1 Ling Rong - Keynote Presentation English

711 views
603 views

Published on

At the 2013 Fieldbus Foundation General Assembly in Shanghai, China on March 14, 2013, Mr. Lin Rong from Sinopec delivered a Keynote presentation to the crowd of roughly 250 people. This is the English version of his presentation.

0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total views
711
On SlideShare
0
From Embeds
0
Number of Embeds
2
Actions
Shares
0
Downloads
11
Comments
0
Likes
0
Embeds 0
No embeds

No notes for slide

1 Ling Rong - Keynote Presentation English

  1. 1. Foundation fieldbus technology application and progress in China petrochemical industry Rong Lin Shanghai, 2013/03/14 September 20121 1 © 1994 – 2012 Fieldbus Foundation
  2. 2. 1. Introduction 2. PetroChem Industry Trends and Challenges 3. Ff fieldbus technical and economic analysis 4. Ff fieldbus technology trends 5. The Ff fieldbus Example 6. Conclusion September 20122 © 1994 – 2012 Fieldbus Foundation
  3. 3. 1. Introduction In the beautiful season of Spring returning to the good earth and all things recovering, the world-remarkable Fieldbus Foundation Global Member and User Conference has come to China again. The foundation fieldbus is recognized quickly in the world every year and its application has coveredsuch industries as oil, gas, petrochemical, electric power, paper making, pharmacy and so on. The installation ofthe foundation fieldbus technology has reached the record-making level; globally, there are totally hundreds ofthousands of systems and millions of devices in service at present. Therefore, we may say that the foundationtechnology has changed the future of industry automation, including the design mode of control systems. Thesufficiently rich information makes preventive maintenance possible. The theme of this forum “In a World of Choices, FOUNDATION™ Brings it all Together” is consistent with thedevelopment direction of “large, integrated, park-based, intelligent and clean” currently implemented by ourChinese petrochemical enterprises. In particular, it’s of significantly practical value in the strategic deploymentof “establishing digitalized factories” implemented by Sinopec. The gradual promotion and application of Fftechnology in China has greatly improved the intelligentization level of the production of petrochemical. We hope, by virtue of this “Conference”, the technical exchange and communication among theproduction users, engineering companies, scientific research institutes and manufacturers from the processautomation field in Ff technology development and application can be greatly promoted. Therefore, I would liketo, on behalf of SEI Instrument Team, show our sincere acknowledgement to such end users, engineeringcompanies, scientific research institutes, manufactures as CSPC, SECCO, FREP, Yantai Wanhua and so on thatwe cooperated and are cooperating with and that greatly promote Ff technology’s development in China, and theexperts and friends from FFCMC, CFFC, etc.! September 2012 3 © 1994 – 2012 Fieldbus Foundation
  4. 4. 2. PetroChem Industry Trends and Challenges World Economy - the center of gravity from West to East September 20124 4 © 1994 – 2012 Fieldbus Foundation
  5. 5. 2. PetroChem Industry Trends and ChallengesChinas sustained economic growth has contributed to the progress of thepetrochemical industry The Daily Telegraph of UK reported on November 5, 2012: “China will become the largest economy inthe world by 2025”. This newspaper quoted a research report of Frost & Sullivan, a US authoritative marketresearch company. This report pointed out: “By 2025, China will become the largest economy of the world withthe nominal GDP up to USD 38 trillion”. Soon later, HSBC also issued a similar report. Petrochemical industry, as foundation energy and raw material industry, has become an important pillarindustry in the development of national economy and plays an irreplaceable role in GDP contribution andimprovement of people’s life. In terms of oil refining, according to the latest forecast, the demand growth rate ofpetroleum products in China in the 12th Five-year Plan period will be about 4.4%. According to thePetrochemical Industry Development Program in the 12th Five-year Plan Period set out by the National Reformand Development Commission, by 2015, the demand of crude oil in China will be 600MT/a and that of steam,coal and diesel 360MT/a. During the 12th Five-year Plan, the oil refining capacity of China will increase by atleast 100MT and reach 670MT/a. Attention will be paid to the construction of more than ten 10MT level oilrefineries in Sichuan, Beihai, Quanzhou, Zhanjiang, Huizhou, Jieyang, Hainan, Zhenhai, Taizhou, Lianyungang,etc.; by 2015, the predicted production capacity of ethylene will reach 27MT and the demand will reach 34~38MT,with the gap of about 7-11MT. The demand growth rate of ethylene in China is about 5.1% and the attention willbe paid to the construction of nine MT level ethylene plants in Sichuan, Wuhan, Zhanjiang, Huizhou, Hainan,Zhenhai, Taizhou, Lianyungang, Qingdao, etc.. September 20125 © 1994 – 2012 Fieldbus Foundation
  6. 6. 2. PetroChem Industry Trends and ChallengesThe momentum of petrochem industry - China is the worlds largestpetrochemical market.By 2015, the market demand will take up about 1/3 of the world’s demand and 1/2 of Asian demand. China is the main driver of the global petrochemical industry. Asia, MT World, MT September 2012 6 © 1994 – 2012 Fieldbus Foundation
  7. 7. 2. PetroChem Industry Trends and Challenges Sustained growth of the petrochemical industry in refining capacity The Oil RefiningChina: The oil refining capacity continuously increase, but the growth Industry Developmentspeed is lower than that of ethylene production capacity. Program in the 12th Five-year Plan Period issued by the Ministry of Industry and Information Technology requires that: The crude oil refining capacity of China by 2015 should reach about 600MT/a; the demand of refined petroleum products in the incoming 5 years should increase by 4.4% every year on average and the fuel demand by 2015 should be estimated to increase from 245MT in 2010 to 360MT. September 2012 7 © 1994 – 2012 Fieldbus Foundation
  8. 8. 2. PetroChem Industry Trends and Challenges Sustained growth of the petrochemical industry in The Alkene Industry rapid growth of Ethylene production Development Program in the 12th Five-year Plan Period issued by the Ministry of Industry and Information TechnologyEthylene production capacity: will grow quickly in the requires that: During the 12th Five-yearcoming years. Plan period, the alkene industry of China should insist on the diversity of raw materials and the target is as follows: by 2015, the production capacity of ethylene in China should reach 27MT/a and that of propylene 24MT/a. It is predicted that the ethylene demand in China by 2015 will increase by 5.1% every year, up to 38MT/a. September 2012 8 © 1994 – 2012 Fieldbus Foundation
  9. 9. 2. PetroChem Industry Trends and Challenges Petrochemical industry development trend: the production capacities of oil refining and ethylene grow synchronously.For example, in Guangdong, from 2008, Sinopec prepared to cooperate with Kuwait in joint venture form to construct an integrated project of 15MT oil refining and 1MT ethylene capacity (Zhanjiang, Guangdong); PetroChina prepared to cooperate with Venezuela in joint venture form to construct a 20MT oil refining project (Jieyang, Guangdong); CNOOC prepared to continue the construction of the project of 12MT oil refining and 1MT ethylene (Huizhou, Guangdong), and such projects have been initiated by now. 图1-1 中国大型炼油项目分布图 Figure 2-1 Distribution Map of China‟s Figure 2-2 Distribution Map of China‟s Large Oil Refining Projects Large Ethylene Projects Fushun Fushun Fushun Fushun Fushun Dushanzi Dushanzi Dushanzi DushanziDushanzi DUSHANZI Dushanzi FUSHUN DUSHANZI Tianjin Tianjin FUSHUN Tianjin Tianjin Tianjin Tianjin TIANJIN QINGDAO LIANYUNGANG QINGDAO LIANYUNGANG Qingdao Qingdao Qingdao Qingdao ZHENHAI WUHAN Wuhan BYC TAIZHOU Secco SICHUAN Fujian Fujian Fujian Fujian SICHUAN Qinzhou Qinzhou Qinzhou Qinzhou Huizhou Huizhou Fujian Huizhou Zhenhai ZHENHAI Qinzhou Huizhou QUANZHO TAIZHOU U Fujian BEIHAI HUIZHOU Maoming HUIZHOU FUJIAN Hainan Hainan Hainan Hainan MAOMING JIEYANG Hainan ZHANJIANG HAINAN ZHANJIANG HAINAN September 20129 © 1994 – 2012 Fieldbus Foundation
  10. 10. 2. PetroChem Industry Trends and Challenges Post-oil era is approaching Marion King Hubbert, a famous US geologist, predicted in 1956, the turnout of the world petroleum would reach the peak in certain time in the future, followed by petroleum turnout decrease and supply shortage, namely, the beginning of the post-petroleum era. We may also think the day where the turnout of the world petroleum reaches the peak is the day where the post-petroleum era begins (e.g. after 2020 indicated in Figure 2-3). 产量 turnout 需求 demand Oil Supply 石油供应量 1900 1940 1980 2020 2060 2100 时间/ 年 Figure 2-3 Schematic Diagram of World Petroleum Turnout September 201210 © 1994 – 2012 Fieldbus Foundation and Demand Trends
  11. 11. 2. PetroChem Industry Trends and Challenges Post-oil era is approaching The energy consumption structure comparison between China and the world is as shown in Figure 2-4 and Figure 2-5: 能源比例 能源比例 煤 Coal 煤 Coal 7.8% 0.3% 1.0% 3.9% 石油 Oil 9.0% 28% 石油 Oil 18% 24.0% 天然气 Gas 天然气 Gas 70% 水电、核电、风电 Hydropower, 38% Hydropower, 水电、核电、风电 nuclear power, nuclear power, wind power wind power 其它(太阳能、潮 Other (Solar 其它(太阳能、潮 Other (Solar 汐能等) tidal energy, 汐能等) tidal energy, energy, etc.) energy, etc.) Figure 2-4 China Energy Figure 2-5 World Average Consumption Structure Energy Consumption11 Structure September 2012 © 1994 – 2012 Fieldbus Foundation
  12. 12. 2. PetroChem Industry Trends and Challenges Two hot spots of the petrochem industry One of hot spots: Coal to oil, coal chemical, Coal to gas and shale gas exploration are flourishing, Coal to oil, coal chemical, natural gas chemical and biomass chemical develop rapidly: Power Heating Generation Natural Gas Industrial and domestic fuel Oil GTL Gasoline Diesel Transportation fuel Aviation Vessel kerosene oil Coal Biomass CTL Petrochemical raw material BTL Ethylene Propylene Aromatics Other organic chemicals September 201212 © 1994 – 2012 Fieldbus Foundation Figure 2-6 Diagram of Carbon-contained Energy Comprehensive Utilization
  13. 13. 2. PetroChem Industry Trends and Challenges One of hot spots: Coal to oil, coal chemical, Coal to gas and shale gas exploration are flourishing BDO PTMEG, TH F Coalbed Natural Coke Calcium Acetylene carbide gas/Shale gas gas PVC Coalbed gas, commonly called as gas, is Coke oven Coal tar Crude Triphenyl a kind of new clean energy. The new gas benzol /PX round of national coalbed gas resource evaluation result indicates that the depth Olefin of embedment of the 42 major gas- Methane MTO/MTP contained basins of China is 2,000m and the shallow coalbed geological resources Dimethyl are 36.8 trillion m3; therefore, China is the Methanol ether third largest coalbed gas reserve country Acetic following Russia and Canada. In the Glycol DMF acid Coalbed Gas Development and UtilizationCoal in the 12th Five-year Plan, the National Energy Administration of China points out Ammonia Urea that, by the end of the 12th Five-year Plan, the turnout of coalbed gas in China Gasification will reach 20-24 billion m3. syngas Carbon Nitrate Ammoniu monoxide m nitrate The result in the National Shale Gas Resource Potential Survey, Evaluation Hydrogen DMC/DPC Polycarbo and Favorable Zone Selection issued nate recently by Ministry of Land and PC Resources of the People‟s Republic of Indirect China shows that, the shale gas liquefactio n geological resource potential of China is 134 trillion m3 and the recoverable Naphtha Olefin resource potential is 25 trillion m3. In Direct addition, the greenhouse effect of coalbed liquefaction Gasoline gas emission is 21 times as much as that oil and diesel of CO2 emission! September 2012 13 Figure 2-7 Coal to oil and Coal Chemical Comprehensive Utilization Diagram © 1994 – 2012 Fieldbus Foundation
  14. 14. 2. PetroChem Industry Trends and Challenges The second of hot spots:The rapid develop of fine chemicals Tier 1-Inner Oil, Natural gas, Coal Tier 2 9 basic chemical raw materials: ethylene, propylene, butene, butadiene, methane, butane, benzene, toluene and xylene Tier 3 More than 90 derivatives Hundreds of synthesized resin, synthesized rubber, Tier 4-Outer synthesized fiber and other chemical raw materials and products. Figure 2-8 Petrochemical Product Chain Hierarchical Graph The seven major strategic emerging industries China mainly supports (i.e. energy saving and environmental protection, new generation information technology, biology, high-end equipment manufacture, new energy, new material and new energy automobile) all are closely related to fine chemical industry. According to the report of the website of www. chem.hc360.com, it is predicted that by 2015, the output value of the fine chemical industry of China will reach RMB 1.6 trillion, double of that in 2008; the self-sufficiency rate of fine chemicals of China will reach above 80%; therefore, China will enter September 201214 © 1994 – 2012 Fieldbus Foundation the world fine chemical major countries and powers.
  15. 15. 2. PetroChem Industry Trends and Challenges Challenges-Focus on Resource & Environment 1. Short crude oil resources and relying on imported crude oil for processing; 2. Inferior crude oil resources and difficult crude oil processing; 3. More and more remarkable supply and demand contradiction of oil refining and petrochemical raw materials; 4. Fluctuating crude oil price, higher production cost and higher operation risk; 5. Stricter safety, energy saving, emission reduction, environmental protection specifications and indices requirements; 6. The world-famous petrochemical companies establish plants in China, so the market competition is furious; 7. The rapid development of the petrochemical industry in Middle East has brought more and more furious competition; 8. The Coal to oil and coal chemical projects also face up the following special challenges: 1) Large water consumption and severe water shortage in the coal rich areas; 2) Large 3-wastes (waste water, waster gas and industrial residue) and severe environmental protection situation; 3) High project investment and key equipment needing to be imported; 4) Immature production technology and very high energy consumption; 5) High equipment maintenance cost; 6) Shortage of Coal to oil and coal chemical technicians; 7) Concentrated project distribution points and thus large market impact. September 201215 © 1994 – 2012 Fieldbus Foundation
  16. 16. Why FF? 3. Ff fieldbus technical and economic analysis Characteristics of Ff Fieldbus Technology The fieldbus control system (FCS) is the new generation control system after the distributed control system (DCS) and one important branch in the program control field; however, it will not substitute DCS completely. FCS has the following remarkable characteristics:• FCS is of openness, interoperability and inter-usability;• FCS has site equipment intelligence and functional autonomy;• FCS has high functional decentralization (CIF);• FCS has high accuracy and high reliability;• FCS may save installation materials, reduce debugging load and shorten construction period;• FCS has advanced diagnosis and predictive maintenance (AMS) function and thus may save maintenance cost and reduce the cost for the life cycle of the system. September 2012 16 © 1994 – 2012 Fieldbus Foundation
  17. 17. Why FF? 3. Ff fieldbus technical and economic analysis Advancement and Necessity of Ff TechnologyThe fieldbus technology has changed instrument maintenance strategy, greatly decreasing non-planned downtime! Traditional Brand new • Dedicated to developing one team consisting of operation, process and maintenance personnel and with cross function; maintenance maintenance • Eliminate fault sources; strategy strategy World-class 65% maintenances are corrective maintenances, i.e. maintenances after failures. The key is to take actions before faults rather than 30% maintenances are preventive after faults! maintenances, i.e. regular maintenances as planned. 5% maintenances are predictive Maintenance management trend maintenances, i.e. the maintenances conducted according to equipment situation. Corrective Preventive Predictive September 2012 17 © 1994 – 2012 Fieldbus Foundation
  18. 18. Why FF? 3. Ff fieldbus technical and economic analysis Advancement and Necessity of Ff TechnologyThe fieldbus technology has changed instrument maintenance strategy, greatly decreasing non-planned downtime! The key is to take actions where necessary, no need doing too much! 63% instrument preventive maintenances are excessive, i.e. waste resources. September 2012 18 © 1994 – 2012 Fieldbus Foundation
  19. 19. Why FF? 3. Ff fieldbus technical and economic analysis Advancement and Necessity of Ff Technology Comparing with the traditional DCS, FCS has the following remarkable characteristics: Characteristics DCS FCS RMKS Transmission signal Analog signal or analog Fully digital signal and digital mixed signal Communication Unidirectional Bidirectional direction Connection mode Point-to-point Multi-node Routine control Inside DCS controller- In site equipment- Concentrated Distributed Fault diagnosis Basic Advanced (with fault forecast) Measurement accuracy Average (≤0.2% FS) High (≤0.1% FS) Measurement Few Many (more convenient parameters for factory informationization) System capacity Configuration to be Plug & play, system * DD document expansion revised and offline automatic identification needed. installation Interoperability Average Very good Hardware quantity 100% 30%~50% According to ARC report. Cabling 100% 30%~50% According to ARC report. Installation cost 100% Approx. 91% (9% According to ARC saved!) report. Maintenance cost 100% Approx. 80% (20% According to ARC saved!) report. *Note: ARC is an authoritative consulting company in the international automation field. September 201219 © 1994 – 2012 Fieldbus Foundation
  20. 20. Why FF? 3. Ff fieldbus technical and economic analysis Investment Comparison between Ff Technology and Traditional DCS TechnologyInvestment Step Decomposition Schematic Diagram Investment1 DCS LAN DCSControl Station H1Bus interface cards Investment 3 Investment 4 H1 FF Fieldbus Field wiring box Power supply unit Terminator Terminator Investment 2 Non-Ex- FF structure i FF Bus instrumentation and adjust valveFigure 3-1 Investment Decomposition Diagram of Ff Technology and 20 September 2012 © 1994 – 2012 Fieldbus Foundation Traditional DCS Technology
  21. 21. Why FF? 3. Ff fieldbus technical and economic analysis Investment Comparison between Ff Technology and Traditional DCS Technology Fujian Refining and Ethylene Projects In respect of FREP project, at the bid invitation stage of the main instrument control contractor (MICC) and in the process control system (PCS) inquiry, it‟s required the three bidders should have the quotation for the Ff technology (Proposal 1) and the traditional DCS technology (Proposal 2); and it is required that the utilization ratio of the FF segment should be 6 field devices on average and adopt the domestically manufactured FF cables. When cable investment is not considered, from Table 3-1, the quotations of the three bidders for Ff technology (Proposal 1) all are higher than those for the DCS technology (Proposal 2); when cable investment is considered (as per domestically manufactured FF cable price), from Table 3-2, the quotations of the three bidders for Ff technology (Proposal 1) all are a little lower than those for the DCS technology (Proposal 2). From the above investment comparisons, we may draw the following conclusion: When the utilization ratio of the Ff segment is 6 field devices on average and adopts the domestically manufactured Ff cables, Ff technology investment September 201221 (Proposal 1) is a little lower than the DCS technology investment (Proposal 2). © 1994 – 2012 Fieldbus Foundation
  22. 22. Why FF? 3. Ff fieldbus technical and economic analysis Economic comparisonFujian Refining and Ethylene ProjectsTable 3-1 Investment Comparison between Ff Technology and Traditional DCS Technology (without cable) September 201222 © 1994 – 2012 Fieldbus Foundation
  23. 23. Why FF? 3. Ff fieldbus technical and economic analysis Economic comparison Fujian Refining and Ethylene Projects Table 3-2 Investment Comparison between Ff Technology and Traditional DCS cTechnology (with able) September 201223 © 1994 – 2012 Fieldbus Foundation
  24. 24. Why FF? 3. Ff fieldbus technical and economic analysis Economic comparison Conclusion I. The overall investment with Ff technology adopted is a little less than that with the traditional DCS system. Key factors to reduce project investment: 1. Increase the utilization ratio of segment to 6 devices or above. 2. Fully adopt domestically manufactured Ef fieldbus cables. II. Benefits expected from the adoption of the Ef technology: 1. Saves engineering investment and speeds up project progress (CAPEX); 2. Can realize the preventive maintenance, increase maintenance efficiency and lower maintenance and operation expenses (OPEX); 3. Has boosted plant digitalization and intelligentization level and thus facilitates mean production and operation management; 4. May lower plant full life cycle cost and maximize corporate benefit. September 201224 © 1994 – 2012 Fieldbus Foundation
  25. 25. 4. Ff fieldbus technology trends Ff Fieldbus technology keeps developing and perfecting 1) FDT/DTM development (AG-181 Rev3.1); In March 2010, FF Foundation 2) Stricter host computer interoperability test (FF-569); issued Version 3.1 of 3)Safety instrument function (SIF) application (FF-895,SIL3); FOUNDATION™ Fieldbus System Engineering Guidelines(AG‐181) 4)Fieldbus advanced diagnosis function (FF-912); and later successively issued several FF series codes. As the 5)Essential safety segment application research (AG-163); FDT technology is widely used on field equipment, the new version 6) Quicker execution period (CIF stressed, non-period time of such guideline has added the increased); function that the MCS should support the FDT/DTM standard in 7)Complicated control strategy application research (FF-892); addition to EDDL. 8)Enhanced integration of DCS/Ff and AMS (NAMUR NE91); 9)f engineering application guide and project implementation code version upgraded. September 201225 © 1994 – 2012 Fieldbus Foundation
  26. 26. 4. Ff fieldbus technology trends Figure 4-1 Ff Communication Model FF HI SIS FF H1 FF HSE User layer OSI-RM reference model User layer User layer IEC 61508 Application layer 7 Fieldbus message sub-layer FMS/FDA Fieldbus message sub-layer (FMS) and fieldbus access sub- (FMS) and fieldbus access sub- layer (FAS) layer (FAS) Presentation layer 6 3-6 layers omitted IETF TCP/UDP 3-6 layers omitted IETF IP Dialog layer 5 Transmission layer 4 Network layer 3 Data link layer 2 H1 data link layer Data link layer H1 data link layer Physical layer 1 IEC 61158-2@31.25Kbps IEEE 802. 3u @100 Mbps IEC 61158-2@31.25Kbps26 User Layer based on IEC 61804 September 2012 © 1994 – 2012 Fieldbus Foundation
  27. 27. 4. Ff fieldbus technology trends Ff Development Trend1. The instrument and control system based on Ff technology will develop rapidly; Ff technology will become one important branch in the process automation field but cannot replace the traditional DCS system completely.2. Research the application demands of petrochemical users on Ff technology: 1) High security; 2) High reliability (robustness); 3) Good real time; 4) Good openness and interoperability; 5) Develops multiple complicated applications; 6) Develops multiple Ff field devices in line with FDT/DTM; 7) Develops AMS user functions; 8) Pays attention to the development of Ef configuration and application software and boosts the embedment between software module and hardware; 9) Some travel test functions that may be used for safety interlock SIL loop, especially interlock control valve; 10)Develops redundancy fault-tolerant Ef segment and related equipment; 11)Researches the interface between Ff technology and industrial wireless network 27 technology, etc.. September 2012 © 1994 – 2012 Fieldbus Foundation
  28. 28. 5. The Ff fieldbus Example5.1 Ff Latest Application Case 1: FREP Bottleneck Removing Reconstruction Project Fujian Refining and Ethylene Project (FREP) is a large refining and chemical integrated project with the joint capitals (25% each) of Sinopec, Fujian Province, ExxonMobil and AOC and fully completed and put into operation at the end of August 2009. Phase I Ef technology application: By now, this project has been in operation for 3.5 years with the control systems (DCS, ITCC, PLC) operating stably and flexibly, safe and reliably safety protection systems (SIS, FGS, MMS), other systems (OTS, RTDB, MES, ERP, etc.) operating online and the automation system and information management system highly integrated. According to user statistics, including Ef fieldbus and HART instrument, the perfectness ratio and utilization ratio of instruments both have reached 99.8% (the regulations of Sinopec on equipment management: perfectness ratio and utilization ratio≥95%). As the project has completely adopted intelligent instrument technology, the maintenance load on instruments has been reduced greatly and all the maintenance personnel for the control systems and field instruments of the whole plant are only 30% of those in normal case. World-class large refining and chemical integrated project September 2012 28 © 1994 – 2012 Fieldbus Foundation
  29. 29. 5. The Ff fieldbus ExampleThe Engineering Research and Application of the Integrated Automation System forLarge Oil Refining and Chemical Integrated Plant developed on the EREP projectobtained the first prize of Science and Technology Advancement 2010 under “Scienceand Technology Award of Petroleum and Chemical Automation Industry”. September 201229 © 1994 – 2012 Fieldbus Foundation
  30. 30. 5. The Ff fieldbus Example5.1 Ff Latest Application Case 1: FREP Bottleneck Removing Reconstruction Project A. Oil refining reconstructed portion: C. Chemical reconstruction portion: Normal decompression devices Ethylene splitting devices reconstructed reconstructed from 8MT/a to 10MT/a; from 0.80MT/a to 1.10MT/a; New dry gas purification devices built; Gasoline splitting & hydrogenation Hydrogenation and cracking devices devices reconstructed; reconstructed to 2.50MT/a; Polyethylene devices reconstructed from MTBE/butylene-1 devices 0.80MT/a to 0.90MT/a; reconstructed. Polypropylene devices reconstructed B. Newly built oil refining portion: from 0.40MT/a to 0.55MT/a; New arene extraction devices built: PX devices reconstructed from 0.40MT/a; 0.70MT/a to 0.86MT/a. New dry gas purification devices built; D. Newly built chemical portion: New S-zorb devices built. New EO/EG devices built: 0.18/0.25MT/a; New butadiene devices built: 0.06MT/a. September 2012 30 © 1994 – 2012 Fieldbus Foundation
  31. 31. 5. The Ff fieldbus Example5.1 Ff Latest Application Case 1: FREP Bottleneck Removing Reconstruction Project The total investment of FREP is about RMB 31.6 billion (equivalent to USD 4.60 billion); and the total investment of FREP2 is about RMB 6.0 billion; FREP construction progress: The oil refining portion was completed and put into operation at the end of April 2008 and the ethylene portion at the end of August 2009; FREP2 is planned to be completed and put into operation at the end of 2013; The construction mode of FREP adopts PMC (FEED) +EPC and E+P+C while FREP2 adopts E+P+C; only EO/EG device adopts EPC mode; The whole plant has 11 process control systems (PCS), totally about 56,000 process I/O points and 180,000 communication I/O points; FREP2 has added 1 PCS (EO/EG device) and has totally about 10,000 process I/O points and 35,000 communication I/O points; The whole plant has totally 2 central control rooms (CCR), 11 local control rooms (LCR) and 26 field auxiliary rooms (FAR); FREP2 has added 1 LCR (EO/EG device) and 5 FARs; The main optical cables of the whole plant are 106km; FREP2 has added about 25km; The whole plant has used 8,033 Ff and 8,229 Hart devices; FREP2 has added about 1,450 Ff and 1,500 Hart devices; 277 848T multi-way temperature transmitters (TT) are used, saving about 2,000 temperature transmitters; On average, every FF network segment has about 5.3 instruments. If the number increases, more investment may be further saved. September 2012 31 © 1994 – 2012 Fieldbus Foundation
  32. 32. 5. The Ff fieldbus Example5.2 Ff Latest Application Case 2: Wanhua Yantai Industrial Park Project Project name: Yantai Wanhua Polyurethanes Co., Ltd. Wanhua Yantai Industrial Park Project Construction site: Shandong Yantai Economic and Technologic Development Zone Port Chemical Industrial Park Project construction investment: RMB 27 billion DCS points (estimated): Including but not limited to the DCS/Ff used by such devices as MDI devices, coal gasification devices, nitrobenzene devices, propylene epoxide devices, acrylic acid and ester devices, propane dehydrogenation devices, butanol devices, utilities and so on, the number of the system I/O points is estimated to be 3,500 and the number of Ff devices is about 8,000. The total of the I/O points of such systems as DCS/SIS/CCS/PLC and so on is about 50,000. CCR category Area Device name DCS name Device No. CCR1 A MDI device MDI 13 CCR2 B Coal gasification device GAS 11 CCR3 C Nitrobenzene device Aniline 12 H Utilities UT 01, 04 CCR4 D Propylene epoxide device 22 E Acrylic acid & ester device AA 24 F Propane dehydrogenation PDH 21 device G Polylol device Polyol 23 I LPG and storage and LPG 05 September 2012 32 © 1994 – 2012 Fieldbus Foundation transportation
  33. 33. 5. The Ff fieldbus Example5.2 Ff Latest Application Case 2: Wanhua Yantai Industrial Park Project Improvements from the previous projects: 1)Network segment utilization ratio has increased to 6~8 units/segment; 2)For the sequential control and interlock completed in DCS, Ff digital I/O coupler is recommended; 3)For most devices, explosion-proof proposal is recommended; for some high-risk devices (such as coal gasification, nitrobenzene and so on), the high-energy trunk +Field Barrier segment may be adopted.5.3 Potential Ff oil refining and chemical projects 1)CNOOC Huizhou Oil Refining and Chemical Project (Phase II): 12MT/a oil refining +1MT/a ethylene; 2) Sino-Kuwait Guangdong Zhanjiang Oil Refining and Chemical Integrated Project: 15MT/a oil refining + 1MT/a ethylene; 33 3) Other projects. September 2012 © 1994 – 2012 Fieldbus Foundation
  34. 34. 5. The Ff fieldbus Example5.4 Ff Implementation Points1. Enhanced AMS Application in DCS/Ff The predictive diagnosis function of AMS makes predictive maintenance possible. From user‟s angle, this is the most attractive point of fieldbus. With such function, before FF field devices have real failures, maintenance request information may be issued and the maintenance personnel are reminded of conducting maintenance, thus greatly decreasing the non-planned halt times and maintenance fees of devices. The specific implementation points are as follows:1) Enhancing training. As the communication protocol between FF field equipment and control system is different from the traditional instrument, its maintenance mode and method are different; therefore, the training on the instrument maintenance personnel is necessary.2) Version upgrade: The DD File of Ff field instruments should be updated and upgraded continuously; comparing with the traditional routine instruments, when the FF field equipment is replaced, we must consider the version of the DD File of Ff field equipment and whether it passes the HIST test (Host Interoperability Support Test).3) Field patrol and daily maintenance. Although one major advantage of fieldbus is “able to see one „transparent‟ field in the control room”, it does not mean “take in everything in a glance” or no field patrol is needed, and the advanced diagnosis function it has cannot achieve no maintenance daily, for example, ambient temperature change, mechanical vibration, damp, dust, oil stain, etc., may greatly affect the reliability of Ff field equipment. September 2012 34 © 1994 – 2012 Fieldbus Foundation
  35. 35. 5. The Ff fieldbus Example5.4 Ff Implementation Points2. Control in Field (CIF) The most important characteristic of Ff is that it hardly relies on control room equipment and the control strategy may operate directly in the field equipment, namely, its field equipment has very strong autonomy. This guiding ideology is directly reflected on the unique “function block” and “function block connection” of the user layer. As a result, this needs the field equipment to provide function blocks as many as possible so as to meet the process control demand of different application environment. The users have a different angle to consider a problem from Ff developers; they do not focus on technology advancement such as “fully digital signal”, “bi-directional and multi-point communication”, “function block” and so on but pay attention to the benefits brought by these “advanced technologies” in actual applications. The research conclusion of the Fieldbus Foundation:1) In respect of quick control loop, the control performance of the fieldbus on H1 is much better than 4-20mA;2) In respect of pressure and flow loops, the control performance is 10-15% more improved than the loop with 4-20mA signals;3) In respect of the slow loop (50s or 1min), the control performance is not so advantageous;4) In respect of P and PD control, the bus and the 4-20mA loop are the same in performance;5) In respect of PI and PID control, the bus (CIF) is better than the 4-20mA loop in control: 14.8% is better for orderly disturbance; 29.3% is better for random disturbance. September 2012 35 © 1994 – 2012 Fieldbus Foundation
  36. 36. 5. The Ff fieldbus Example5.4 Ff Implementation Points3. FF Network Segment Loop Allocation Principle- Fail-safe Design1) To realize field control, all fieldbus devices on the same regulating loop should be allocated on the same segment;2) The transmitter and regulating valve of the single regulating loop should be allocated on the same segment;3) Only 1 key regulating loop is allowed within every FF segment (the failure of such regulating valve may lead to the local halt of one process unit); no other regulating loops but monitoring loop are allowed;4) 2 common regulating loops should be allocated within every FF segment and at most 3 common regulating loops are allowed;5) 6~8 FF devices or 1.5~2 FF locators (which have the maximum value) should be allocated for every FF segment on average;6) For the equipment with energy transmission (such as rectifying tower, reactor and so on), the instrument in relation to heating equipment (such as reboiler) and the instrument in relation to cooling equipment (such condenser) should be allocated in different segments;7) The fieldbus device for the main process equipment (such as master pump) and the fieldbus device for the backup process equipment (such as backup pump) should be allocated in different segments;8) The equipment adopting multi-point measurement, for example, the reactor with multi-point temperature and multi- point pressure measurement, should allocate the fieldbus devices equally in different segments;9) The regulating valve and the switching valve of the fieldbus shall be configured as when the main control system communication is faulty, the position of the valves is the same as that in case of gas source fault. September 201236 © 1994 – 2012 Fieldbus Foundation
  37. 37. 6. Conclusion1. To sum up, via the comprehensive analysis of Ff technology engineering application status quo and development trend, it is fully necessary for large petrochemical projects to adopt Ff technology and such technology is reliable, stable, advanced and workable and can save much debugging, startup time and labor and increase instrument operation rate.2. The application of Ff technology may greatly promote plant‟s intelligent production, maintenance and management level and establish a good foundation for the whole-plant automation system and information management system to realize integrated management and control.3. The combined use of Ff technology and AMS may realize remote predictive maintenance, realize plant‟s intelligent management, lower plant‟s maintenance cost and life cycle cost and heighten economic benefit and social benefit.4. The successful performance of Ff technology in large petrochemical projects must achieve 5- implementation, i.e. “technology implementation, investment implementation, HR implementation, progress implementation and management implementation”.5. Although Ff technology develops very slowly at present in China, as such large oil refining and chemical projects as Shanghai SECCO Ethylene Project, Nanhai Shell Ethylene Project, Caojing Bayer Project, Fujian Oil Refining and Ethylene Project and so on have been smoothly put into operation, it indicates that Ff technology has come to the new stage of large application in China. We believe, as the Chinese economy further develops and the demand of petrochemical enterprises in China for advanced production and technological innovation becomes increasingly higher, Ff technology will have great development in China and even in the world. In the end, wish this conference successful! September 2012 37 © 1994 – 2012 Fieldbus Foundation Thank you!

×