CHARMED Upgrading the UT Pickle Separations to DeltaV v11

CHARMED Upgrading UT Pickle Separations to DeltaV v11 with integrated CHARMS Dr. Frank Seibert – University of Texas Mark Nixon – Emerson Research Manager

Presenters
Frank Seibert, University of Texas at Austin
Mark Nixon
Research Manager
Austin, Texas

Abstract
This presentation follows the modernization of the UT Pickle Research Center in Austin, TX. The project includes an upgrade to CHARMS IO (electronic IO) and S-Series controllers, installation of new junction boxes, upgrade of graphics, conversion to rack mounted PCs and Servers, and modernization of the control room. The presentation follows the planning and execution of the project from initial planning, through execution, to commissioning, to taking the project on-line.

Separations Research Program, University of Texas at Austin
The Separations Research Program was established at the J.J. Pickle Research Campus in 1984
This cooperative industry/university program performs fundamental research of interest to chemical, biotechnological, petroleum refining, gas processing, pharmaceutical, and food companies.
CO2 removal from stack gas is a current focus project

Undergraduate Students

Research Areas
Distillation
CO2 Absorption/Stripping
Liquid-Liquid Extraction
Oil Extraction from Algae
Verification of Separation Processes
Scale-up/Trouble-Shooting

Harvesting Filtration Settling Water Biofuels Processing Concentration Preparation Lysing Extraction Biomass Coproducts Algae Production Biodiesel Biogas JP-8 Ethanol Feeds Fertilizers Others Sunlight Time Make-up water UT Program Simplified Algae Oil Process Nutrients CO2

Algae Oil Extraction
Recovery of submicron oil drops from slurry
Solvent selection
Extraction process – two options
Feed: flocculated or de-flocculated?
Preliminary material/energy balances and economics
Open Algae and UT Proprietary

CO2 Capture Process

SRP CO2 Capture Pilot Plant
Gas Capacity, m 3 /min = 25
Solvent Capacity, liter/min = 130
Inlet CO2 Composition, mol% =1-20
Capabilities:
- Solvent Screening
- Packing Performance
- Effect of Absorber Inter-cooling
- Solvent Regeneration Variations
- Evaluate Process Dynamics
- Evaluate Heat Exchangers
- Model Validation

Absorption Column
Column Diameter, cm = 42.8
Packed Height, cm = 600
Pressure, bar = 1
Windows for Observation
Inter-cooling Capability
Extensive Temperature Measurements

Stripping Column
Column Diameter, cm = 42.8
Packed Height, cm = 600
Pressure, bar = 0.2-4
Provides for Flashing Feed
Windows for Observation
Kettle Reboiler
Shell and Tube Condenser
Plate and Frame Cross Exchanger
11 bar Saturated Steam
10 C Chilled Water

Skid Fabrication – Initial Stage

High Temperature Two-Stage Flash Skid

High Pressure Flash Stripping System

Absorber Intercooling Operation

Scope of the upgrade Project
Upgrade to DeltaV v11 and AMS
Replace M series with S series controllers & IO
Two standard DeltaV JB’s w/ RCIOC’s & CHARMS
Retrofit one of existing JB’s with RCIOC’s & CHARMS
Upgraded Fieldbus
Added WIOC
Upgrade PROplus, Application Station & Workstations to Windows 7
Update Displays
Added new Switches
Upgrade Control Room
Remove existing overhead utility piping and abandoned conduit
Add new wall to separate operators from equipment room
Move analyzers to single cabinet and relocate
Upgrade lighting and install suspended ceiling in Operator room
Add new Operator room furniture

Upgrade continued…
Workstations and Servers – Rack Mount
Four DELL Workstations (Operator Stations)
One DELL Server (Application Station)
Three Redundant CIOCs
181 CHARMS
AI, AO, DI, DO, RTD, Thermocouple
Two sets of Redundant S-Series Controllers
41 S-Series Cards
AI, AO, DI, DO, Serial, FF

CO2 Skid
Five Rosemount 3095 Flowmeters
Two Rosemount 3051 Level Transmitters
One Micromotion Coriolis Flowmeter
Two Micromotion Viscometer
Six Fisher DVC Valves
One Rugged PC configured as a ProPlus (for local interface & commissioning).

Schedule
The work at-site started in late April and completed in mid-July
The physical plant was down for 3 weeks
Operators worked out of temporary control room for the duration

Previous System – Classic IO, FF, HART

JB11 Marshalling Cabinet

Analyzers & Computers

Cabinet 1 (before)
Redundant MD Controllers
Mix of IO Cards
AI, AO, DI, DO
Thermocouples, RTDs
Serial
FF
WirelessHART
Fisher valves, Rosemount pressure, flow, and level instruments
Micromotion flow meters
Rosemount Analytics pH
Analyzers

Cabinet 1 (after)
Redundant S-Series Controllers
S-Series IO Cards
AI, AO, DI, DO 24 VDC, DO 120/230VAC, Fieldbus, Serial
Redundant UPS Systems
Redundant 24 VDC Power
Assembled enclosures off-site and dropped into site during switchover

Upgraded System

System Preferences Ref: Ed Center S-series Electronic Marshalling Configuration

Connecting a CIOC
When you first connect a decommissioned CIOC to the Control Network it will automatically appear in the Decommissioned Nodes category.
Ref: Ed Center

Identifying a CIOC
If multiple CIOCs are connected at the same time an Identify feature allows you to flash the LEDs on the CIOC to match the name to a specific CIOC.
Ref: Ed Center

Commission The CIOC
The CIOC can be commissioned by dragging and dropping it on the I/O Network.
Drag ‘n Drop Ref: Ed Center

Commission The CIOC
The commissioned CIOC appears with the auto-sensed CHARMS.
Ref: Ed Center

CIOC Downloads
The illustration below shows CIOC commissioned and not assigned to any controller.
Ref: Ed Center

Auto-sense CHARMS
Electronic Marshalling allows you to change I/O types easily without re-wiring.
Ref: Ed Center

UT – Expanded IO Network
Controller shown with assigned IO from JB’s and WirelessHART Gateways
IO Network shown with autosensed CICO’s

JB1 Expanded

CHARM Properties
Individual CHARMs can be enabled/disabled
Each CIOC can be assigned to up to four controllers
Each AI CHARM can be configured with or without HART
Filtering can be enabled on each analog input

Example Process Noise (related to VSD’s)
NOTE: For additional information refer to Workshop: 118 - Guidelines for
Setting Filtering and Module Execution Rates

Enabling Filtering

Diagnostics
Status of CIOC (in this case named by JB)
Can also view diagnostics of individual CHARMS

AMS – CHARMS

AMS - Fieldbus

WIOC Ethernet To DeltaV (redundant) WIOCs (redundant) 24V DC (redundant) RS485 and power to 781

Control Room (traffic patterns)

Control Room (design)

Control (artist drawing)

Control Room

Moved back in…

Things learned along the way
Have knowledgeable person on-site at all times
Tags must be carefully tracked
Keep a virtual machine handy with previous system configuration on it
It is very easy to move DST assignments between controllers – utilize the split window view on Explorer and drag/drop DSTs between destinations
Use controller upgrade utility to double check version information
Use autosense to double check CHARM types
Use diagnostics to look for wiring & calibration issues
Use AMS to quickly check FF and HART devices

Business Results Achieved
Flexibility. With CHARMS IO UT can easily add and remove devices in the field and move configuration between controllers without being limited by where wires are terminated.
Supporting multiple projects. It will be much easier to run parallel tests. The improved control room layout makes it much easier for operators to run their portion of the tests.
More data. Upgraded servers makes it easier to hold on to more data.

Summary
CHARMS IO provides UT with considerable project flexibility. The new control room layout and upgraded servers provides UT with much a better environment to run concurrent projects, collect data, and provide reports for their customers.
We appreciate you taking the time to attend our session. We would like feedback on the presentation or your own experiences.
Questions?

Where To Get More Information
Emerson Exchange 2010
Workshop: 168 - DeltaV Development Systems in a Virtualized Environment
Exhibit: Virtual CHARMS IO Simulation Demonstration - Advanced Control Booth
Workshop: 118 - Guidelines for Setting Filtering and Module Execution Rate
Ed Svrcs: 13-555 - DeltaV S-series Electronic Marshalling
DeltaV Literature
Product Data Sheet: DeltaV Virtual CHARMS IO Simulation
Books On Line v11
Visit www.emersonprocess.com/smartwireless

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CHARMED Upgrading the UT Pickle Separations to DeltaV v11

by Emerson Exchange on Oct 14, 2010

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CHARMED Upgrading the UT Pickle Separations to DeltaV v11 — Webinar Transcript