Foundation Fieldbus Experiences in · PDF fileFoundation Fieldbus Experiences in Shell ... 4...
Transcript of Foundation Fieldbus Experiences in · PDF fileFoundation Fieldbus Experiences in Shell ... 4...
Foundation Fieldbus Experiences in Shell
Bindert Douma; Senior Consultant Measurement, Instrument & Plant Automation
Presentation Outline
• Introduction - Foundation Fieldbus (FF)
• Benefits/Risks• Shell Group experiences• Summary
Shell Global Solutions
Houston
ThorntonRijswijk
Amsterdam/ The Hague
Kuala Lumpur
Calgary
Bangalore
Combining the operating experience of over 5000 staff with proven implementation skills and advanced technologies
• Over 50 years of implementing business and engineering solutions
• Diverse cultures and nationalities
• Continued investment in innovation
Measurement, Instrument and Plant Automation
Delivery Group located in The Hague (NL), Amsterdam (NL),Rijswijk (NL), Thornton (UK), Houston (USA), Calgary (Can), KL (Mal), Bangalore (India) ~100 staff.
Technical Services & Project Support primarily for Refinery, Up-stream and Gas businesses - both Shell and 3rd party customers.
Vendor independent advice & operational experience
R&D budget for development of new products & services.Working closely with Strategic Suppliers – 4 DCS suppliers.
Support for early implementations of new developments.Corporate Implementation Teams - key to success of new technology up-take
Technology - Traditional
Control - DCS
Process control:500 - 2000 measurement and control points per process unit
Up to 15000 - 25000 per plantSignal Cables 4-20 mA
Smart Computer talks to
dumbdevices
P
T
L
F
Process Unit
Technology – Foundation Fieldbus (FF)
P
L
F
Automation and
Display Systems
ProcessUnit
A digital, two-way multi-drop communication link among intelligent measurement and control devices, and automation and display systems.
LANSmart
Computer talks to
Smart devices
Vision & Expectation for FF
Promises from Industry:Open System Architectures with FF technology will provide:
Enabling Platform for Operational Excellence andReduced Capex and Opex
• Time & cost effective automation project execution• Enable fast commissioning• Provide improved reliability/availability• Enable unmanned operations• Enable remote operations support• Enable pro-active maintenance schemes
Our Route from Vision to FF Implementations
VisionDevelopment
Testing
Early Adopters
1996 2001 2003
Technology acceptanceand up-take
2005 2007
Relevance of End-user Testing• End-user testing has been important
- To provide feed-back on early Industrial developments - hardware, infrastructure
- To check basic interoperability- To build up own knowledge
• A representative test environment has been essential as technology demonstrator, to grow End-user confidence
• Testing is essential to evaluate End-user value - applications- Diagnostics- Asset Management- Overall integration
• A representative test environment is essential to provide training facilities
11Shell Global Solutions
Technology Up-take within Shell
EPM HW
NI Bus Mon.NI Config.
Yok.
bus supply (redundant)24 VDC
DCS-controllerI/O card(s)
DCS systems:
SmarEPM
Valtek
Foxboro
Yokogawa: CS3000; StardomEmerson: DeltaV 7.3Honeywell: Experion PKS R201, R300ABB: Industrial IT 800xA; under testFoxboro: IA system; under test
HW
29 devices:
Burkert
P&FE&H
H1-bus (1)
H1-bus (2)
Samson
Metso
H1-bus (3)
EPM
Yok.
P&F
FF Test Facility at SRTCA - Lay-out
Projects Experiences
Our Route from Vision to FF Implementations
VisionDevelopment
TestingStandard
Early Adopters
BroadProjects Up-take
Support functions& Guidelines,
Training
1996 2001
Lessons Learnt
2003
Technology acceptanceand up-take
2005 2007
FF DEP11Shell Global Solutions
Technology Up-take within Shell
EPM HW
NI Bus Mon.NI Config.
Yok.
bus supply (redundant)24 VDC
DCS-controllerI/O card(s)
DCS systems:
SmarEPM
Valtek
Foxboro
Yokogawa: CS3000; StardomEmerson: DeltaV 7.3Honeywell: Experion PKS R201, R300ABB: Industrial IT 800xA; under testFoxboro: IA system; under test
HW
29 devices:
Burkert
P&FE&H
H1-bus (1)
H1-bus (2)
Samson
Metso
H1-bus (3)
EPM
Yok.
P&F
FF Test Facility at SRTCA - Lay-out
Technology ready for
utilisation in Projects
FF Project Implementation from 2001 FF Implementation Support Team – 7 global staff
• FF Implementation Support Packages- Technology awareness package
• Consultancy for technology decision- Business Case analysis
• Practical project implementation support- URS, MAC selection, Design input, Design verification,
FAT/SAT, Trouble shooting, Training, PIR
• FF DEP (Design & Engineering Practice)- Safety requirements, topology, cable choice, cable routing,
redundancy, spare capacity, segment loading
• Capture first operational experience after 12 – 18 months; input to lessons learnt and guideline improvement and close the loop
Some specific Project experiences• Malampaya – New building; Up-stream - Early Adopter• Nanhai – New building; Large Chemical Complex• Norco – Re-instrumentation; Hydrotreater• BAR – Re-instrumentation; Offshore platform
Experiences from Malampaya -1Key-drivers• High Reliability/Availability• Future Unmanned Operations• Reduced Maintenance
Installation Details• 1600 FF devices, • > 80 % CIF,
Experiences from Malampaya -2Start up 2001
Capex Savings - compared to conventional systems
• Platform: + 22% - due to Eexi implementation(1)
• OGP: –13.5% - Eexd implementation
Main Benefit• High process availability - PCS reliability, CIF• Reduced manning – remote control, diagnostics• Fact based decision via all extra
information – diagnostics/asset management
(1) Would be different to date
Key-drivers• Create and infrastructure for ‘DCS anywhere ’• Create an infrastructure to enable efficient and cost-
effective maintenance planning & execution.
Installation Details• >13,000 FF devices, • 6036 segments• 16 FAR’s, • 3 CR’s • Start-up early 2006
Experiences from Nanhai – 1
Design• Conservative Design Guidelines
- GL: Max 8 dev/segment- Result:< 3 dev/segment
• For Process Automation, one PMC + 9 major EPC’s- Yet FF for most skid packages
• Design and design validation with INTools• 85% Yokogawa field devices – single vendor approach• At start-up no CIF
Experiences from Nanhai – 2
Commissioning• Useful Interoperability test at Yokogawa on all utilised Tx• 7-10 dev/day-team• Version problems with Tx in Packaged Systems
- Not clear to Yokogawa Tx were ordered for Nanhai Project
• Insufficient use of PRM- More training up-front
• No problems to implement basic control functionality
Experiences from Nanhai – 3
Experiences from Nanhai – 4
Unhealthy status FF devices
7%
4%
15% 14%
3%
6% 6%
1%
13%
0%
2%
4%
6%
8%
10%
12%
14%
16%
LOP
SMPO
EO/EG
Utilitie
s
HDPE
LDPE PP
Polyols
Logis
tics
Key-drivers• Replace obsolete system
- Re-instrumentation of 1980 constructed instrumentation and control of Gasoline Hydrotreater Unit
- From pneumatic system to Yokogawa CS 3000 DCS system
Installation Details• 1379 devices• 245 segments• Average 5.6 devices/segment
- min 2, max 12• No CIF• Hot cut-over
Experiences from Norco Olefins - 1
Design• January 2004: Start design and engineering• Clear functional spec up-front• FF Design Guidelines
Commissioning• 3 field teams, one CR team• On average 14 dev/day• January 2005: Cut-over completed
Experiences from Norco Olefins - 2
Experiences from Norco Olefins - 3
The End Result• Better process stability• Less nuisance alarms• Great DCS reliability• Better data quality
Experiences from Norco Olefins - 4
Experiences from Brent AlphaInstallation Details BAR
• 165 FF dev, • 24 segments,• Initially no CIF,• Commissioning 2002/03
Capex Savings - compared to conventional systems• No quantification available• No shut-down required for commissioning; commissioning per
wellhead; commissioning time 2h per well iso 24 h per well; less people needed
Main Benefit• No deferred production• Unmanned operations over night – control from Brent Bravo
Actual Project Implementation
Larger Systems have DCS, F&G, Safety Systems
Hart/Classic I/O
FF I/O
AS-I, DP, DeviceNet FF
Linking DeviceHSE-
FF device
Project Support• Where to apply FF - architecture
• How to apply FF – guidelines/DEP
Next steps in FF technology development
• Grow FF contents in Projects – increase % IO coverage- FF for SIS / Demo; development ongoing- FF for F&G / First products for testing available- (FF HSE for analyzers)
to better utilize FF technology benefits, both in Projects and in the Operational Phase.In this context FF SIS is a key initiative, strongly supported.
• FF SIS technology will grow the diagnostics coverage factor in operating facilities and as such support the Safety Compliance aspect.
Amsterdam SIS Demo
Smar Temperature
HIMA Logic Solver
Emerson Valve
Level Siemens
HIMA Logic SolverConfiguration Tool
Yokogawa Asset Management
Yokogawa BPCS
Level Magnetrol
H1 H1
Pressure E+H
Pressure Yokogawa
Pressure Smar
Westlock Positioner
SoftingLinkingDevice
SoftingLinkingDevice 123
Softing DeviceConfiguration Tool
HSEFCS
Configuration Runtime
Ethernet
Segment # →H1
RuggedCom Switch
P+F
Moore
MTL
Metso ValveNon-SIF
DO
RuggedCom Switch
HSE
HSE
SIF Protocol
H1
SIFSIF
SIF
2oo3
Strategy to Introduce New Technology
Technology pushTechnology pull/Solutions offering
• Create technology awareness; project sessions, seminars, workshops
• Assess benefits and risks; risk management plan
• Technology choice & management buy-in
• Provide implementation support incl. Risk ManagementUse Lessons learned from previous projectsTrack early operational experience
Summary• FF is widely used in Projects
• Company wide, both green field and brown field• Recommended standard for projects since 2001• Major up-take since 2002 - > 160,000 FF I/O’s in Projects• No more risk than traditional technology
• Great saving potential in Capex, but mainly in Opex
• Status of FF developments and application experience is different for various vendors
• Implementation Support Packages & FF DEP available
• Early and broad technology training is essential
• Ongoing development to broaden the FF applicability