PÖYRY AUTOMATION AND ELECTRICAL DEPARTMENT AUTOMATION ... · PDF file• Process...

17.4.2012

AS-0.1502 AUTOMAATIO1

PÖYRY FINLAND OYJAAKONKATU 3, P.O.BOX, FI-01621 VANTAA, FINLANDDIRECT +358 10 33 [email protected] © PÖYRY FINLAND OYALL RIGHTS ARE RESERVED. THIS DOCUMENTOR ANY PART THEREOF MAY NOT BE COPIED ORREPRODUCED WITHOUT PERMISSION IN WRITING FROMPÖYRY FINLAND OY

PÖYRY AUTOMATION AND ELECTRICAL DEPARTMENTAUTOMATION ENGINEERING AT PÖYRY 14.03.2016

MARCH 15, 2016IPP FINLAND, AUTOMATION AND ELECTRICAL 2

• Pulp mill projects• Paper mill projects• Chemical mill projects• Rebuild projects• Relocation projects• Maintenance design

• Finnish (native), English, German

• Over 20 years of experience in automation projects in various positions

• Process control engineering, Automation engineering management, Automation procurement,Instrumentation, Control engineering, Factory acceptance tests (FAT), Instrument installationsupervision, Field engineering, Commissioning and start up services

• Studies, Automation investment cost estimates, Maintenance design

Know-how of our People

CV of Automation and Electrical Department Manager

Heikki Jääskeläinen, tel: +358 40 835 7661Department Manager, Automation and Electrical, Engineering Centre, FinlandB.Sc. Helsinki institute of Technology, Network Engineering

Consultancy experience

Areas of expertise

Languages

Relevant projectexperience

Onnellisimmat ammatitTime-lehti listasi ammatteja, joissa ihmiset ovat onnellisimmillaan. Tässä viisi ammattia,joissa ihminen on onnellisimmillaan:

· 1. Rehtori– Oppilaiden mielestä rehtori saattaa olla pelottava ja etäinen, mutta rehtoreina työskentelevät

henkilöt nauttivat työstään. Rehtorit kehuvat erityisesti kollegoiden välisiä suhteita jakannustavaa työilmapiiriä.

· 2. Keittiömestari– Keittiömestarit tuntevat onnellisuutta työstään. Keittiömestarin työssä on mahdollisuus

luovuuteen ja oman vision toteuttamiseen, työ on melko itsenäistä.· 3. Lainaneuvottelija

– Pitkät työpäivät kilpailullisessa työympäristössä ja kannustava palkkaus motivoivatlainaneuvottelijoita.

· 4. Automaatioinsinööri– Automaatioinsinööreinä työskentelevät ihmiset arvostavat sitä, kun he voivat auttaa muita

ihmisiä.· 5. Tutkimusassistentti

– Tutkimusassistentit kokevat tyydytystä siitä, että saavat nähdä tutkimusten ja testaustentuloksia. Onnellisuutta lisää myös itsenäisen työskentelyn mahdollisuus.

Lähde: Time, Talouselämä

MARCH 15, 2011EC FINLAND, AUTOMATION AND ELECTRICAL 3

COMPANY PRESENTATION

March 2016

COPYRIGHT©PÖYRY

STARTED AS A ONE MAN’S DREAM…

PÖYRY - COMPANY PRESENTATION

“Being close to customers, employing talented people andexecuting projects perfectly has been our formula for success for

over 50 years.”

Dr. Jaakko Pöyry, Founder1924 – 2006

Dr. Jaakko Pöyry, Founder1924 – 2006

“Being close toclients, employing

talented people andexecuting projectsperfectly has been

our formula forsuccess.”

MARCH 20165

COPYRIGHT©PÖYRY

Clients

UniqueLifecyclePartner

UniqueLifecyclePartner

LocalRelation-

ships

LocalRelation-

ships

World-class

expertise

World-class

expertise

TODAY DELIVERING CONSULTING AND ENGINEERING GLOBALLY

Pöyry is an international consulting andengineering company, dedicated toserving clients across the world’s energyand industrial sectors

· 6,000 experts· 10,000+ projects delivered annually· Solid track record in pulp and paper· Leading hydro and power market engineers· EUR 575 million net sales in 2015

MARCH 2016PÖYRY - COMPANY PRESENTATION 6

COPYRIGHT©PÖYRY

ENGINEERING AND CONSULTING POWER HOUSE


Connecting deep insight and competence across our selected sectors

• Forest IndustryManagement Consulting

• Hydropower• Renewable Energy• Thermal Power• Nuclear Energy

• Transmission &Distribution

• Energy ManagementConsulting

• Pulp & Paper• Chemicals & Biorefining• Mining & Metals

• Transportation• Water• Real Estate (Buildings)

ENERGY

INDUSTRY

INFRASTRUCTURE

COPYRIGHT©PÖYRY

PROJECT LIFECYCLE SERVICES


Operations supportOperational Improvement

O&M ManagementOutsourced Operations

Project implementationSite Supervision

Project / ConstructionManagement

EPCMEPS / EPC

Engineering servicesTechnical ConsultingConceptual DesignBasic EngineeringDetailed Engineering

Management consultingStrategyMarketsTransactionsOperational ExcellenceBiofutures

Consulting. Engineering. Projects. Operations

COPYRIGHT©PÖYRY

EXCHANGING INSIGHT AND KNOWLEDGE

· Understanding the big picture – megatrends affecting the businessenvironment

· Experts connected through a global network – insight of the local conditions


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MANAGEMENT CONSULTING

7 Global Management Consulting Practices:

· Energy Market Analysis and Design· Energy Companies· Forestry, Biomass and Wood Industry· Biorefining, Paper and Packaging· BioFutures· Operational Excellence· Transactions

Providing strategic advice across the valuechain underpinned by deep expertise, marketinsight and understanding

PÖYRY - COMPANY PRESENTATIONMARCH 2016

10

COPYRIGHT©PÖYRY

ENERGY

4 Global Competence Lines:

· Hydropower· Thermal Power & Renewable Energy· Nuclear Energy· Transmission & Distribution

Providing clients with clean and effectiveenergy solutions

Strong track record in designing andimplementing complex energy projectsinvolving innovative technologies



COPYRIGHT©PÖYRY

INDUSTRY

2 Global Competence Lines:

· Pulp & Paper· Chemicals & Biorefining

Strong track record in forest industry,expanding services in chemicals &biorefining

Broad service offering; delivering solutionsfor complex new investment projects andrebuilds of existing plants



COPYRIGHT©PÖYRY

REGIONAL OPERATIONS – DELIVERING TO CLIENTS LOCALLY

· Broad range of engineering, technicaladvisory and environmental services

· Delivered across energy, industry,transportation and water sectors

· Experts understanding specific localsituation, underpinned by globalcompetence and insight

· Multi-domestic presence and officeslocated in easy reach of client’s operations



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LOCAL PRESENCE


· 5 Regions– Northern Europe– Central Europe– Asia-Pacific– North America– Latin America

· 7 Key Countries– Finland – Austria– Sweden – Thailand– Germany – Brazil– Switzerland

COPYRIGHT©PÖYRY PÖYRY - COMPANY PRESENTATION

ORGANISATIONAL STRUCTURE

GlobalCompetence Lines

RegionalBusiness Lines

StrategicAdvisory

ManagementConsulting

Energy Industry Regional Operations

Strategic adviceand transaction

support forselected sectors

Engineering for complex processes,feasibility studies and process based

technology

Broad range of servicescovering engineering and

technical advisory

World’s capital andresource intensive

industries

Competence driven global business insectors with attractive opportunities

Generic offering in selectedkey countries

MARCH 201615

COPYRIGHT©PÖYRY

OUR VISION

MARCH 2016PÖYRY HEXA IMAGES 16

Our vision is to be the trusted partner, delivering smartsolutions through connected teams.

Consulting. Engineering. Projects. Operations.www.poyry.com

AUTOMATION ENGINEERING

AUTOMATION ENGINEERING AT PÖYRY14 March 2016Heikki Jääskeläinen

COPYRIGHT © PÖYRY FINLAND OYALL RIGHTS ARE RESERVED. THIS DOCUMENTOR ANY PART THEREOF MAY NOT BE COPIED ORREPRODUCED WITHOUT PERMISSION IN WRITING FROMPÖYRY FINLAND OY

COPYRIGHT©PÖYRY17.4.2012

AS-0.1502 AUTOMAATIO 19

AUTOMATION ENGINEERING AT PÖYRY

· We provide– Pre-engineering for an Investment– Basic Automation Engineering– Detail Automation Engineering– Commissioning and Site Services– Energy efficiency studies– Measurement services– Operational efficiency services– Maintenance related services

· For– Green field new investments– Brown field new investments– Production line rebuilds– Production line relocations– System upgrades

PÖYRY FINLAND OY, ENERGY PROJECTS

AUTOMATION AND ELECTRICAL ENGINEERINGMARCH, 2016TUOMO HAANPÄÄ

MARCH 2016ENERGY PROJECTS / A&E ENGINEERING 21

AUTOMATION & ELECTRIFICATION (A&E), MAIN FOCUS

· Feasibility studies and pre-engineering– A&E concept design– A&E specifications for main equipment ITT’s– Extend estimations– Cost estimations

· Implementation projects, EPCM– Management and coordination of A&E discipline in power plant projects

– Schedules– Resources– Cost and man-hour follow-up

– A&E systems and equipment procurement– ITT’s– Negotiations and tender evaluations– Contracts

– Basic engineering– Typically in “Balance of Plant” (BOP) area– Supervision in main equipment areas

– Delivery supervision– A&E packages in main equipment deliveries– A&E systems and equipment

COPYRIGHT©PÖYRYMARCH 2016

ENERGY PROJECTS / A&E ENGINEERING 22

AUTOMATION & ELECTRIFICATION, MAIN FOCUS

– Detailed engineering– Carried out by other Pöyry units (Tampere, Kouvola …)

– Site services– Supervision of A&E installations– Commissioning assistance→ Full EPCM package– In co-operation with other Pöyry units

· Technical advisory services (TAS)– Process automation– Control and instrumentation– Power distribution– Process electrification

· Owner’s engineering services (OE)– For power plant projects

· In conclusion →– A&E project management, basic engineering and procurement services ’in-house’– Detailed engineering for bigger implementation projects is typically carried out by other Pöyry

units

COPYRIGHT©PÖYRY

THERMAL IN FINLAND - LOCATION AND RECENT EPCMPROJECTS

MARCH 2016ENERGY PROJECTS / A&E ENGINEERING 23

Offices· Pöyry Finland Oy, Energy (PÖYRY head office Vantaa, Imatra, Tampere)

On-going projects· Turun Seudun Energiantuotanto Oy, CHP project (Naantali, Finland)

Recent completed EPCM projects· Fortum Power and Heat CHP project, Järvenpää, Finland· Fortum SIA CHP project, Jelgava, Finland· Fortum Suomenoja 2 CCGT-CHP project, Espoo, Finland· Stora Enso Ostroleka CHP project, Ostroleka, Poland,

aka ”Narew-project”· Porin Prosessivoima CHP project, Pori, Finland· Vantaan Energia Oy, JV1-project,Vantaa, Finland· Lahti Energia Oy, KYVO2-project, Lahti, Finland· UPM Schongau Gmbh, CHP project,

Schongau, Germany· Stora Enso Maxau CHP project, Maxau, Germany· Stora Enso Langerbrugge CHP project,

Langerbrugge, Belgium· UPM Caledonian Paper mill CHP project, Scotland UK· UPM Chapelle BFB boiler plant, Chapelle Darblay, France· UPM Biofuel BF boiler plant, Shotton, Wales UK



STAGES OF PROJECTS

Procurement of main machines

Investmentdecision

Implementationstarts

Comissioningstarts

Productionstarts

Detail engineering

MEI Installation

Production

0 14 2420

Civil Construction

Power plant 15…20 month

Paper mill 15…18 month

Bio product plant 22…26 month

Chemical Island 12…40 month



VIRTUAL MILL



DETAIL ENGINEERING DOCUMENTS IN A PAPER MILL PROJECT

17.4.2012


PRE-ENGINEERINGCOPYRIGHT © PÖYRY FINLAND OYALL RIGHTS ARE RESERVED. THIS DOCUMENTOR ANY PART THEREOF MAY NOT BE COPIED ORREPRODUCED WITHOUT PERMISSION IN WRITING FROMPÖYRY FINLAND OY

PÖYRY AUTOMATION AND ELECTRICAL DEPARTMENT



PRE-ENGINEERING

· Conceptual study· Pre-study· Pre-engineering· Basic engineering· Pre-feasibility study· Feasibility study· Extended feasibility study· Main study· Front end engineering



PRE-ENGINEERING

· The basic solutions for mill automation– automation and IT design criteria– systems : DCS, QCS, WIS, other systems– level of the automation : field devices– the basic solutions for implementation : cabling techniques

· Size and locations of automation and control rooms (space reservations)· Calculation of investment for automation· In some cases also part of the basic engineering is done during the pre-engineering

– Instructions and standards for procurement and engineering



ISA 95 FUNCTIONAL HIERARCHY OF ACTIVITIES



THE BASIC SOLUTIONS FOR MILL AUTOMATION

· Level 4: Business Planning and Logistics– Applications for Sales and Distribution– Applications for Materials Management and Purchasing– Applications for Maintenance– Applications for Financial Management– Applications for Human Resources Management and Payroll– Applications for Information Management, Data Warehousing– Applications for Collaboration

· Level 3: Manufacturing Operations Management– Production Management (PPMS)– Process Information Management (PIMS)– Dynamic Asset Management (AMS)– Document Management




· Level 2: Monitoring, Supervisory and Automated Control– Distributed Control System (DCS)– Machine Control Systems (MCS)– Supervisory Quality Controls

– Quality Control System (QCS), Web Inspection System (WIS), Web Monitoring System(WMS), Machine Monitoring System (MMS),…

– Product Management, Warehouse and Logistics Systems– Physical Access Control System (PACS)

· Level 1: Sensing and Manipulating the Production Processes– Sensors and Transmitters– Final Control Elements, Remote-operated Control and On-off Valves– Discrete Switches– Analyzers




· Infrastructure and Communications– Networks– User Interface

– Control Rooms– Administrative Functions Interface– Manufacturing Operations Management User Interface– CCTV Systems

– Computing– Storaging and Back-ups– Communications

– Manufacturing Operations Management Communications– Voice Communications



AUTOMATION AND CONTROL ROOMS



CALCULATION OF INVESTMENT FOR AUTOMATION

· If the cost estimate accuracy is requested to be less than ±5 %, some enquiries shall beprepared;– DCS (Distributed Control System)– QCS (Quality Control System)– PIMS (Process Information Management System)– PPMS (Paper Production Management System)– ICT (Information and Communication Technology)

· Calculation is based on loop and circuit amounts and Pöyry cost files– Standard instruments– DCS– Installation

· Special instruments are listed and priced separately




Automaatio5 %

Electrical11 %

Others13 %

Buildings16 %Piping

7 %

Machines47 %

5% 850 MEUR = 42 MEUR

17.4.2012


BASIC ENGINEERINGCOPYRIGHT © PÖYRY FINLAND OYALL RIGHTS ARE RESERVED. THIS DOCUMENTOR ANY PART THEREOF MAY NOT BE COPIED ORREPRODUCED WITHOUT PERMISSION IN WRITING FROMPÖYRY FINLAND OY




BASIC ENGINEERING

· General Automation Engineering– Co-ordination– Engineering Instructions and Standards– Procurement Services

· Safety of Automation– Hazard and Risk Analysis– Safety Requirements Allocation– Overall Safety Requirements

· Process Control System Design (DCS)– General Process Control System Engineering– Control and System Room Design

· Field Equipment Design– Measurement and control methods– Process data acquisition– Equipment selection– Process connection design



CO-ORDINATION

· Checking and approving of the design, drawings and documents to ensure compliancewith the set project standards and criteria

· Communication with other disciplines– Project management– Process engineering– Mechanical and piping engineering– Civil engineering– HVAC engineering– Electrical engineering– ICT engineering (under automation engineering management)



ENGINEERING INSTRUCTIONS AND STANDARDS

· Automation and instrumentation in machine deliveries· Auxiliary equipment for automation and instrumentation· Automation and instrumentation design criteria· Numbering procedure for automation and instrumentation· Cable standard· General instruction for automation and instrumentation symbols and identification· Marking and name plates for automation and instrumentation· Function blocks for functional diagrams· Automation and instrumentation commissioning instructions



AUTOMATION AND INSTRUMENTATION IN MACHINE DELIVERIES



AUTOMATION AND INSTRUMENTATION DESIGN CRITERIA



PROCUREMENT SERVICES

· Technical enquiry specifications· Participation in technical and commercial tender negotiations

– Minutes of meetings· Tender evaluation and comparisons· Equipment and material specifications for purchase requisitions and orders



TECHNICAL ENQUIRY SPECIFICATIONS

· DCS (U)· ICT infrastructure (U)· Control and on-off valves (U)· HP control valves· Magnetic flowmeters (U)· Nozzles and orifice Plates· Vortex flowmeters (U)· Mass flowmeters· Consistency transmitters and pulp sampling

valves (U)· Pressure, dP and level transmitters (U)· Temperature sensors and transmitters (U)· Refractometers· Radiometric density measurements· Radiometric level measurements· pH transmitters (U)· Conductivity transmitters (U)· Pyrometers and lime kiln scanner· Special level measurements· Smelt bed cameras

· Flue gas analysers (SO2, NOX, CO, CO2, HCl,HF, CH4, C2H4, C3H3, O2, Dust, Temperature,Flow)

· Flue gas O2 analysers· Cooking and washing liquor analysers· Kappa, brightness and residual chemicals

analysers· Boiler water analysers (SiO2, pH, Conductivity,

O2)· Pulp sheet dirt count analysers· Pulp quality analysers· Ultrasonic flowmeters· Viscosimeter· Weighbridges· Gas detectors· CCTV system (U)· Junction boxes (U)· Network cabling and installation (U)· Instrument installation (U)

· U=Unit price based frame contract



SAFETY OF AUTOMATION

· Hazard and Risk Analysis– Hazard and risk reports

· Safety Requirements Allocation– Hazard and risk reports with the safety integrity levels (SIL)

· Overall Safety Requirements– Specification for the overall Safety requirements (Specification of SIL functions)



PROCESS CONTROL SYSTEM DESIGN (DCS)

· General Process Control System Engineering– Allocation of I/O’s for loops

– I/O list (amounts)· Control and System Room Design

– Specification for control and system room requirements for layout design– Control and system room layouts– Requirements and specification of floor and ceiling openings– Requirements and specification of control and system room HVAC– Cable tray arrangement drawings in control and system rooms



CONTROL AND SYSTEM ROOM DESIGN



FIELD EQUIPMENT DESIGN

· Measurement and control methods– Instrumentation of process flow diagrams

– PI-diagrams– Requirements and specification for field equipment

– Selection guide of field instruments and control valves by application type· Process data acquisition

– Process data acquisition for field equipment selection and sizing– Application list for process data

· Equipment selection– Field equipment type definition

– Device standard– Sizing of flow meters and control valves

– Calculation sizing sheets– Equipment specification for loops

– Specification for equipment in loops– Calibration list– Application list

· Process connection design– Requirements and specification for mechanical engineering

– Installation instructions for field instruments in process piping and machinery– Dimensional drawings of process connections and field instruments



INSTRUMENTATION OF PROCESS FLOW DIAGRAMS => PI-DIAGRAMS



PROCESS DATA ACQUISITION



EQUIPMENT SELECTION



PROCESS CONNECTION DESIGN



DETAIL ENGINEERING

· Safety of Automation– Engineering Instructions and Standards– Risk Assessment– Safety System Design– Permit Documents and Inspections

· Process Control System Design (DCS)– General Process Control System Engineering

· Installation design– Installation Engineering– Location Design– Maintenance design



DETAIL ENGINEERING

Process Control Design· Process Description for Process Control Design

– Alternative 1– Process description– Interlocking, group start and sequence diagrams– Functional diagrams for instrument loops– Distributed Control System DCS graphic display sketches

– Alternative 2– Process description– Loop and circuit wise functional descriptions or diagrams– Distributed Control System DCS graphic display sketches

– Alternative 3– Process description– Loop and circuit wise process description– Distributed Control System DCS graphic display sketches



LOOP WISE FUNCTIONAL DESCRIPTION FOR PROCESSCONTROL DESIGN



FUNCTIONAL DIAGRAM FOR PROCESS CONTROL DESIGN



SAFETY OF AUTOMATION

· Engineering Instructions and Standards– Implementation procedure for Safety Related Systems (SRS)

· Risk Assessment– Specification of automation in hazardous and classified areas– Participation to hazard and risk analysis– Hazard and risk analyse reports with safety integrity levels (SIL)– Functional safety requirements

· Safety System Design– Safety Instrumented Systems (SIS)– Documentation and participation in FAT, SAT and lifetime tests as related to safety system design– Installation and commissioning planning– Composing the operation and the maintenance instructions as related to safety system design

· Permit Documents and Inspections– Permit documents of safety related systems– Permit documents of automation in hazardous and classified areas– Permit documents of radioactive material in automation– Compiling the required documents for verification– Verification reports handling– Participation in verification meetings with authorities



PROCESS CONTROL SYSTEM DESIGN (DCS)

· General Process Control System Engineering– Specification of DCS concept– Panel, cabinet and rack layouts– Wiring diagrams for panels, cabinets and racks– Cross connection layouts– Wiring diagrams for cross connection– Allocation of applications in process stations (controllers)– Allocation of I/O’s and signals to the DCS– Allocation of field bus segments



CROSS CONNECTION LAYOUTS



INSTALLATION DESIGN

· Installation Engineering– Typical installation drawings and general instructions– Field box and panel layouts– Wiring diagrams of field equipment to field boxes and panels– Wiring diagrams of field bus segments– Control equipment and box lists– Cable lists– Name plate and marking lists– Application list for installation

· Location Design– Location drawings for field instruments and boxes

· Maintenance design– Loop diagrams– Collection of the operation and the maintenance instructions of instruments



TYPICAL INSTALLATION DRAWINGS AND GENERALINSTRUCTIONS



WIRING DIAGRAMS OF FIELD EQUIPMENT TO FIELD BOXES ANDPANELS



ALLOCATIONS OF INSTRUMENTS IN PROCESS PIPING (3D-MODEL)



LOCATION DRAWING



LOOP DIAGRAMS



SITE SERVICES

· FAT (Factory Acceptance Test) for DCS– 4 …12 weeks– Application configuration checking in simulation situation– Base parameters for control loops

· Installation supervision– 6 … 12 month

· Loop checks (SAT Site Acceptance Test)– 6 … 12 weeks– Every signal will be tested (measurements, controls, binary signals

· Test runs and commissioning– 6 … 12 weeks– Tuning of the control loops

17.4.2012


CAREER AT PÖYRY AUTOMATION




CAREER AT PÖYRY AUTOMATION AND IELECTRICALDEPARTMENT

· Required skills– language important: English, Swedish, Germany, Russia, Portuguese, etc.– social skills– Team player skills– Open mind– perseverance in many details– tolerance of stress

· We offered– interesting international working environment– possibilities for international career– personal and professional development– versatile project assignments (changes after 12 … 24 month)– many contacts (client, suppliers, contractors, other designers)

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