FFEUC-ME Multaqa 2007

Transcription

1 FFEUC-ME Multaqa 2007 Rabigh Development Program Implementation Of A Mega Foundation Fieldbus Project By: Eyad H. Garatly Olefins Plants Division Rabigh Development Project December 2007

2 Outline Rabigh Development Program Overview Foundation Fieldbus Design & Implementation Recommendation Conclusion

3 Introduction Saudi Aramco & Sumitomo Chemical signed the MOU on May 9 th, 2004 to study the project feasibility. On August 1 st, 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

4 Location Of Petro-Rabigh

5 Rabigh Development Program At Present Crude 400 MBD Refinery Upgrade 170 MBD VDU 120 MBD VGO/HDT CDU 92 MBD Naphtha Merox Naphtha Kerosene Merox Kerosene Diesel Hydro-Treater Diesel Gasoline HOFCC Fuel Oil Alkylation Isomarization Offsite/Utility: Power, Water & Steam Cooling Water, Potable Water Compressed Air Tankage Flare System Marine Loading Supporting Units: Sulphuric Acid Plant Sulphur Recovery Unit Amine Regeneration Units Sour Water Strippers H2 Production Unit Flue Gas Desulphurization Petrochemical Ethane 95 MMSCFD Ethane Cracker Ethylene 1350 KTA Propylene 900 KTA Petrochem. Derivative Plants EPPE LLDPE HDPE PP1 PP2 PO MEG

6 Project EPC s Whessoe, Darlington, UK UO2 Tecnimont Milan, Italy PC1 & PC3 FWEL Reading, UK UOU Tecnicas Reunidas Madrid, Spain Refining JGC / SCEC / MES / Hitachi /TSK Japan (OP, PC2, PC3, UO1 & WWT)

7 PCS Major Vendors DCS 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

8 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)

9 Hardwired I/O Points (System): Project PCS Scope DCS SIS VMS F&G Total 37,707 13,235 3,075 4,247 58,264 Hardwired I/O Points (I/O Type DCS): FF AI AO DI DO Total 13,134 3,427 1,029 13,863 6,254 37,707 Field FF Instrumentation: FF FF FF FF FF FF FF Total (FT) (PT) (DT) (PDT) (TT) (Positioner) (LT) 2,342 2, ,943 2,902 1,111 13,134

10 Project PCS Scope Process Control Systems Cabinets: FF DCS SIS VMS F&G 90 Total 1,140 Process Control Systems: DCS SIS VMS F&G Total

11 Control Rooms & PIB s 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. PIBs 25 process new SS and 12 existing. 73 M Rack Rooms 41 M HOFCC IWSP EC UTILITIES VGO & HPU TANK & MEG CDU/VDU & SWS ARU C4 & PO CCR-1

12 PR Overall PCS Block Diagram CCR-1

13 PCS System Architecture 18 Control Domains Remote Engineering

14 Control Infrastructure 6.6 Km MFCR PIB-04 PIB-03 PIB-20 DCC PIB01 PIB-02 PIB-11 PIB-13 PIB-12 PIB-16 PIB-17 PIB Km PIB-19 CCR-2 PIB-22 PIB-21 CCR-1 PIB-18 PIB-26 PIB-05 PIB-06

15 Outline Rabigh Development Program Overview Foundation Fieldbus Design & Implementation Recommendation Conclusion

16 FF Design Spur Spur System Cable Trunk System Cable Spur Spur Used SAES-J-904 Tree Topology. Maximize FF devices. Max. 12 devices including 2 control valves/ segment. Max. 10 devices with 2 installed spare/segment. Max. of 8 segments /JB (8 pair cable) Trunk Cable length 800 M 20% installed spare Total Segment Length 1700 M Redundant H1 Cards 10% Installed I/O spare All PID blocks implemented at Host (not in the field devices). LAS in both H1 cards. (No LAS in field device). Spur Cable 75 M Field Instrumentation Field JB PIB Marshaling Cabinet PIB System Cabinet

17 FF Temperature Multiplexer Field T/C & RTD Temperature Multiplexers (Field JB) Segment Protectors (Field JB) FF Power Supplies (PIB) FCS & H1 Cards (PIB) Maximum 5 Multiplexers (40 elements / segment) Actual installation 4 Temp. Multiplexers (32 elements / Segment) Used for Monitoring Points 101 FF multiplexers 1 second macrocycle

18 FF Instrument Segment Diagrams (ISD) 1 PIB MC PIB MC PIB SC Trunk Field JB 2 3 FF ISD & ISS Standardized using Intools. 8 All packages database will be merged together Installed Spare 9 6

19 FF Marshaling Cabinets Rittal, 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.

20 FF Vs. Conventional I/O Marshaling Cabinets Rittal, 800mm W X Rittal, 800mm W X 800mm D X 2000mm H 800mm D X 2000mm H Terminal Blocks on Terminal Blocks on side of side of cabinet cabinet Max No. of P+F FF Maximum number of boards 22 / cabinet, 88 Yokogawa AI/AO terminal segments boards / cabinet is 12 Average 6 devices / Fully Loaded AI/AO segment = 528 Points FF Marshaling AI/AO Marshaling Marshaling cabinet 12 x 16=192 Points FF Vs. Conventional Marshaling at EC FF AI/AO # of Marshaling 6 7 # of Devices FF Vs. Conventional Marshaling at HOFCC FF AI/AO # of Marshaling 3 3 # of Devices

21 FF Field Junction Boxes 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. RDP Projects Olefin's Plant Refining Plants EPPE,LLDPE, HDPE & Butene-1 PC2 (PO & MEG) PP UO1 UOU Total No. of FF JB s

22 FF Field Installations Field Installations: FF Devices Enclosure type Ex n FF cables meeting the technical specifications & standards. SWA cables run in trays & droppers. RDP Projects Olefin's Plant Refining Plants EPPE & LLDPE PC2-PO HDPE PP No of FF points/segment (average) No of FF segments MEG UOU New 5 20 UO Total 6 2,398

23 FF FAT & Interoperability Test FAT: 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 1 st time due to DD files problems. Tested downloading & uploading data from both DCS EWS & PRM.

24 FF SAT & Calibration SAT: 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.

25 FF Loop Test & Pre-Commissioning Training 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. PIB FCS (ALF111) CCR L2SW L2SW Vnet/IP HIS ENG Field Advanced Diagnostic Module DVC600f GWR EJA 375 Communicator

26 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.

27 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.

28 Acknowledgment Team Work, Support & Cooperation: Detailed Engineering, Procurement & Construction Management By all RDP EPC s & PCS vendors: Tsukishima Kikai Co., Ltd.

29 Team Work, Support & Cooperation: PR Management, Operations & Maintenance. Acknowledgment Project Management & PCS Team Yokogawa Rabigh Team Triconex Rabigh Team Bently Nevada Rabigh team OP C&I Construction Team OP Operations and C&I Team