Prepared By Turki AL-Mugaiteeb Control System Engineer EASTEREN PEROCHEMICAL COMPANY SHARQ 3 rd Expansion Project (OLEFIN)

Transcription

1 Olefin PLANT PCIMS NETWORK OVERVIEW Prepared By Turki AL-Mugaiteeb Control System Engineer EASTEREN PEROCHEMICAL COMPANY SHARQ 3 rd Expansion Project (OLEFIN)

2 PCIMS I. Introduction A. Introduction to Olefin Plant products. B. What is PCIMS? C. Control system requirements & Honeywell EPKS Features. II. PCIMS Layout A. Buildings Segregation; RIB1, RIB2, and CCB. B. PCIMS Highway Systems and Network philosophy. C. Networks Application in PCIMS. III. Conclusion

3 Introduction to Olefin Plant products 1. The Olefin plant is a complex plant that will produce Ethylene and by-products. 2. Main product: 1.3 Mt/Y Ethylene. 3. By-products: Methane, Hydrogen, Propylene, Butane2, Raw mixed C4 to storage, and BTX product.

4 PCIMS Definition and Description What is PCIMS? The Plant Control and Information Management System (PCIMS) is the collective name assigned to the core control system components located in the unit control building and remote instrument buildings (RIB s). PCIMS

5 PCIMS Definition and Description PCIMS will include the following: a) DCS (EPKS C200 controllers, servers, stations, modbus connectivity to other systems). b) PESS s (Programmable Electronic Shut down System V9-10) Triconex. c) Uninterruptible Power Supplies (UPS s), batteries and chargers located in the control rooms. d) RIB s pre-fabricated buildings housing PLC, PESS, and DCS input/output and control equipment located in each process unit. e) PLC s (SEIMENS S7). f) A Real Time Information Management System (RTIMS) data historian. g) Advanced Process Controls (APC). PCIMS

6 Package Systems in PCIMS Operator shall be able to view all plant actions & processes through the following systems: 1. PLCs: Programmable logic controller, used for non critical sequence process 2. TMC: Turbo Machinery Controller, used for speed turbine control. 3. BMS: Burner Management System, dedicated safe guards for all fire process in the plant; e.g., Boiler, and incinerator. 4. CTM: Custody Transfer Metering, will be used to view the feed meters readings from ARAMCO and the readings from Olefin products meters. ($$$$) 5. MMS: Machinery Monitoring i Systems, for monitoring i vibration upsets in rotating ti machines.

7 Systems in PCIMS 6. OPSER: Overall Plant Sequence of Event Record, central location for sequence of event (SOE) information's derived form DCS, PESS, MMS, PLCSs 7. OPFDMS: Overall Plant Field Device Management System, 8. T&CGDS: Toxic & Combustible Gas Detectors, will show the operator the hazardous area where it shall be monitored for any leakage.

8 General Control Systems Requirements Consist of power supply, controller modules, communication modules, I/O processors, termination panels, cabling, termination accessories. Process control devices and marshalling shall be dedicated to each process area. Field signals and/or control functions shall not be brought from one process area to another. Discrete signals shall be in separate marshalling panels. Protective/PESS signals and intrinsically safe circuits, however, shall be in dedicated marshalling panels and shall be segregated from process control signals. Dedicated marshalling for electrical interface shall be provided. I/O power supplies that are dedicated to each process control device. All I/O power supplies are fully redundant d Spared process equipment (e.g. stand by pump in spare configuration) shall be wired to separate I/O cards. PCIMS

9 DCS System Components DCS shall comprise of the following : - EPKS process servers. - EPKS operator stations. - Honeywell C200 controllers. - PHD servers (RTIMS). - OPC and modbus connectivity for PESS, PESS-SER, 3 rd party PLCs, Machinery monitoring systems (MMS), Compressor controllers, Auxiliary boiler burner management system, and TCGD.

10 Experion PKS Honeywell Experion PKS features: EPKS is a software and hardware suit which combines all plant operations data from the DCS, PESS, PLCs, TMC, BMS, CTM, MMS, OPSER and OPFDMS, T&CGDS, and APC into one real time global database. 1. Alarm and events; provides the operator with comprehensive alarm and event detection, management, and reporting facilities. 2. History Collection; available over a wide range of frequencies in both average and snapshots/production formats. A large amount of history can be retained on line. 3. Trending; allows viewing of historical point data. 4. Reporting; can be configured in many different types and generated either on demand or periodically. 5. Security; provides configurable security access levels. 6. Distribution Server Architecture (DSA); allows the different (process area) Experion PKS Servers to communicate with each other, and allow data sharing. PCIMS

11 What are Buildings? 1. CB is the central control building that will accommodate the consoles, the associated controllers, 3 rd party systems and shut down systems. All the operation decisions, and actions will be taken from this building in control room. CB is divided into; control room, rack room, engineering room, UPS room, and AC room. 2. Two RIBs (remote instrument building) are designed so that all the process controllers will maintain and control near by process units. In this project two RIBs are constructed in two different geographic area. PCIMS

12 PCIMS Highway Systems 1. The highway shall allow exchange of multimedia traffic including data, video, audio, graphics, fax, and telephony with negligible time delay. 2 The highway shall be the common layer for running plant industrial applications 2. The highway shall be the common layer for running plant industrial applications related to automation applications in addition to business applications and office automation software.

13 PCIMS Highway Systems The important characteristics of the highway systems as follow: A) Open system architecture to allow multiple vendor system devices and peripherals. B) Ample bandwidth for future expansion. C) Fault tolerant design so that a single failure will not effect the functionality of the system. D) Data transmission speed that allows for the safe operation of a facility and supports real time video imagery.

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15 Networks in PCIMS 1. FTE: The Fault Tolerance Ethernet network is the control network for the EPKS. - Dedicated d for the control mission. - Provides fast response, determinism, and security. - Fast switchover time under one second. - Tolerates more faults by providing twice as many communication paths between nodes. FTE

16 Level 4: Firewall between L3 & L4. LIMS, and PWIMS. Level 3: FTE Levels PESS OPC servers, Bentley Nevada System 1, RTIMS, OPSER servers, APC Servers, and GPS time server. Level 2: EPKS servers, EPKS console stations, EPKS flex stations, EPKS engineering workstation, OPFDMS, and terminal server. Man agem ent Info. Interface gateway to DCS and tracking events! Process Data and station monitoring for maintaining and configuration purposes Control processor execution Level 1: C200 Controllers

17 Networks in PCIMS 2. Modbus network: modbus is the communication interface with other systems; PESS, PLCs, TMC, etc. PESS & DCS integration : - For analog signals the OPC integrator software will be utilized over the FTE network. - For the non-critical digital signals (Trip reset, Force manual Open/Close), modbus serial interface protocol via TS will be used.

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27 Honeywell EPKS C200

28 Control network for operation interaction with plant Conclusion FTE Network Interface between all 3 rd party systems to FTE network For retrieving Tricon program Modbus Network PC Network Between Tricon nodes for time synchronizat ion PTP Network

29 Summary Future of the wireless: Wireless Technologies will play an important role even in safety critical industrial applications First step is to implement non-critical applications and get wireless technology accepted in the industrial sector For safety critical applications, more research is required

30 Thanks Questions?