Foundation Fieldbus Technology: “ JUST ONE CASE”
“ JUST ONE CASE”CLELIO GUIMARAES ALVES.:Control, Automation & Instrumentation Senior SpecialistPETROBRAS-PETRÓLEO BRASILEIRO S.A.Downstream- Investment Programs- Technical SupportAdmitted in: Feb, 1986 in REDUC-RefineryI/C Maintenance Support Division: 15 yearsNew Projects Division; 10 yearsDownstream Premium Projects: since Oct, 2010Graduation: Eng. ElectronicsSpecialization: Project ManagementBaccalaureate: in Semiotics
“JUST ONE CASE” Project: HDS-Carteira de Gasolina Reduc-Refinery, Rio de Janeiro-BrazilStart (FEL-I): 2005Conclusion (Start-up): March-2011Specs:•FCC- Naphta FEED 4500 m3/d•FCC Battery-limit direct to HDS Process unit.•Licensor: AXENS
“ JUST ONE CASE” FEL-II to FEL-III: decision for the use of the FF Technology: Project Manager, Sponsor, Final Client (Operators) Supported by the Licensor Pros: (in 2006) -EPC: reduction in materials & HH, Inteligent Instruments (more information). -Maintenance: prediction -Advanced Control: indicated by the Licensor- U$ 1MM per year in Profits -Better response (PID´s running in the field) -Accuracy Cons: -Instruments and Cabling: more expensive -Service: expertise in FF Technology by EPC team -Review in Loop tests: new procedures -Review in Schedule: Commissioning, Loop tests, etc.
“ JUST ONE CASE” FEL-III (FEED) FEED scope FEED deliverables Before Phase IV: Generation of “Specific Documents”: MD for FF specs, including Cables MD for EPC contract: Automation Chapter MD for Integrator-Contract, included in EPC scope LD for Specific FF deliverables (documents) by “Detailing Eng.” RL´s for: Commissioning, Loop-tests, Start-up procedures
“ JUST ONE CASE” General Project Criteria: 12 Devices per H1 segment-maximum 10 Devices instaled per H1 segment 03 Field-barriers per H1 segment 12 Spurs= 10 installed + 02 spares Voltage calculation for 12 Devices Microcicle Calculation for 12 Devices 1000ms for Microcicle time(maximum) per H1 segment, indicated by Licensor Acceptable: 02 Control valves per H1 segment Connectors in the Fieldbarrier and Cable-glands in the Instrument ITK-4.5 (minimum) DCS: ABB IIT, Devices: Multiple Suppliers (PETROBRAS Vendor-List) Control Valve Criticity FF Loop Analisys Report Procedures and Calculations by CENPES Participants: CENPES (MC), Operators, Automation Experts, EPC, Ext. Consultant. Results: 58% of Loops accepted PID running in the Field (Valve Positioner).
“ JUST ONE CASE” Testing Procedures: Instruments Set-up (in the Bench) DCS parameters, configurated previously, should not modify “bench set-up”: loss of Certification Dynamic Test for FF devices “in the Bench”: Procedures consolidated with “Integrator” Reports as Standards for Tests General Criteria: >Cable maximum lengh cut for H1 >Cable maximum lengh cut for Spurs >Simulate each H1, in the bench, with all devices and cables to test Voltage and Microcicle values to certificate each H1 segment >Consolidation of Voltage and Microcicle Memory Calculations. DCS parameters, configurated previously, should not modify “bench set-up”: loss of Certification
“ JUST ONE CASE” Testing Procedures(Cont): Procedures for Connectorization Connectorization should be performed in a clean enviroment, never in the field/ site. Static test for Cables plus Connectors, in the bench. “Dynamic” test for Cables plus Connectors instaled in Trays in the field. Loop Tests: Faster, accurate Reports “from the Bench” as a reference to Field results Consolidate: Voltage and Memory Calculations- minumum deviation Use of FF signal Wave Form pictures in the Reports comparing bench to site values. Composition of a File containing information for each Device in each H1 segment with all Devices. Acceptance procedure: file to be approved before and after tests.
“ JUST ONE CASE” Important Aspects: Are EPC´s prepared to support a project in FF(2012)?• Certification for Automation Engeneers• DCS Suppliers are prepared to develop a project in FF?• Very Important: include a FF Certified Integrator in the EPC Contract.• Interoperability: DCS versus Instrument Suppliers.• Internet: FF Website and Instrument Suppliers Website DCS Suppliers shall “open doors” to other Instrument Suppliers. DCS Suppliers shall “work close” to EPC´s PID running in the Field is not a “Monster”.