CHARMED Upgrading the UT Pickle Separations to DeltaV v11


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This presentation was given at Emerson Exchange 2010 and shows how the control system at the UT Pickle Separations unit was upgraded to DeltaV v11. Before and after pictures are included that show the new controllers, IO, and major changes made in the control room.

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  • The first step to configuring CHARM I/O is to Enable the I/O Network on the system preferences. This will you to configure the I/O Network on the DeltaV Explorer. This is accomplished as indicated in step 1. by selecting System Preferences under the DeltaV Engineering category of programs and checking the Enable I/O Network. As noted in the dialog you must restart the DeltaV database server for this added preference to be recognized. Restarting the DeltaV database server can be accomplished by first shutting it down as indicated in step 2. by using the Database administration tool and selecting Shutdown Server from the File menu. Once the Server is shutdown. Launch the DeltaV Explorer and it will automatically restart the database server. At this point you will be able to configure CHARM I/O from the DeltaV Explorer.
  • Upon connecting a decommissioned CIOC to the Control Network it will announce itself and show up in the Decommissioned Nodes category as shown in this screen capture. Here a CIOC shows up with the default name CIOC-00128E. The default name is prefixed CIOC and to make it a unique name and allow for multiple decommissioned CIOCs a numerical suffix is applied which comes from it’s MAC address.
  • 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 the physical CIOC. All LEDs will flash alternately on the two CIOCs during the identify state. This is the same as you have done with DeltaV controllers from day 1 with DeltaV.
  • The CIOC can be commissioned by dragging and dropping it on the IO Network. This will create a new CIOC as opposed to dropping it on the placeholder named CIOC which is already configured and assigned to the controller named CTLR. The placeholder allows you to configure a CIOC without having the physical hardware available and then when the hardware arrives the decommissioned CIOC would be assigned to the placeholder. In this example we are creating a new CIOC, the properties box dialog appears immediately after dropping the CIOC on the IO Network allowing you to define the new CIOCs name. Several other properties are defined here as well, including whether you want hardware alarms generated for this CIOC, Network redundancy etc.. Again similar to a controller. Unique to the CIOC is the Enable Cascade Port. This option must be checked to turn on the bottom cascade port for daisy chaining one CIOC to another. Upon completing this dialog click OK and the act of commissioning will assign a valid DeltaV Network address to the CIOC as well autosense the CHARM types attached.
  • Here you see the newly commissioned CIOC with the autosensed CHARM types in the right hand window. A couple points of interest for this CIOC. First, CHARMS are assigned with default DSTs, the default naming convention includes the CIOC Name followed by CHM for charm, and the carrier – charm number. So the first default DST is 1-01 for carrier 1 CHARM 1 through 2-12 for carrier 2 charm 12. When configuring each CHARM you will assign the appropriate device tag or DST. Also notice the new CIOC, named CIOC – double zero one twenty-eight E is not assigned to any controller yet, as the placeholder above it has the CHARMS assigned to the controller named CTLR as denoted by the parenthesis. Additionally, the yellow triangle indicates this node has no configuration and requires a download.
  • This illustration shows the CIOC commissioned and not assigned to any controller, if it were assigned following, the CIOC name in parenthesis it would have the assigned controller name. The point here is that the CIOC and it’s CHARMS can be commissioned, auto sensed and configured independent of controllers. Additionally, the CIOC and CHARMS can be downloaded independent of the controller to allow a baseline check of the configuration and wiring, in which a green LED will illuminate on the individual CHARMS for a good indication of the CHARM and it’s associated wiring to the field device.
  • One of the key features of Electronic Marshalling is the ability to change CHARM types easily. Consider this example CHM1-2 is an Analog Input while CHM1-6 is an Analog Output. We have just been informed that the CHARMS need to be reversed to match the field instruments. No re-wiring is required we just need to swap the physical CHARMS between positions 2 and 6, then Auto-sense the CHARMS in their new location. The next slides take you through the steps of swapping locations.
  • CHARMED Upgrading the UT Pickle Separations to DeltaV v11

    1. 1. CHARMED Upgrading UT Pickle Separations to DeltaV v11 with integrated CHARMS Dr. Frank Seibert – University of Texas Mark Nixon – Emerson Research Manager
    2. 2. Presenters <ul><li>Frank Seibert, University of Texas at Austin </li></ul><ul><li>Mark Nixon </li></ul><ul><ul><li>Research Manager </li></ul></ul><ul><ul><li>Austin, Texas </li></ul></ul>
    3. 3. Abstract <ul><li>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. </li></ul>
    4. 4. Separations Research Program, University of Texas at Austin <ul><li>The Separations Research Program was established at the J.J. Pickle Research Campus in 1984 </li></ul><ul><li>This cooperative industry/university program performs fundamental research of interest to chemical, biotechnological, petroleum refining, gas processing, pharmaceutical, and food companies. </li></ul><ul><li>CO2 removal from stack gas is a current focus project </li></ul>
    5. 5. Undergraduate Students
    6. 6. Research Areas <ul><li>Distillation </li></ul><ul><li>CO2 Absorption/Stripping </li></ul><ul><li>Liquid-Liquid Extraction </li></ul><ul><li>Oil Extraction from Algae </li></ul><ul><li>Verification of Separation Processes </li></ul><ul><li>Scale-up/Trouble-Shooting </li></ul>
    7. 7. 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
    8. 8. Algae Oil Extraction <ul><li>Recovery of submicron oil drops from slurry </li></ul><ul><li>Solvent selection </li></ul><ul><li>Extraction process – two options </li></ul><ul><li>Feed: flocculated or de-flocculated? </li></ul><ul><li>Preliminary material/energy balances and economics </li></ul>Open Algae and UT Proprietary
    9. 9. CO2 Capture Process
    10. 10. SRP CO2 Capture Pilot Plant <ul><li>Gas Capacity, m 3 /min = 25 </li></ul><ul><li>Solvent Capacity, liter/min = 130 </li></ul><ul><li>Inlet CO2 Composition, mol% =1-20 </li></ul><ul><li>Capabilities: </li></ul><ul><li>- Solvent Screening </li></ul><ul><li>- Packing Performance </li></ul><ul><li>- Effect of Absorber Inter-cooling </li></ul><ul><li>- Solvent Regeneration Variations </li></ul><ul><li>- Evaluate Process Dynamics </li></ul><ul><li>- Evaluate Heat Exchangers </li></ul><ul><li>- Model Validation </li></ul>
    11. 11. Absorption Column <ul><li>Column Diameter, cm = 42.8 </li></ul><ul><li>Packed Height, cm = 600 </li></ul><ul><li>Pressure, bar = 1 </li></ul><ul><li>Windows for Observation </li></ul><ul><li>Inter-cooling Capability </li></ul><ul><li>Extensive Temperature Measurements </li></ul>
    12. 12. Stripping Column <ul><li>Column Diameter, cm = 42.8 </li></ul><ul><li>Packed Height, cm = 600 </li></ul><ul><li>Pressure, bar = 0.2-4 </li></ul><ul><li>Provides for Flashing Feed </li></ul><ul><li>Windows for Observation </li></ul><ul><li>Kettle Reboiler </li></ul><ul><li>Shell and Tube Condenser </li></ul><ul><li>Plate and Frame Cross Exchanger </li></ul><ul><li>11 bar Saturated Steam </li></ul><ul><li>10 C Chilled Water </li></ul>
    13. 13. Skid Fabrication – Initial Stage
    14. 14. High Temperature Two-Stage Flash Skid
    15. 15. High Pressure Flash Stripping System
    16. 16. Absorber Intercooling Operation
    17. 17. Scope of the upgrade Project <ul><li>Upgrade to DeltaV v11 and AMS </li></ul><ul><ul><li>Replace M series with S series controllers & IO </li></ul></ul><ul><ul><li>Two standard DeltaV JB’s w/ RCIOC’s & CHARMS </li></ul></ul><ul><ul><li>Retrofit one of existing JB’s with RCIOC’s & CHARMS </li></ul></ul><ul><ul><li>Upgraded Fieldbus </li></ul></ul><ul><ul><li>Added WIOC </li></ul></ul><ul><ul><li>Upgrade PROplus, Application Station & Workstations to Windows 7 </li></ul></ul><ul><ul><li>Update Displays </li></ul></ul><ul><ul><li>Added new Switches </li></ul></ul><ul><li>Upgrade Control Room </li></ul><ul><ul><li>Remove existing overhead utility piping and abandoned conduit </li></ul></ul><ul><ul><li>Add new wall to separate operators from equipment room </li></ul></ul><ul><ul><li>Move analyzers to single cabinet and relocate </li></ul></ul><ul><ul><li>Upgrade lighting and install suspended ceiling in Operator room </li></ul></ul><ul><ul><li>Add new Operator room furniture </li></ul></ul>
    18. 18. Upgrade continued… <ul><li>Workstations and Servers – Rack Mount </li></ul><ul><ul><li>Four DELL Workstations (Operator Stations) </li></ul></ul><ul><ul><li>One DELL Server (Application Station) </li></ul></ul><ul><li>Three Redundant CIOCs </li></ul><ul><li>181 CHARMS </li></ul><ul><ul><li>AI, AO, DI, DO, RTD, Thermocouple </li></ul></ul><ul><li>Two sets of Redundant S-Series Controllers </li></ul><ul><li>41 S-Series Cards </li></ul><ul><ul><li>AI, AO, DI, DO, Serial, FF </li></ul></ul>
    19. 19. CO2 Skid <ul><li>Five Rosemount 3095 Flowmeters </li></ul><ul><li>Two Rosemount 3051 Level Transmitters </li></ul><ul><li>One Micromotion Coriolis Flowmeter </li></ul><ul><li>Two Micromotion Viscometer </li></ul><ul><li>Six Fisher DVC Valves </li></ul><ul><li>One Rugged PC configured as a ProPlus (for local interface & commissioning). </li></ul>
    20. 20. Schedule <ul><li>The work at-site started in late April and completed in mid-July </li></ul><ul><li>The physical plant was down for 3 weeks </li></ul><ul><li>Operators worked out of temporary control room for the duration </li></ul>
    21. 21. Previous System – Classic IO, FF, HART
    22. 22. JB11 Marshalling Cabinet
    23. 23. JB1 Marshalling Cabinet
    24. 24. JB2 Marshalling Cabinet
    25. 25. Analyzers & Computers
    26. 26. Cabinet 1 (before) <ul><li>Redundant MD Controllers </li></ul><ul><li>Mix of IO Cards </li></ul><ul><ul><li>AI, AO, DI, DO </li></ul></ul><ul><ul><li>Thermocouples, RTDs </li></ul></ul><ul><ul><li>Serial </li></ul></ul><ul><ul><li>FF </li></ul></ul><ul><li>WirelessHART </li></ul><ul><li>Fisher valves, Rosemount pressure, flow, and level instruments </li></ul><ul><li>Micromotion flow meters </li></ul><ul><li>Rosemount Analytics pH </li></ul><ul><li>Analyzers </li></ul>
    27. 27. Cabinet 1 (after) <ul><li>Redundant S-Series Controllers </li></ul><ul><li>S-Series IO Cards </li></ul><ul><ul><li>AI, AO, DI, DO 24 VDC, DO 120/230VAC, Fieldbus, Serial </li></ul></ul><ul><li>Redundant UPS Systems </li></ul><ul><li>Redundant 24 VDC Power </li></ul><ul><li>Assembled enclosures off-site and dropped into site during switchover </li></ul>
    28. 28. Upgraded System
    29. 29. System Preferences Ref: Ed Center S-series Electronic Marshalling Configuration
    30. 30. Connecting a CIOC <ul><li>When you first connect a decommissioned CIOC to the Control Network it will automatically appear in the Decommissioned Nodes category. </li></ul>Ref: Ed Center
    31. 31. Identifying a CIOC <ul><li>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. </li></ul>Ref: Ed Center
    32. 32. Commission The CIOC <ul><li>The CIOC can be commissioned by dragging and dropping it on the I/O Network. </li></ul>Drag ‘n Drop Ref: Ed Center
    33. 33. Commission The CIOC <ul><li>The commissioned CIOC appears with the auto-sensed CHARMS. </li></ul>Ref: Ed Center
    34. 34. CIOC Downloads <ul><li>The illustration below shows CIOC commissioned and not assigned to any controller. </li></ul>Ref: Ed Center
    35. 35. Auto-sense CHARMS <ul><li>Electronic Marshalling allows you to change I/O types easily without re-wiring. </li></ul>Ref: Ed Center
    36. 36. UT – Expanded IO Network <ul><li>Controller shown with assigned IO from JB’s and WirelessHART Gateways </li></ul><ul><li>IO Network shown with autosensed CICO’s </li></ul>
    37. 37. JB1 Expanded
    38. 38. CHARM Properties <ul><li>Individual CHARMs can be enabled/disabled </li></ul><ul><li>Each CIOC can be assigned to up to four controllers </li></ul><ul><li>Each AI CHARM can be configured with or without HART </li></ul><ul><li>Filtering can be enabled on each analog input </li></ul>
    39. 39. Example Process Noise (related to VSD’s) <ul><ul><li>NOTE: For additional information refer to Workshop: 118 - Guidelines for </li></ul></ul><ul><ul><li>Setting Filtering and Module Execution Rates </li></ul></ul>
    40. 40. Enabling Filtering
    41. 41. Diagnostics <ul><li>Status of CIOC (in this case named by JB) </li></ul><ul><li>Can also view diagnostics of individual CHARMS </li></ul>
    42. 42. AMS – CHARMS
    43. 43. AMS - Fieldbus
    44. 44. WIOC Ethernet To DeltaV (redundant) WIOCs (redundant) 24V DC (redundant) RS485 and power to 781
    45. 45. Control Room (traffic patterns)
    46. 46. Control Room (design)
    47. 47. Control (artist drawing)
    48. 48. Control Room
    49. 49. Control Room
    50. 50. Moved back in…
    51. 51. Things learned along the way <ul><li>Have knowledgeable person on-site at all times </li></ul><ul><li>Tags must be carefully tracked </li></ul><ul><li>Keep a virtual machine handy with previous system configuration on it </li></ul><ul><li>It is very easy to move DST assignments between controllers – utilize the split window view on Explorer and drag/drop DSTs between destinations </li></ul><ul><li>Use controller upgrade utility to double check version information </li></ul><ul><li>Use autosense to double check CHARM types </li></ul><ul><li>Use diagnostics to look for wiring & calibration issues </li></ul><ul><li>Use AMS to quickly check FF and HART devices </li></ul>
    52. 52. Business Results Achieved <ul><li>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. </li></ul><ul><li>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. </li></ul><ul><li>More data. Upgraded servers makes it easier to hold on to more data. </li></ul>
    53. 53. Summary <ul><li>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. </li></ul><ul><li>We appreciate you taking the time to attend our session. We would like feedback on the presentation or your own experiences. </li></ul><ul><li>Questions? </li></ul>
    54. 54. Where To Get More Information <ul><li>Emerson Exchange 2010 </li></ul><ul><ul><li>Workshop: 168 - DeltaV Development Systems in a Virtualized Environment </li></ul></ul><ul><ul><li>Exhibit: Virtual CHARMS IO Simulation Demonstration - Advanced Control Booth </li></ul></ul><ul><ul><li>Workshop: 118 - Guidelines for Setting Filtering and Module Execution Rate </li></ul></ul><ul><ul><li>Ed Svrcs: 13-555 - DeltaV S-series Electronic Marshalling </li></ul></ul><ul><li>DeltaV Literature </li></ul><ul><ul><li>Product Data Sheet: DeltaV Virtual CHARMS IO Simulation </li></ul></ul><ul><ul><li>Books On Line v11 </li></ul></ul><ul><ul><li>Visit </li></ul></ul>