ENGINEERING AND EXECUTION ADVANTAGES USING FOUNDATION FIELDBUS (FF) Ravi Gupta Manager-Engineering HPCL Mittal Energy Ltd.

Transcription

1 ENGINEERING AND EXECUTION ADVANTAGES USING FOUNDATION FIELDBUS (FF) Ravi Gupta Manager-Engineering HPCL Mittal Energy Ltd.

2 Who we are HPCL-Mittal Energy Limited A Joint Venture Company of M/s Hindustan Petroleum Corporation Limited L (HPCL) and M/s Mittal Energy Investments Pvt. Ltd.

3 3 Project Profile

4 State of Art Refinery STATE OF ART REFINERY DESIGN TO MAXIMIZE VALUE ADDITION CONSIDERING DEMAND IN THE REFINERY SUPPLY ZONE PROCESS DESIGNED TO REFINE A WIDE VARIETY OF CRUDE OILS INCLUDING COMPARATIVELY ECONOMIC CRUDES SUCH AS HEAVY, SOUR AND OTHER OPPORTUNITY CRUDES REFINERY TO PRODUCE HIGH VALUE ADDED PRODUCTS SUCH AS POLYPROPYLENE, FOOD-GRADE HEXANE AND SOLVENTS IN ADDITION TO LPG, NAPHTHA, PETROL, DIESEL, AVIATION FUEL, ETC. FUTURE READY REFINERY - DIESEL / PETROL OF EURO IV QUALITY ZERO BOTTOMS REFINERY

5 Guru Gobind Singh Refinery(GGSR)-Key Highlights RCC USED 4.19 LAKH TONS 30% MORE THAN RCC USED IN AL BURZ, WORLD S TALLEST BUILDING HALF OF RCC USED IN BHAKRA DAM STEEL USED 4.22 LAKH TONS IN THE PROJECT EQUAL TO STEEL USED IN MAKING OF 2500 NOS. 747 JUMBO JETS 4 TIMES THE STEEL USED IN BHAKRA DAM CDU/VDU COLUMN STANDS AT 82 METER HEIGHT, 10 METERS MORE THAN QUTAB MINAR

6 Pictures

7 Pictures

8 Control Levels in HMEL Refinery Planning Level Execution Level MES (Manufacturing Execution System) ERP-SAP (Enterprise Resource Planning) Control Level FF based DCS & SIL 3 ESD system (Distributed Control System Emergency Shutdown System) Field Instrumentation APC (Advanced Process Control)

9 System & FF Component Partners Prosafe by Yokogawa DCS ESD Centum Vp by Yokogawa FF Control Room & Field Hardware by P+F FF devices Transmitters - Emerson, Honeywell, E+H Valve Positioner - Fisher Sanmar, Metso

10 DCS Size SYSTEM SIZE- APPROXIMATE FOR DCS TOTAL NUMBER OF FOUNDATION FIELDBUS SEGMENTS = 2000 NOS. TOTAL NOS. OF FF CLOSED LOOPS = 1045 NOS. TOTAL NOS. OF FF OPEN LOOPS = 7288 NOS. TOTAL NOS. OF 4-20 MA / HART DCS CLOSED LOOPS = 1944 NOS.

11 Controlling Methodology V-net IP MCR SRRs SATELLITE RACK ROOM (SRR) MAIN CONTROL ROOM (MCR) CONCEPT SRR FIELD

12 Foundation Fieldbus Topology Redundant FF- H1 interface

13 FF implementation-brief Specifications Fieldbus concept followed in Process units for all Open loops and simple closed loops having 1 input, 2 Output devices or 2 inputs, 1 output devices One closed loop is considered per segment,coexistence of open & closed in same segment High Powered Trunk with Field Barriers concept is implemented (Power Supply capability is minimum 350 ma at 25 VDC) Control on wire concept is partially implemented Fieldbus junction boxes with field barrier assembly placed in SS316 Housing 16AWG Trunk Cable with a loop resistance of 29.8 ohms/k.m 18AWG spur Cable with a loop resistance of 44 ohms/k.m (In some units, FF is implemented only for Open Loops, as per Licensor recommendation)

14 FF implementation- Brief Specifications..contd. Not more than 3 field barrier assemblies are considered in one segment per FFJB Chicken Foot Topology 25% spare connections for field devices are provided in each segment Each spur is Intrinsically Safe & galvanically isolated from trunk Fieldbus terminator & surge protector provided for each segment LED indicator for each spur short circuit & for trunk voltage Scheduled communication on segment not to exceed 50% of the Segment Macro cycle time Max. Trunk Cable Length + Spur Cable Length 1900mtrs

15 Typical 3 Barrier FFJB in a segment

16 Advantages realized REDUCED DCS HARDWARE REDUCED MULTIPAIR CABLING REDUCED CABLE DUCTS/TRAYS REDUCED E&C EFFORTS REDUCED SRR SIZING

17 Reduced Quantum: DCS Hardware REDUCED DCS HARDWARE LESSER NUMBER OF CONTROLLERS LESSER SYSTEM & MARSHALLING CABINETS REDUCED ASSOCIATED HARDWARE ENERGY SAVING

18 Reduced Quantum: Cabling, Cable Duct & Erection Efforts REDUCED CABLING/CABLE DUCT Calculation: Total 2000 segments: Instead of 2000 runs of 6/12 pair of multi-cables 500m (average) i.e. 2000x500=1,000,000 m Only 1 Pair of equal length of FF 16 AWG cable used from each segment up to SRR LESSER DUCT/TRAYS REQUIREMENTS TO ACCOMMODATE LESS COPPER/METAL

19 Reduced E&C Efforts LESSER TERMINATIONS FIELD SIDE CHANGES DOES NOT IMPACT TOO MUCH ON SRR SIDE FLEXIBILITY FROM SRR SIDE TO ALLOCATE I/OS WITHOUT ACTUAL CHANGING CABINETS TIME SAVING

20 Sizing of Satellite Rack Room(SRR) REDUCED SRR SIZING ENOUGH SPACE LEFT IN SRR S FOR FUTURE BELOW FALSE FLOORING MANAGEABLE CABLE ROUTING EASY MAINTENANCE

21 Reduced Quantum: FAT Efforts FAT DURATION REDUCED THREE PHASES OF FAT EACH OF AVERAGE 12 DAYS FOR ENTIRE REFINERY

22 Questions.. if any??

23 Thanks for your cooperation