BP Bulwer Refinery: Foundation Fieldbus Implementation on FCS 3.0 Michael McKenzie DCS Systems Engineer. Opsmanage Australia

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1 BP Bulwer Refinery: Foundation Fieldbus Implementation on FCS 3.0 Michael McKenzie DCS Systems Engineer Opsmanage Australia

2 BP Bulwer Island Refinery BP Bulwer Island Refinery is located in the Pinkenba area on the outskirts of Brisbane, Australia. Our refinery is situated on 90 hectares (223 acres) of reclaimed land bound by the Brisbane River. There are currently around 365 permanent personnel employed on site, with a further 300 contractor staff. The maximum crude capacity for our refinery is 100,000 barrels/day. Crude oil is delivered from Australia, SE Asia and the Middle East. The refinery produces mostly diesel and jet fuels as well as petrol, kerosene, heating oil and sulphur. Most of our product is supplied to markets in Queensland. 2

3 Control System and SIS Invensys I/A DCS, with a mixture of Nodebus and MESH connected workstations and CP s. Currently we have V6.5.2, V7.1.4 and 8.6 with FCS 3. Operator workstations are Solaris, and still using Display Manager. There are currently 23 CP270 s, 6 CP40B s, 2 CP40A s &1 CP60 Projects are underway to: Update all CP s to 270 s Change HMI to FoxView Upgrade the entire system to I/A 8.8 with FCS v4 8 Triconex deployed as our primary SIS for major process units. 3

4 Foundation Fieldbus currently within the Refinery 9/ new valve positioners with Fieldbus position indication installed on newly installed Hydrogen Compressor. Used as a trial for FF at site. Implemented with Infusion 2.0 8/2011 New Reformer furnace installed. All indications via FF FF utilised to reduce the requirement for I/S field cabinets 23 Thermocouples connected via P&F thermocouple multiplexers 5 Pressure transmitters, 4 Valve Position indicators 12/2012 LPG terminal Upgrade. 35 MOV valves installed with position indication and control. Implemented using FCS 3 4

5 LPG Terminal Project Overview Installation of Triconex at the LPG terminal to enable: Trip closed the terminal rundown, and all LPG bullets in the event of gas or fire detection. Trip individual LPG bullets in the event of a high level. This required the upgrade of 35 existing MOV s and manual valves, which would enable control of the valves both from Triconex and the DCS. The LPG terminal is remote from the Refinery, and as such only limited I/O was available for DCS control and indication of the valves. This was the major factor in the decision for utilising FF 5

6 Foundation Fieldbus Configuration in FCS 3 There are 3 main steps required to configure foundation fieldbus within FCS. Setup of the FF ECB s and segments. FF Device configuration FF Block configuration 6

7 FF ECB Configuration in FCS 3 Generate ECB for FBM 228 s Configure ECB with name and segment information. Open field device manager and: Set Fieldbus cycle times Verify fieldbus connectivity Assign device ID s and names to each device. 7

8 FF ECB Configuration in FCS 3 (cont). 8

9 FF ECB Configuration in FCS 3 (cont). 9

10 FF ECB Configuration in FCS 3 (cont). 10

11 FF ECB Configuration in FCS 3 (cont). 11

12 FF Device Configuration in FCS 3 Steps taken to configure each FF device: Creation of new FF device template using the vendor supplied DD file. Generation of a new instance of the template for each device on the fieldbus. Configure the device name and ID, as defined earlier Setting of device s preferred state within the transducer block to Auto. Verification of connectivity with the device. 12

13 FF Device Configuration in FCS 3 (cont) 13

14 FF Device Configuration in FCS 3 (cont) 14

15 FF Block Configuration in FCS 3 Create an appropriate FF block for the purpose. Using the device browser, assign the block to the correct device. Open the block configuration, and select the appropriate FF channel Open the block in FoxView, place into Auto and ensure a healthy reading is received. 15

16 FF Block Configuration in FCS 3 (cont). 16

17 FF Block Configuration in FCS 3 (cont). 17

18 FF Block Configuration in FCS 3 (cont). 18

19 Any Questions?. 19