FIELDBUS IN ONGC C2C3 PLANT

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Arron Gilbert
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1 FIELDBUS IN ONGC C2C3 PLANT Agenda - FF Technology Conference GNFC, Bharuch on 4th February, 2011 MITHUN BISWAS AEE(I) ONGC PMC : Foster Wheeler Energy EPC : Toyo Engineering i India Limitedit DCS Vendor : Yokogawa India Limited Plant Location : Dahej, Gujarat 1

2 FIELDBUS IN ONGC In C2 C3 C3 Plant ONGC has first conceptualized and implemented Fieldbus both for open and closed loops. ONGC has embarked upon a project for Enterprise wide SCADA system for production and Drilling facilities. The scope of this project is to capture datafrom bothoff shoreandon shoreassets off on assets which covers 157 offshore platforms,10 offshore rigs, 247 nos onshore installations, interconnecting pipeline, 5 on shore process plants and 65 onshore rigs. As per strategy adopted, all new additional devices has been opted for having FF interface except for some typical applications where special type of instruments have been necessary and the manufacturers are yet to develop models with FF interface Also in Rajamundry ONGC G1 project fieldbus installation is in progress 2

3 C2-C3 PLANT, ONGC ONGC has set up a C2, C3 and C4 extraction ti plant at DhjG Dahej, Gujarat. C2 C3 C3 & C4 will be extracted t from the rich LNG Petronet LNG Ltd. imports at Dahej in Gujarat from Qatar. These compounds would then be fed into a petrochemical plant OPAL to manufacture polymers. Recovery of these valuable products from feed LNG is attractive as lean LNG after recovery of these components still has the similar value in terms of heat content. In this plant 90% of the process loops are in Fieldbus. 3

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6 SYSTEM CONFIGURATION 6

7 Fieldbus Infrastructure for ONGC C2C3 YOKOGAWA HOST POWER SUPPLY JUNCTION BOX FIELDBARRIERS FIELDBUS TERMINATOR SURGE PROTECTOR PROCESS INTERFACE FIELDBUS DEVICES 7

8 Fieldbus Infrastructure for ONGC C2C3 8

9 The Power Hub: Rd Redundant d FF Power Supply Enclosed Motherboard Passive Power Conditioning CREST Technology for safe operation even under fault conditions Fault output via diagnostic module (Basic or Advanced) Redundant or non redundant board versions Host connection via system cable available Segment protection against host spur faults High efficiency (85%) Fully galvanically isolated 30V / 500mA Output for maximum number of field devices 9

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11 Isolation Switch Terminator 11

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13 PRM(PLANT RESOURCE MANAGER) PRM employs FOUNDATION fieldbus technology to transform maintenance from manual work mainly done on site into information technology based device management that can be performed remotely and automatically. With FOUNDATION fieldbus, PRM can acquire information such as the device ID, device parameters, and self diagnostics information, in addition to measured data. This wealth of information is used for administration andsupervision of assets such as field devices, andalsoalso for remote automated inspections. PRM supports the FOUNDATION fieldbus, HART, PROFIBUS, and ISA100.11a communications protocols, ensuring an extensive range of devices to choose from. PRM fully embraces an open, rich, andintuitive access to intelligent field devices. 13

14 Fieldbus Design with Segment Checker In a fieldbus segment all the connected tddevices are interdependent The layout of a segment is a complex calculation with various variables: Number of connected devices Impedances of the devices Cable lengths and type Fieldbus signal level Type of topology (line, tree, chicken foot...) FieldConnex Segment Checker automates segment calculation Many device libraries approved by popular manufacturers 14

15 Where FF Technology is not considered by ONGC 1. Emergency Shutdown Systems. 2. Fire & gas Control systems. 3 Fast loops like Compressor Controls.( Anti Surge ) 4. Various packages like Heaters, Compressors. 5. Analyzer Systems 6. Custody Transfer Metering 7. Truck Loading Package 15

16 PROBLEMS FACED WITH FIELDBUS 1. Isolation of individual id instrument t in a particular barrier. 2. IOP in the faceplate of instruments.the problem is solved by restarting of instrument power. 3. Sometimes device which h is connected with ihcommunicator does not show in the live list whereas other devices are available. 4. O/S mode problem comes regularly in instrument due to some software issues in PRM 5. Calibrator for FF devices 16

17 Carbon Footprint Reduction in C2 C3 Plant,Dahej Material % Reduction % Reduction in Carbon Footprint Facts CABLE m Fieldbus cable used. Conventional Instrumentation will require around m of cable. TERMINATION I/O Card cards required for 1632 I/O in Fieldbus. Whereas conventional system will require 60 cards System/ Marshalling cabinet for 1632 I/O Marshalling whereas 6 Marshalling cabinet will be Cabinet used for the same no. of I/O for conventional system. I.S Barrier barrier in Fieldbus against 12 barriers in conventional for 12 instruments. 17

FF Physical Layer Components

FF Physical Layer Components Best Practices Binoy Kamath AGM Project Pursuit Pepperl+Fuchs India Pvt. LTd.,Bangalore Agenda Introduction to FF and FF Physical Layer FF Physical Layer Components FF Wiring