Foundation Fieldbus technology was selected for use in a Hydrodesulfurization (HDS) project in Brazil. [1] Some key benefits cited for using Fieldbus included reduced materials and manhours, intelligent instruments providing more information, improved maintenance through predictive capabilities, and advanced control potentially yielding $1 million per year in profits. [2] Specific documents were generated to specify Fieldbus requirements and deliverables. Testing procedures were consolidated with the Fieldbus integrator to validate devices, cables, and connections both on the bench and in the field. [3] Important aspects for future Fieldbus projects include ensuring EPCs, DCS suppliers, and instrument suppliers are prepared to support the technology through certification and interoperability.
2. “ JUST ONE CASE”
CLELIO GUIMARAES ALVES.:
Control, Automation & Instrumentation Senior Specialist
PETROBRAS-PETRÓLEO BRASILEIRO S.A.
Downstream- Investment Programs- Technical Support
Admitted in: Feb, 1986 in REDUC-Refinery
I/C Maintenance Support Division: 15 years
New Projects Division; 10 years
Downstream Premium Projects: since Oct, 2010
Graduation: Eng. Electronics
Specialization: Project Management
Baccalaureate: in Semiotics
3. “JUST ONE CASE”
Project: HDS-Carteira de Gasolina
Reduc-Refinery, Rio de Janeiro-Brazil
Start (FEL-I): 2005
Conclusion (Start-up): March-2011
Specs:
•FCC- Naphta FEED 4500 m3/d
•FCC Battery-limit direct to HDS Process unit.
•Licensor: AXENS
4. “ JUST ONE CASE”
FEL-II to FEL-III: decision for the use of the FF Technology:
Project Manager, Sponsor, Final Client (Operators)
Supported by the Licensor
Pros: (in 2006)
-EPC: reduction in materials & HH, Inteligent Instruments (more information).
-Maintenance: prediction
-Advanced Control: indicated by the Licensor- U$ 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.
5. “ 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
6. “ 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).
7. “ 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
8. “ 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.
9. “ 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”.