End User Conf. Mumbai (19.06.09)

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© 2009 Fieldbus Foundation

2009 FFIEUC-Mumbai Conference

Jasbir SinghEssar Oil [email protected]

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

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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

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2009 FFIEUC-Mumbai Conference200207

Businesses

Essar Group

Shipping Ports & Logistics

Steel Energy Power Projects

Essar Steel Ltd4.6 MTPA integratedsteel plant

Essar Steel (Hazira)4 MTPA integrated steel plant (under implementation)

Essar Steel Orissa6 MTPA pellet plant(under implementation)

Algoma Steel, Canada4.0 MTPA integrated steel plant

Minnesota Steel6 MTPA pellet plant (planned)

1.4 billion tonne iron ore reserves

PT Essar Indonesia0.4 MTPA cold rolling complex

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 ShippingFleet of 26 vessels, DWT of 1.49 mn

Vadinar Oil TerminalTerminal facility of 32 MTPA – Liquid Cargo

Bulk TerminalDry bulk port facilities

Essar Oilfields A drilling company with 13 rigs

Essar LogisticsOwns and operates transshipment assets

Essar Power / Bhander Power1,015 MW combined cycle Vadinar Power125 MW co-generation; expanding to 1250 MW

Essar Power MP1,200 MW coal based(under implementation)

Essar Power Gujarat1,200 MW coal based(under implementation)

Essar Power Jharkhand1,200 MW coal based(under implementation)

Essar Construction - Engineering - Fabrication - Construction

Fully geared to execute turnkey EPC jobs in India and overseas

Essar Offshore SubseaExpertise in marine construction

Global Supplies (UAE) FZE Global procurement company

Heavy Engineering Services

Project Management Consultants

Asia’s largest equipment bank

Communications

Vodafone Essar60 million subscribers

Essar Telecom Infrastructure3,500 telecom towers operational; 20,000 planned by 2010

The MobileStoreOver 1,300 outlets operational; 2,500 planned by 2010

Aegis - BPO30,000 people in offices in the Philippines, Costa Rica, USA and India

BPL MobileMore than 1.8 million subscribers

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From Rig to Retail

Essar Oil is a fully-integrated oil company of international standard and scale

Energy

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Field Bus Foundation provides the way to bridge the gap between business goals and specific Plant

performance factors

Aligning Performance Improvement Opportunities with Business Objectives

$$$

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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 / documentations4. FAT Guidelines 5. Error Measurement and control guidelines6. Installation, commissioning procedure and

Check Sheets

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Capital Expenditure CAPEX Excellence (Lowest Cost of ownership):

1. Level of Redundancy 2. Selection of Segment components3. Optimum FF Segment design4. Error measurement and Control5. Hardware selection for Installation


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Probability of failure Recovery time Loss per failure Level of Confidence

1. Level of Redundancy


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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

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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

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Design Development Implementation Maintenance

4. Error Management (monitor and control)


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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

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Support of Engineering and Project Management Consultancy in Field Bus System:5.Hardware Selection & Installation

Requirements: Solutions, Benefits:

long distance (up to > 8000 m) remote I/O

fiber optic

hazardous locations remote I/O for Zone 2 with IS inputs/outputs

high amb temperature (>50 °C) special „cabinet“ design

high availability redundancy

fiber optic ring structure

HART + FF connect remote I/O to DCS´s HART + FF management tool

IS and non IS signals handled by remote I/O

Cont.:

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Support of Engineering and Licensers:

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 field4. Use strength of other field bus such as ASi,

devicenet or others

Capital Expenditure CAPEX Excellence:

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Identification of control loops that can be considered in FFB:Identification of control loops that can be considered in FFB:

Super Critical Control Loops: 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.

1.1. Critical Control Loops Critical Control Loops 2.2. Semi Critical Control Loops Semi Critical Control Loops 3.3. Non Critical Control loopsNon Critical Control loops

1.1. Critical Control Loops: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.

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2.2. Semi Critical Control LoopsSemi 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:Non Critical Loops:

(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.

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User’s perspective:

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.

General Consideration for the use of FF in Essar:

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Type – 1Type – 1(One device (One device per output)per output)

Bulk Power Bulk Power SupplySupply

Type – 2Type – 2(Two device (Two device per output)per output)

Type – 3Type – 3(Three device (Three device

per output)per output)

Power Power ConditionerConditioner

T T - - ONON

Field Barrier-Field Barrier-FbFb

FbFb

FbFbFbFb

Safe AreaSafe Area

Hazardous AreaHazardous Area

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Device Manufacturer in Field Bus systems:

1. Hardware design & Level of Redundancy 2. Software3. Commissioning Tools

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System & Device Manufacture support:

1. Hardware design & Level of Redundancy

Easy cable connection of H1 card with Field bus power supply and replacement on faultRugged construction of FF components for easy cabinet mounting and resistance to shock and vibrationRobust field-proven and reliable Field Bus componentsLEDs indicators to identify failed module, Hot swapping of components to allow replacement under powerSupport multiple LAS devicesFF Basic-to-LM device wizard

“Safe” way to enable/disable Backup LAS Provides wizard to step through sequence

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Device Replacement

Device Replacement by Operator Quick Auto replacement From Operator Station or Engineering Station Support for:

o like device, and,o like devices with revisions

2.Software

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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 devicesCode Download

Allows upgrading devices on-line Includes enhancements to current capability and file

managementEasy device Configuration

Plug and play tool for device addition Device configuration wizard

DD file addition & Device Configuration

2.Software

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Device management in Field Bus:

• 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

3. Commissioning Tools

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Easy Commissioning and Help

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!

3. Commissioning Tools



1ALF111-1

PT 2002

Friday, September 22,2006 10:00:00 AM

Device on FF-H1 Bus Information Basic Information

Device Tag Name: PT 2002Device ID:594543000CJ000856Device Class: BASICUpdate Time: Friday, September 22,2006 10:00:00 AM

Detail Information

CV 4001


CV 4002


L 6001


Device Tag Name: CV 4001Device ID:5945430001J009185Device Class: BASICUpdate Time: Friday, September 22,2006 10:00:00 AM


Device Tag Name: L 6001Device ID:56474B0770Device Class: BASICUpdate Time: Friday, September 22,2006 10:00:00 AM

MANUFAC_ID: 0DEV TYPE:0X07DEV_REV:0X03


MANUFAC_ID: 0 DEV TYPE:0DEV_REV:0X030

Device Tag Name: TE1001Device ID:594543000550011361Device Class: BASICUpdate Time: Friday, September 22,2006 10:00:00 AM


MANUFAC_ID: 0 DEV TYPE:0DEV_REV:0X03

FCS 1001

NODE 01

ALF 111

ALF 111-1

PT 2002

CV 4001

CV 4002

L 6001

TE1001

TE1001


ALF 111-2

ALF 111-3

ALF 111-4

TAF

240

241

242

243

244

245

Device Management:

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1ALF111-1

PT 2002


Device on FF-H1 Bus Information Basic Information


Detail Information

MANUFAC_ID: 0X00594543(Yokogawa Electric)DEV TYPE:0X0770()DEV_REV:0X03

CV 4001


CV 4002


L 6001







MANUFAC_ID: 0X0056474B(VEGA)DEV TYPE:0X0770()DEV_REV:0X03



TE1001


240

241

243

244

245

242

Device Management:



1ALF111-1

PT 2002



MANUFAC_ID:0X00594543(Yokogawa Electric)DEV TYPE:0X0770()DEV_REV:0X03

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RB(RESOURCE_01) Auto

TB(TRANSDUCER_01) 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)







CV 4001


CV 4002Friday, September 22,2006 10:00:00 AM

L 6001




TE1001


241

242

243

244

245

Device on FF-H1 Bus Information Basic Information Detail Information

Device Management:



1ALF111-1

PT 2002




240

RB(RESOURCE_01) 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)







CV 4001



L 6001




TE1001



Device Management:

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1ALF111-1

PT 2002




240







CV 4001



L 6001




TE1001



Device Management:

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1ALF111-1

PT 2002




240







CV 4001



L 6001




TE1001



Device Management:

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Network Safe and Trouble Free operationNetwork System Design & LayoutNetwork Communication / Software Safety

Support for Network Design

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Fundamental considerations/Fault Avoidance

Information collection and safely processing

Enterprise Network

Dual Homing

HiPER RingRSTP

Secure Access to Plant Floor

Secure Access to Enterprise Network

LinkAggregation

OCTOPUS

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Design Considerations / Fault Avoidance

Industrial Connectors

Industrial Networking

Electronic Control and Management Systems

• Industrial Ethernet

•Optical Fiber Interfaces

• Industrial Connectors

•Load Moment Indicator

•Control Systems and Sensors

•Graphic Control Panels and Displays

Fundamental considerations/Fault Avoidance

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Networking at Multiple layers

Multilayer Safety Network

Operating System

Application

FF accessories

Device

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Design of Safety in communication systems1. Safe communication over a bus alone does not ensure

that the transferred information is safe2. No loss / encryption of data3. Programming Failure4. Improper installation of networking hardware5. Data transmission

Consistency checking Confirmation of correct data transmitted & received Watch dog for external affect

6. Safe communication Risk reduction Fault avoidance Fault control

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Reason of Failure in networking:

1. Mis-configured Fire wall2. Connection of infected laptop for engineering or trouble

shooting3. Infected remote support4. Unauthorized connection with unsecured system5. Connection with Modem, printer6. Non proven fire wall

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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

…

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Operational Excellence (OpX)

Maintenance cost

Availability

HSE cost

HSE compliance ratex x=

Production cost

Performance rate Quality ratex

Maximization of asset excellence factor

OPE: Overall Plant Effectiveness

OPECost

+ +

Maximization of production excellence factor

Maximization of safety excellence factor

Asset Excellence

ProductionExcellence

SafetyExcellence

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Asset management:

Easy Commissioning and Easy Life

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Easy Troubleshooting and Easy Life

Asset management:

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Documents

End User Conf. Mumbai (19.06.09)