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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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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 www.emersonprocess.com/smartwireless </li></ul></ul>

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