INA - OFIG/ETAN - Gas treatment plant DCS - Automation System

Transcription

1 INA - OFIG/ETAN - Gas treatment plant DCS - Automation System

2 About the Plant Gas treatment plant OFIG/ETAN is operated by national oil & gas company "INA industrija nafte d.d.". The plant started with production in Raw materials, i.e. natural gas, arrives via gas pipeline, from gas plant "Podravina" in Molve- Croatia. OFIG/ETAN plant processes input gas to prepare it for distribution transport and extracts ethane, as well as liquefied natural gases (propane, isomers of butane and pentanes). Produced gases are shipped via gas pipeline to "Etilen" plant in Zagreb, or by special trucks and railcars to various locations. ABOUT THE CONTROL SYSTEM Since september 1995., the process was controlled by four ABB Master generation process controllers. In one controller MasterPiece 200/1 (PS1) was replaced with ABB AdvantController 450. In 2016., the remaining three MP200/1 were replaced with another AC450. Current automation system's block diagram is presented on page 5.

3 Distributed Control System (DCS) - Features DCS controls/supervises: valves motors software PID regulators hardwired I/O signals serial I/O signals external communication links Supervision and control scope Entire production process is controlled and supervised by means of process controllers. Process runs fully automatic. Operator intervention is required rarely and only exceptionally. Main tasks of the DCS are: Supervision and control of complete production process from one, central, operators workplace. Quality assurance programmed gas chromatographs control. According to measurements results, DCS programs can directly act to maintain gas quality. Availability assurance programmed prevention of major disturbances and production losses. Efficiency assurance - coordination of all plant and process parts. Energy saving programs. Safety improvement for the plant and people. Complete plant shut-down logic is implemented in process controllers software. Integration of extenal systems in the DCS via serial communication links.

4 DCS Main Parts Equipment Production, treatment and distribution of final products are controlled and supervised mainly by ABB Advant and 800xA family equipment. Some smaller process sections are controlled by OPTO22 equipment and ifix SCADA systems. Following equipment is in use: Process controllers - ABB AdvantController ABB AC800M - OPTO22 - mistic 200 and SNAP Operator stations - ABB 800xA - ABB AdvantStation 500 OS - PC with ifix system Communication - Process control network MasterBus plant network TCP/IP, - EXCOM and RCOM serial RS232 links, MODBUS, PROFIBUS Alarm and event printers, hardcopy printer and reports printer. AdvantController 450 Controller cabinets AdvantController 800M SNAP 800xA OS mistic 200 AS 500OS PC + ifix Hardcopy printer Events & reports

5 DCS - Block Diagram Gas turbines Allen Bradley - PLC RS485 MODBUS RS232 MODBUS business network Inlet H-701A Mitsubishi - PLC OPTO22 - Snap RS485 EXCOM RS232 MODBUS RS232 PS14 Remote client n PS32 Remote client 2 Remote client 1 Dispatching Steam prep. common console 800xA server cabinets router/ firewall Storage Z-900 Stahl - remote I/O RS485 PROFIBUS-DP IMS DC/AS/CS 1 DC/AS/CS 2 APC optimising Propane compressor Siemens - PLC RS485 PROFIBUS-DP AC450 AC450 AC800M AC800M Spare UPS video server PC Analyzers AH1 Stahl - remote I/O RS485 PROFIBUS-DP MasterBus 300 switch Reports printer B/W Hardcopy color printer camera AS500 OS 800xA OS1 800xA OS2 800xA OS3 TCP/IP LEGEND Fire&gas detection OPTO22 mistic 200 RS232 PC WIN FIX OS AS CS DC IMS Operator station Aspect Server Connectivity Server Domain Controller Inform. Management Server 55" monitor smart client PC

6 Operator s Process Display Sample In order to enable simple and complete process supervision and control, more than 40 operator station process displays (similar to sample presented) were developed. Besides process displays, there are many others, auxiliary and maintenance displays, trends, lists and reports. Each process display is based on simplified process diagram, showing main process elements and relevant interconnections. Measured values, indications and alarms are represented with values or simbols positioned on the display according to their actual position in the field. Measured values and equipment statuses are constantly updated, so displays are always reflecting actual process conditions. Operator can select any process object by clicking on it's screen symbol (e.g. motor). Process dialog is then presented, providing a possibility to control the object (e.g. start/stop motor).

7 INTEA Assignments and Tasks Activities scope INTEA took part in all DCS design stages: application analysis programming - level 1: (type-circuits and process controller s signals database) programming - level 2: (logic, sequences) operator stations - configuration, application design, operator displays and dialogs simulation programs development factory acceptance site installation commissioning end-user s technical training Activities per sections Initially (in 1995.) INTEA was responsible for process controller PS1 application design, development and commissioning, as well as for complete application in both operator stations. Afterwards INTEA was awarded all extensions, modifications and maintenance of ABB DCS system. Duration and results During the september 1995., outdated relay control logic and hardware regulators were replaced with ABB DCS system. Major achievement: complete rewiring of all process signals, new control system implementation, start-up and commissioning - all completed in less than a month, within regular annual overhaul period. INTEA's contribution was qualified as outstanding and highly professional, by both the client and the enduser. Post start-up activities Annual overhaul Adding new controller PS4, for penthane and butane production Year 2000 compliance resolving Annual maintenance new PLC and oil heater 15.1MW Annual maintenance, DCS upgrades, extensions and modifications, technical trainings,... Since 1993, INTEA received 64 orders related to OFIG/ETAN DCS.

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