and control guidelines 6. Installation, commissioning procedure and Check Sheets 6

7 Support of Engineering and Project Management Consultancy in Field Bus System: Capital Expenditure CAPEX Excellence (Lowest Cost of ownership): 1. Level of Redundancy 2. Selection of Segment components 3. Optimum FF Segment design 4. Error measurement and Control 5. Hardware selection for Installation 7

8 Support of Engineering and Project Management Consultancy in Field Bus System: 1. Level of Redundancy Probability of failure Recovery time Loss per failure Level of Confidence 8

9 9 Support of Engineering and Project Management Consultancy in Field Bus System: 2. Segment components Essential component selection and design for use Remote I/O Field barriers Surge Protector Repeaters Defines rules for Selecting and installing FISCO networks Rule for additional components to increase safety factor Redundant FISCO Power supply Free ports in Field barrier Additional Empty segments Selection of devices based on requirement LAS function PID function Local display

10 Support of Engineering and Project Management Consultancy in Field Bus System: 3. FF Segment design Optimize number of Devices per segment (use of segment design software) Control loop devices in same segment (optimum loop performance) Use of multiple information (multivariable devices) Device selection proper to hazardous area classification only Use updated changes in standards and hazardous area practice Guidelines for selection between Explosion proof & Intrinsic safe System / Devices Use of Ex ic/fnico (Fieldbus Non-Incendive Concept) for Zone 2 hazardous areas 10

11 Support of Engineering and Project Management Consultancy in Field Bus System: 4. Error Management (monitor and control) Design Development Implementation Maintenance 11

12 Support of Engineering and Project Management Consultancy in Field Bus System: 5. Hardware Selection & Installation Good Installation practices of Field barriers / Segment Protector Close to Main cable duct / tray Easy termination Hazardous area and weather protection Installation of device at ground level based on process requirement should not be made as General Rule Use of optical fiber for long distance data transfer Revamping plant Use of hybrid positioner with existing valve Verify the interference issue and use of existing cables Use of Hybrid concept for plant revamping 12

13 Support of Engineering and Project Management Consultancy in Field Bus System: 5. Hardware Selection & Installation Cont.: Requirements: Solutions, Benefits: long distance (up to > 8000 m) hazardous locations high amb temperature (>50 C) high availability HART + FF IS and non IS signals remote I/O fiber optic remote I/O for Zone 2 with IS inputs/outputs special cabinet design redundancy fiber optic ring structure connect remote I/O to DCS s HART + FF management tool handled by remote I/O 13

14 Support of Engineering and Licensers: Capital Expenditure CAPEX Excellence: 1. Loop identification: Philosophy for Super critical, critical, semi critical and non critical loops of plant Simple close loop Open loop Transmitters (devices) with indicator / without indicator Local indicator with multiple parameters 2. Physical Location of devices in field 3. Physical Location field bus barrier in field 4. Use strength of other field bus such as ASi, devicenet or others 14

15 Support of Engineering and Licensers: Identification of control loops that can be considered in FFB: Super Critical Control Loops: Fast response loops are considered in super critical loops eg. Anti surge loops, Drum level control etc causing safety concern and / or major equipment damage. 1. Critical Control Loops 2. Semi Critical Control Loops 3. Non Critical Control loops 1. Critical Control Loops: (Level 1) Failure of level 1 loops will result in a total system trip, causing a shutdown of the entire unit, or other unavoidable losses. Normal Valve failure mode is to be used for this classification. 15

16 Support of Engineering and Licensers: 2. Semi Critical Control Loops (Level 2) Failure of a level 2 loops will result in a total system trip, causing a shutdown of the entire unit, or other unavoidable losses. However, the Level 2 valve s process dynamics allows time for the quick recovery from the failure, either by quickly fixing a fault or by taking manual control. The material and energy capacity of associated vessels, geographic location, and elevation/accessibility of such a valves should be considered. The difference in Level 1 and Level 2 valves are dependent on operations ability to respond to single failure. 3. Non Critical Loops: 16 (Level 3) Failure of this valve will not result in any short term risk of total unit shutdown or major operation loses. Level 3 valves can go to their fail position without requiring immediate operator action.

17 User s perspective: General Consideration for the use of FF in Essar: Field Bus is not used for Separator pressure control and reciprocating makeup gas pressure control loops, because of all the split ranges and signal selectors involved in those loops Field Bus is not used Steam FI, steam generator LIC and BFW FIC on steam generators Field Bus is not used for Anti-surge, etc. as those types of controllers may required faster response times. Field Bus is not used in shutdown systems or for complex control loops. 17

18 Type 1 (One device per output) Fb Type 2 (Two device per output) Fb Type 3 (Three device per output) Fb Power Conditioner T - ON Safe Area Bulk Power Supply Hazardous Area Field Barrier-Fb 18 Fb

19 Device Manufacturer in Field Bus systems: 1. Hardware design & Level of Redundancy 2. Software 3. Commissioning Tools 19

20 System & Device Manufacture support: 1. Hardware design & Level of Redundancy Easy cable connection of H1 card with Field bus power supply and replacement on fault Rugged construction of FF components for easy cabinet mounting and resistance to shock and vibration Robust field-proven and reliable Field Bus components LEDs indicators to identify failed module, Hot swapping of components to allow replacement under power Support multiple LAS devices FF Basic-to-LM device wizard Safe way to enable/disable Backup LAS Provides wizard to step through sequence 20

21 Device Replacement 2. Software Device Replacement by Operator Quick Auto replacement From Operator Station or Engineering Station Support for: o like device, and, o like devices with revisions 21

22 DD file addition & Device Configuration 2. Software Ability to Add DD Files Integrated into Engineering tool Easy tool for adding DD files Easy Parameter Data Entry tool to edit New DD file for similar devices should be possible to be used with existing devices Code Download Allows upgrading devices on-line Includes enhancements to current capability and file management Easy device Configuration Plug and play tool for device addition Device configuration wizard 22

23 Device management in Field Bus: 3. Commissioning Tools Device Checking software (Maintenance / Management Tool) Configuration changes from DCS Calibration from DCS Maintain Audit trail of devices Taking device signature at the time of initial startup Workshop tools for FF 23

24 Easy Commissioning and Help 3. Commissioning Tools Commission device without pre-configuration Easy way to add a device in an existing installation Directly from Uncommissioned Device tab Easy to Build and loads device System Comprehensive Help option Dynamic and comprehensive help at every step During adding devices, help information from the manufacturer should be possible to add into system From any parameter in a device, hit F1 to get help information! 24

25 Device Management: TAF Device on FF-H1 Bus Information Basic Information Detail Information FCS 1001 NODE 01 ALF PT 2002 Device Tag Name: PT 2002 Device ID: CJ MANUFAC_ID DEV TYPE:0X0 DEV_REV:0X0 ALF PT 2002 CV 4001 CV 4002 L 6001 TE1001 ALF ALF ALF ALF111-1 Device Tag Name: CV 4001 Device ID: J CV 4001 Device Tag Name: CV 4002 Device ID: J MANUFAC_ID: 0 DEV TYPE:0X CV L TE1001 MANUFAC_ID DEV TYPE:0 DEV_REV:0X0 Device Tag Name: L 6001 MANUFAC_ID: 0 Device ID:56474B0770 DEV TYPE:0 0 Device Tag Name: TE1001 MANUFAC_ID: 0 Device ID: DEV TYPE:0X07 245

26 Device Management: Device on FF-H1 Bus Information Basic Information Detail Information 1ALF PT CV CV 4002 Device Tag Name: PT 2002 Device ID: CJ Device Tag Name: CV 4001 Device ID: J Device Tag Name: CV 4002 Device ID: J MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X0770() MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X001() MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X002() 243 L TE1001 Device Tag Name: L 6001 Device ID:56474B0770 Device Tag Name: TE1001 Device ID: MANUFAC_ID: 0X B(VEGA) DEV TYPE:0X0770() MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X001()

27 Device Management: Device on FF-H1 Bus Information Basic Information Detail Information 1ALF PT 2002 RB(RESOURCE_01) Auto TB(TRANSDUCER_01) Auto TB(TRANSDUCER_02) Auto FB(AI_01) Auto FB(AI_02) O/S FB(AI_03) FB(PID_01) FB(SC_01) FB(IT_01) FB(IS_01) FB(AR_01) Device Tag Name: PT 2002 Device ID: CJ MANUFAC_ID:0X (Yokogawa Electric) DEV TYPE:0X0770() 241 CV CV L TE Device Tag Name: CV 4001 Device ID: J Device Tag Name: TE1001 Device ID: Device Tag Name: L 6001 Device ID:56474B0770 Device Tag Name: CV 4002 Device ID: J MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X001() MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X002() MANUFAC_ID: 0X B(VEGA) DEV TYPE:0X0770() MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X001()

28 Device Management: Device on FF-H1 Bus Information Basic Information Detail Information 1ALF PT 2002 RB(RESOURCE_01) Auto TB(TRANSDUCER_01) Auto TB(TRANSDUCER_02) Auto FB(AI_01) Auto FB(AI_02) O/S FB(AI_03) FB(PID_01) FB(SC_01) FB(IT_01) FB(IS_01) FB(AR_01) Device Tag Name: PT 2002 Device ID: CJ MANUFAC_ID:0X (Yokogawa Electric) DEV TYPE:0X0770() CV 4001 CV 4002 Device Tag Name: CV 4001 Device ID: J Device Tag Name: TE1001 Device ID: MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X001() MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X002() L 6001 Device Tag Name: L 6001 Device ID:56474B0770 Device Tag Name: CV 4002 Device ID: J TE1001 MANUFAC_ID: 0X B(VEGA) DEV TYPE:0X0770() MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X001()

29 Device Management: Device on FF-H1 Bus Information Basic Information Detail Information 1ALF PT 2002 Device Tag Name: PT 2002 Device ID: CJ MANUFAC_ID:0X (Yokogawa Electric) DEV TYPE:0X0770() CV 4001 CV 4002 L 6001 TE1001 Device Tag Name: CV 4001 Device ID: J Device Tag Name: TE1001 Device ID: Device Tag Name: L 6001 Device ID:56474B0770 Device Tag Name: CV 4002 Device ID: J MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X001() MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X002() MANUFAC_ID: 0X B(VEGA) DEV TYPE:0X0770() MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X001() 29

30 Device Management: Device on FF-H1 Bus Information Basic Information Detail Information 1ALF PT 2002 Device Tag Name: PT 2002 Device ID: CJ MANUFAC_ID:0X (Yokogawa Electric) DEV TYPE:0X0770() CV 4001 CV 4002 L 6001 TE1001 Device Tag Name: CV 4001 Device ID: J Device Tag Name: TE1001 Device ID: Device Tag Name: L 6001 Device ID:56474B0770 Device Tag Name: CV 4002 Device ID: J MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X001() MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X002() MANUFAC_ID: 0X B(VEGA) DEV TYPE:0X0770() MANUFAC_ID: 0X (Yokogawa Electric) DEV TYPE:0X001() 30

31 Support for Network Design Network Safe and Trouble Free operation Network System Design & Layout Network Communication / Software Safety 31

32 Fundamental considerations/fault Avoidance Information collection and safely processing Enterprise Network Secure Access to Enterprise Network Link Aggregation Dual Homing RSTP HiPER Ring Secure Access to Plant Floor 32 OCTOPUS

33 Fundamental considerations/fault Avoidance Design Considerations / Fault Avoidance Industrial Networking Industrial Ethernet Optical Fiber Interfaces Industrial Connectors Industrial Connectors Electronic Control and Management Systems Load Moment Indicator Control Systems and Sensors Graphic Control Panels and Displays 33

34 Networking at Multiple layers Multilayer Safety Network Operating System Application FF accessories Device 34

35 Networking at Multiple layers Design of Safety in communication systems 1. Safe communication over a bus alone does not ensure that the transferred information is safe 2. No loss / encryption of data 3. Programming Failure 4. Improper installation of networking hardware 5. Data transmission Consistency checking Confirmation of correct data transmitted & received Watch dog for external affect 6. Safe communication Risk reduction Fault avoidance Fault control 35

36 Networking at Multiple layers Reason of Failure in networking: 1. Mis-configured Fire wall 2. Connection of infected laptop for engineering or trouble shooting 3. Infected remote support 4. Unauthorized connection with unsecured system 5. Connection with Modem, printer 6. Non proven fire wall 36

37 Networking at Multiple layers Use of Robust and Proven Fire wall: Protection from alien control networks Protection from external networks Protection from insecure networks Protection of safety System Protection for unpatchable systems Protection of wireless systems Protection of OPC traffic 37

38 Operational Excellence (OpX) Asset Excellence Production Excellence Safety Excellence OPE Cost = Availability Maintenance cost x Performance rate + Production cost + x Quality rate x HSE compliance rate HSE cost Maximization of asset excellence factor Maximization of production excellence factor Maximization of safety excellence factor OPE: Overall Plant Effectiveness 38

39 Asset management: Easy Commissioning and Easy Life 39

40 Asset management: Easy Troubleshooting and Easy Life 40

41 41