ffeuc-me multaqa 2007” - fieldbus foundation · 2010-11-11 · “freedom to choose. power to...

“Freedom to Choose. Power to Integrate”FIELDBUS FOUNDATION

FFEUC-ME “Multaqa 2007”

Rabigh Development Program“Implementation Of A Mega Foundation Fieldbus Project”

December 2007

By:Eyad H. Garatly

Olefins Plants DivisionRabigh Development Project


Outline

Rabigh Development Program Overview

Foundation Fieldbus Design & Implementation

Recommendation

Conclusion


Introduction

Saudi Aramco & Sumitomo Chemical signed

the MOU on May 9th, 2004 to study the project

feasibility.

On August 1st, 2005, the agreement was signed

to develop the existing SA Rabigh Refinery

into a world class state of the art integrated

refining and petrochemical complex.

New JV company developed called Rabigh

Refining & Petrochemical Company (Petro-

Rabigh)

Project under construction & Start-Up in 2008

May 9th, 2004

August 1st, 2005


Location Of Petro-Rabigh


Rabigh Development ProgramOffsite/Utility:

Power, Water & SteamCooling Water, Potable WaterCompressed AirTankageFlare SystemMarine Loading

Supporting Units:Sulphuric Acid PlantSulphur Recovery UnitAmine Regeneration UnitsSour Water StrippersH2 Production UnitFlue Gas Desulphurization

Ethane

Petrochemical

95 MMSCFD

EPPE

PP1PP2POMEG

Petrochem.Derivative

Plants

Ethylene 1350 KTA

Propylene 900 KTA

EthaneCracker

HDPELLDPE

CDU

Naphtha

Kerosene

Diesel

Crude

At Present

400 MBD

Naphtha Merox

Kerosene Merox

Diesel Hydro-Treater

Gasoline

Fuel Oil

Refinery Upgrade

IsomarizationAlkylation

VDU VGO/HDT 92 MBD

170 MBD

120 MBD

HOFCC


Project EPC’s

Tecnimont Milan, Italy

PC1 & PC3

Tecnicas Reunidas

Madrid, Spain

Refining

FWEL Reading, UK

UOU

Whessoe,

Darlington, UK

UO2

JGC / SCEC / MES / Hitachi /TSK Japan

(OP, PC2, PC3, UO1 & WWT)


PCS Major VendorsDCS by Yokogawa

SIS by Triconex (Invensys)

VMS/CMS by Bently Nevada (GE)

F&G by Yokogawa (Pro-Safe)

CCS by CCC

STC by Woodward

Others by Siemens, Allen Bradley, GE

Func, etc…

DCS Consoles by Evans


FF Field Instrumentation Major Vendors

PT, FT, PDT, TT Transmitters by Yokogawa

Valve Positioners by Fisher (Emerson)

Level Transmitters by Magnetrol

Radar Transmitters by Endress & Houser

Vortex Transmitters by Rosemount (Emerson)

Local FF indicators by Rosemount (Emerson)

Temperature Multiplexers (P+F)


Project PCS ScopeHardwired I/O Points (System):

3,075

VMS

58,2644,24713,23537,707

TotalF&GSISDCS

Hardwired I/O Points (I/O Type DCS):

37,7076,25413,8631,0293,42713,134

TotalDODIAOAIFF

Field FF Instrumentation:

1,111

FF(LT)

13,1342,9023,94348992,3382,342

TotalFF (Positioner)

FF (TT)

FF (PDT)

FF (DT)

FF (PT)

FF (FT)


Project PCS Scope

Process Control Systems:

50

SIS

22

F&G

29689135

TotalVMSDCS

Process Control Systems Cabinets:

648

DCS

100

VMS

1,1409024161

TotalF&GSISFF


Control Rooms & PIB’s

HO

FCC

IWSP

UTILITIES

EC

CD

U/VD

U &

SWS A

RU

VGO

& H

PU

C4 &

PO

TAN

K &

MEG

PIBs’

Rack Rooms

CCR-1

41 M

73 M

PIB’s:12 new & 6 existing.Explosion Proof.Combined Operators shelters with PIB’s.

CCR’s:2 New & PIB-04 converted to Marine Control Room.CCR-1 (73M X 41M)CCR-2 (45M X 37M)

59 new DCS Consoles.25 process new SS and 12 existing.


CC

R-1

PR Overall PCS Block Diagram


PCS System Architecture

18 Control Domains

Remote Engineering


Control Infrastructure

PIB01

PIB-02

PIB-03

DCC

MFCRPIB-04

CCR-1

PIB-11

PIB-13PIB-14PIB-17

PIB-16

PIB-26

PIB-06

PIB-22PIB-21

PIB-12

PIB-05

CCR-2

PIB-18

PIB-19

PIB-20

6.6 Km

4.2 Km


Outline

Rabigh Development Program Overview

Foundation Fieldbus Design & Implementation

Recommendation

Conclusion


FF Design

Used SAES-J-904Tree Topology.Maximize FF devices.Max. 12 devices including 2 control valves/ segment.Max. 10 devices with 2 installed spare/Segment.Spur Cable ≤ 75 M

Max. of 8 segments /JB (8 pair cable)Trunk Cable length ≤ 800 M20% installed spare

Total Segment Length ≤ 1700 M

Redundant H1 Cards 10% Installed I/O spareAll PID blocks implemented at Host (not in the field devices).LAS in both H1 cards. (No LAS in field device).

Spur

Spur

Spur

Spur

Trunk

System Cable

System Cable

Field Instrumentation Field JB PIB Marshaling Cabinet PIB System Cabinet


FF Temperature Multiplexer

Maximum 5 Multiplexers (40 elements / segment)

Actual installation 4 Temp. Multiplexers (32 elements / Segment)

Used for Monitoring Points101 FF multiplexers

1 second macrocycle

Field T/C &RTD

Temperature Multiplexers (Field JB)

Segment Protectors (Field JB)

FCS & H1 Cards (PIB)

FF Power Supplies (PIB)


FF Instrument Segment Diagrams (ISD)

FF ISD & ISS Standardized using Intools.All packages database will be merged together.

1

8

7

69

10

2

3

4

5 Installed Spare

PIB MC

PIB SCPIB MC

Field JB

Trunk


FF Marshaling CabinetsRittal, 800mm Width X 800mm Depth X 2000mm Height.P+F MB-FB-4R.YO –FF power supply boards, 500mA (600).

2 TDK 24VDC, 55A, 1540Watts redundant BPS mounted in parallel configuration

2 independent 120VAC PS from UPS.

Each FF board PS alarm is connected to a common DCS alarm.

All FF boards are daisy chained and connected to a common RS485 terminal point for performing Advanced Diagnostic Function.

The FF field cables are terminated on the side terminal blocks. These are then cross wired to the FF power conditioners using a Type A cable for FF Communication (Beldon 3076F).

A system cable from FF IO module in FCS directly connects FF board.


FF Vs. Conventional I/O Marshaling CabinetsRittal, 800mm W X

800mm D X 2000mm H

Terminal Blocks on

side of cabinet

Max No. of P+F FF

boards 22 / cabinet, 88

segments

Average 6 devices /

segment = 528 Points

17646FF

5267AI/AO

# of Devices

# of Marshaling

Rittal, 800mm W X

800mm D X 2000mm H

Terminal Blocks on side of

cabinet

Maximum number of

Yokogawa AI/AO terminal

boards / cabinet is 12

Fully Loaded AI/AO

Marshaling cabinet 12 x

16=192 PointsFF Marshaling AI/AO Marshaling

FF Vs. Conventional Marshaling at EC

11463FF

2903AI/AO

# of Devices# of Marshaling

FF Vs. Conventional Marshaling at HOFCC


Field Junction Boxes:From Shimada and Crouse Hinds.JB’s NEMA-4X Suitable for Class-I, Div.-II areas. JB 316 Stainless Steel.P+F Segment Protectors used (2,414).20% installed spare.

FF Field Junction Boxes

25UO1

882Total10UOU

70PP133PC2 (PO & MEG)

120EPPE,LLDPE, HDPE & Butene-1

191Refining Plants333Olefin's Plant

No. of FF JB’sRDP Projects


Field Installations:FF Devices Enclosure type Ex‘n FF cables meeting the technical specifications & standards.SWA cables run in trays & droppers.

FF Field Installations

62

5

5

6

6

5

5

6

7

No of FF points/segment

(average)

2,398Total48UO1

20UOU New

176MEG

197PP

216HDPE

268PC2-PO

254EPPE & LLDPE

663Refining Plants

556Olefin's Plant

No of FF segmentsRDP Projects


FF FAT & Interoperability TestFAT:

Visual and BOM checks.Connected one device in each segment to check communication.Test FF ALF111 H1 cards redundancy.Test the FF power supplies and conditioners.Test all cabinet alarms (Temperature, FF PS & BPS).

Interoperability Test:2 Interoperability tests were conducted.Some devices did not work from the 1st time due to DD files problems.Tested downloading & uploading data from both DCS EWS & PRM.


FF SAT & CalibrationSAT:

Visual and BOM checks after final installations.Repeated the FF communication & redundancy tests.

Calibration:Checked the communication between the device and FF communicator (Emerson 375).Checked the input data in all devices.No simulation of the process was conducted.Using the 375, checked the FF Positioners (Fisher) communication where all FF valves were stroked.Early problems and data discrepancies have been discovered and rectified in a timely manner.


375 Communicator

FF Loop Test & Pre-Commissioning

FCS

(ALF111)

L2SW

HIS ENG

L2SWVnet/IP

EJAGWRDVC600f

Field

PIB CCRTraining conducted for all technicians.Initial download/upload required from EWS to devices for data equalization.Using P+F advanced diagnostic module to perform segment Healthiness check.Connect 375 communicator to each field instrument for simulation.No process input simulation will be conducted.

Advanced Diagnostic Module


Recommendation

Interoperability needs more attention and close coordination from vendors.

Further solutions are required to ensure a proper FAT.

Disseminate the FF technology to packaged vendors.

Consider Revising Saudi Aramco standard (SAES-J-904) to:

Delete the critical valves requirement.

Add more devices per segment to achieve more benefits.

Improve FF System initialization and devices configuration.


Conclusion

Successful implementation of the Early Engineering Design (EED),software and hardware prototyping has achieved the PCS standardization among all Rabigh program packages.

FF Engineering documentation was standardized using Intools.

Maximized the use of the FF technology in the Rabigh Program.


AcknowledgmentTeam Work, Support & Cooperation:

Detailed Engineering, Procurement & Construction Management By all RDP EPC’s & PCS vendors:

Tsukishima Kikai Co., Ltd.


AcknowledgmentTeam Work, Support & Cooperation:

PR Management, Operations & Maintenance.

Bently Nevada Rabigh team OP Operations and C&I Team

Project Management & PCS Team

OP C&I Construction Team

Triconex Rabigh TeamYokogawa Rabigh Team

ffeuc-me multaqa 2007” - fieldbus foundation · 2010-11-11 · “freedom to choose. power to...

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