IMPLEMENTATION OF FOUNDATION FIELDBUS (FF) TECHNOLOGY IN IOCL REFINERIES

Transcription

1 IMPLEMENTATION OF FOUNDATION FIELDBUS (FF) TECHNOLOGY IN IOCL REFINERIES 23 rd Nov 2012 Atish Chakrabarty Dy. General Manager (Projects) Indian Oil Corporation Ltd.

2 Global Standing of IOCL Leading Fortune Global 500 company in India in the year for the 13 th year in succession. Ranks 83 rd by revenues (exceeding INR 4 Lac cr./ US$ 80 billion). Within the country Ranks 22 ND largest petroleum company in the world. Refining share : 31% Market share : 49% 2

3 Indian Oil Corporation Ltd. Refineries Marketing Pipelines IndianOil R&D 3

4 Refineries Mathura 8.0 Panipat 15.0 Koyali 13.7 Barauni 6.0 Paradip 15.0 BRPL 2.35 Haldia 7.50 (Figures in MMTPA) Digboi 0.65 Guwahati 1.0 Installed capacity CPCL(Manali) 10.5 Under Implementation CPCL(Narimanam) 1.0 4

5 Globalisation Initiatives Overseas Offices Subsidiary Companies at Mauritius Sri Lanka Regional Offices at Malaysia UAE l DUBAI l SRI LANKA l MALAYSIA l MAURITIUS 5

6 History of Information Technology/ Process Control in IndianOil Punch Cards Second Generation Systems Third Generation Systems/ Dedicated telecommunication systems Relational Database Management Systems & SCADA PC based Control systems Programmable Logic Controller/ Distributed Digital Control Systems Advanced Process Control Project Manthan Implementation of SAP FF Implementation for Process Control 1967 / / / /

7 Automation & Control Initiatives Automation & Control in Refinery Automation & Control in Pipeline Automation & Control in Marketing & product distribution 7

8 State of the Art Refineries 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 refineries - diesel / petrol of Euro IV quality Zero Bottoms refineries 8

9 Control Levels in IOCL Refineries 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) Copyright Indian HPCL-Mittal Oil Corporation Energy Ltd. Ltd. 9

10 Refinery Evolution of FF Technology Implementation in IOCL Refineries Year of implementation Areas of implementation Panipat Refinery Gujarat Refinery Digboi and Guwahati refinery Barauni refinery Paradip refinery 2006 FF implemented in ETP and other nonprocess units for open loops only FF implemented during Residue upgaradation project execution for open loops only FF implemented during MS quality upgradation project for open loops only FF imeplemented during execution of Hydrogen unit and MS quality upgradation project for all open loops and non-critical closed loops. Under implementation FF under implementation in the whole complex of 15 MMTPA refinery for open loops and non-critical closed loops. 10

11 DCS Sizing based on FF SYSTEM SIZE- APPROXIMATE FOR PARADIP REFINERY DCS TOTAL NUMBER OF FOUNDATION FIELDBUS SEGMENTS = 2100 NOS. TOTAL NO. OF FF LOOPS = NOS. TOTAL NOS. OF FF CLOSED LOOPS = 2000 NOS. TOTAL NOS. OF FF OPEN LOOPS = 8000 NOS. TOTAL NOS. OF 4-20 ma / HART DCS LOOPS = NOS. 11

12 Controlling Methodology MCR RACK ROOMs & MAIN CONTROL ROOM (MCR) Data Highway SRRs I/O subsystem with IS barriers FIELD ESD-SIL3 F&G-SIL3 Field JB HART FF JB with field barriers Field JB Field JB 12

13 Foundation Fieldbus topology Foundation Fieldbus Topology DCS Field Instrument Control Room Field Redundant FF- H1 interface Spur Field Junction box with Fieldbus Barriers SURGE PROTECTOR Trunk 13

14 FF implementation Philosophy Fieldbus concept followed in Process units for all Open loops and non-critical closed loops Max. two closed loops are 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 not implemented to avoid process instability. Fieldbus junction boxes with field barrier assembly placed in SS316 Housing 18AWG Trunk Cable with a loop resistance of 44 ohms/k.m is generally used and based on segment validation by system supplier, 16 AWG is also used. 14

15 FF implementation Philosophy..contd Not more than 3 field barrier assemblies are considered in one segment per FFJB Chicken Foot Topology Minimum 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 In general, Max. Trunk Cable Length + Spur Cable Length 1900mtrs. However, based on segment validation for some cases with less number of devices, length of cable is more than 1.9KM. 15

16 Typical 3 Barrier FFJB in a segment 16

17 Operational Excellence using FF Experiences During Installation & Commissioning Cost savings achieved by Reduction in cable cost Faster completion of cable laying work Less number of terminations Reduced cable ducts/ trays. Faster completion of loop checking and validation Faster uptime of instruments Less number of cabinets required Less space required for control room due to lesser cabinets Reduced erection & commissioning efforts. 17

18 Operational Excellence using FF Experiences During Commissioning and Operations Benefits of Interoperability. Lesser time for instrument installation/ modification Easy access to device information More information available for field devices Re-ranging from DCS is easy and faster Advance information, alarms on impending failure Easy trouble shooting 18

19 Challenges & Opportunities for Buyers & Sellers Proper flow of information about the installed systems across the globe. Inclination of buyers towards existing & proven technology for comfort. Cost of ownership of new technology. Gap in understanding on provenness & dependability. Sharing of Report on Failure Analysis with Diagnostic and overall impact. 19

20 Thanks for your cooperation 20