Fieldbus Foundation >>> Moving Ahead

Transcription

1 Fieldbus Foundation >>> Moving Ahead A New perspective FF Contribution and Future Challenges 1

2 Essar Group - Mission To create enduring value for customers and stakeholders in core manufacturing and service businesses, through world-class operating standards, state-of-the-art technology and the positive attitude of our people

3 Overview Promoted by the Ruia Family Employs more than 50,000 people across 20 countries and over 150 offices A well balanced portfolio of assets in manufacturing, services and retail State-of-art a t facilities and technology ogy Global level of operations and strong business relations Moving closer to customers and building strong brands

4 Businesses Essar Group Shipping Ports Steel Energy Power Communications Projects & Logistics Essar Steel Ltd Essar Oil Essar Power / Vodafone Essar Essar Shipping 4.6 MTPA integrated 12.5 MTPA refinery 60 million subscribers Fleet of 26 vessels, steel plant complex DWT of 1.49 mn Essar Steel (Hazira) 4 MTPA integrated steel plant (under implementation) Essar Steel Orissa 6 MTPA pellet plant (under implementation) Algoma Steel, Canada 4.0 MTPA integrated steel plant Minnesota Steel 6 MTPA pellet plant (planned) 1.4 billion tonne iron ore reserves PT Essar Indonesia 0.4 MTPA cold rolling complex Over 1,000 retail outlets Refinery expansion to 34 MTPA in two phases Exploration & Production Assets E&P rights in valuable oil & gas blocks in India and abroad Bhander Power 1,015 MW combined cycle Vadinar Power 125 MW co-generation; expanding to 1250 MW Essar Power MP 1,200 MW coal based (under implementation) Essar Power Gujarat 1,200 MW coal based (under implementation) Essar Power Jharkhand 1,200 MW coal based (under implementation) Essar Telecom Infrastructure 3,500 telecom towers operational; 20,000 planned by 2010 The MobileStore Over 1,300 outlets operational; 2,500 planned by 2010 Aegis - BPO 30,000 people in offices in the Philippines, Costa Rica, USA and India BPL Mobile More than 1.8 million subscribers Vadinar Oil Terminal Terminal facility of 32 MTPA Liquid Cargo Bulk Terminal Dry bulk port facilities Essar Oilfields A drilling company with 13 rigs Essar Logistics Owns and operates transshipment assets Essar Construction - Engineering - Fabrication - Construction Fully geared to execute turnkey EPC jobs in India and overseas Essar Offshore Subsea Expertise in marine construction Global Supplies (UAE) FZE Global procurement company Heavy Engineering Services Project Management Consultants Asia s s largest equipment bank

5 Essar Global Steel Energy Power Communications Shipping, i Ports & Logistics Projects Steel Fully integrated producer from iron ore to ready-to-market products INDIA ESSAR STEEL LTD 4.6 MTPA integrated steel plant ESSAR STEEL (HAZIRA) 4 MTPA integrated steel plant (under implementation) ESSAR STEEL (ORISSA) 6MTPA pellet plant OVERSEAS ALGOMA STEEL,CANADA 4 MTPA steel complex MINNESOTA STEEL, U S A 6 MTPA pellet plant (under implementation) 1.5 billion tonne of iron ore reserves INDONESIA 0.4 MTPA Cold Rolling complex

6 Essar Global Steel Energy Power Communications Energy From rig to retail EXPLORATION & PRODUCTION OVERSEAS Vietnam: 1 offshore block Madagascar: 3 onshore blocks Nigeria: 1 offshore block Australia: 2 offshore blocks INDIA 4 onshore blocks and 1 offshore block Assam, Raniganj and Mehsana: Onshore Ratna & R Series: Offshore REFINING Shipping, i Ports & 12.5 MTPA refinery, capacity being expanded Logistics to 34 MTPA in two phases Projects MARKETING Retail: Over 1,000 retail outlets operational Bulk Marketing

7 Essar Global Steel Energy Power Power India s first independent power producer CURRENT OPERATIONS Hazira 1,015 MW Combined Cycle Power Plants Jamnagar 125MW Co-generation Plant Visakhapatnam 25 MW coal based power Plant Communications Shipping, i Ports & Logistics NEW PROJECTS 3,600 MW Power projects (1,200 MW each in Gujarat, Madhya Pradesh and Jharkhand ) Under development 1,250 MW captive for Vadinar refinery Projects

8 Essar Global Steel Energy Communications Where ever you go, our network follows CELLULAR JV WITH VODAFONE A major force in the industry Over 60 million subscribers Power Communications INVESTOR IN BPL MOBILE AEGIS BPO Call Centres in USA, India, the Philippines and Costa Rica; total capacity of over 30,000 seats TELECOM RETAIL STORES Shipping, i Ports & ESSAR TELECOM INFRASTRUCTURE Logistics Over 3,500 telecom tower sites Projects

9 Essar Global Steel Energy Power Communications Shipping, Ports & Logistics End-to-end transportation logistics solutions SHIPPING OIL TERMINALS BULK TERMINALS OILFIELDS SERVICES LOGISTICS Shipping, Ports & Logistics Projects

10 Essar Global Steel Energy Power Communications Shipping, i Ports & Logistics Projects Projects Over 30 years of experience in constructions INDUSTRIAL PROJECTS CIVIL AND IRRIGATION PROJECTS PIPELINES: ONSHORE & OFFSHORE MARINE PROJECTS HIGHWAYS AND EXPRESSWAYS ENGINEERING CENTRES HEAVY ENGINEERING SERVICES GLOBAL SOURCING

11 Energy From Rig to Retail Essar Oil is a fully-integrated oil company of international standard and scale

12 Energy EOL Business Units Exploration & Production Refining Marketing Exploration Blocks in India, Vietnam, Nigeria, Australia and Madagascar Grassroots Refinery in Vadinar Retail Bulk Development Blocks Coal Bed Methane Blocks

13 Energy E & P Proven Field Ratna and R series with reserves of 500 million barrels of oil Exploration Blocks: Oil Blocks: Mehsana, Gujarat, and Assam CBM Blocks: Raniganj, West Bengal Exploration Blocks in Australia, Madagascar, Nigeria and Vietnam

14 Energy Refinery 12.5 MTPA capacity being increased to 34 MTPA in two phases State-of-the-art technology and flexibility to handle diverse crude mixes Capability to produce EURO III & EURO IV compliant fuels Dedicated infrastructure include port, SBM, tankage, pipeline and power Ideal location; close to source of crude and market

15 Energy Marketing Network of 1,000 retail outlets Presence on highways, rural and semi-rural areas in India Premium fuel brands Institutional sales through bulk marketing

16 ROI Improvement Increase ROI Reduce Capital Cost Increase Profitability Reduce conversion Costs Increase Revenue Increase Productivity Reduction of losses Reduced Project Capital, Installation & Commissioning Cost Reduced Feed stocks Energy and Utilities Maintenance waste Abnormal Events Increased Yield Consistency Equipment Capacity Equip. Efficiency Reduced Unscheduled Downtime & Small stoppages Low Maintenance time Resources, Reliable History 16

17 Current Practices: Process devices start deteriorating and wear out from the minute it s placed in service. Types of maintenance: Run to failure No maintenance till device fail Preventative maintenance Based on schedule given by equipment vendor or past history Predictive maintenance Based on future prediction of condition of devices 17

18 Maintenance Practices 18

19 Three- Level Diagnostics Module - Abnormality Analysis Level 3 Level 2 Drift Operations Level 1 µp Loop Electronics Defective Sensor Drift External influence 19 Device

20 Maintenance Practices in Digital World 20

21 Four - Level Management Module Abnormality Analysis Level 3 Level 4 Enterprise Network Level 1A Level 2 FF Accessories Drift Operations Communication & Networking Loop Level 1 FF Sensors µp 21 Electronics Defective Sensor Drift Device External influence

22 Maintenance Practices in Digital World Device Level Device Configuration: FF Basic-to-LM device wizard Safe way to enable/disable Backup LAS Provides wizard to step through sequence Insures BLAS will work when needed 22

23 Maintenance Practices in Digital World Device Level (Sensing): Device Replacement: Device Replacement by Operator Replacement from Operator Station or Engineering Station Auto replacement Upgrading devices on-line 23

24 Maintenance Practices in Digital World Device Level (Final Element): Asset Measurement & Solutions: Effectiveness for diagnostic 24 Detecting inner valve failure Wearing of seat ring Sticking the foreign object Detecting the failure by vibration Moving from proper mounting position of positioner by vibration. Accurate analysis (No Human error) Information available at Control room ( With Problem Description) i Stroke repetition Hysteresis data, Input output deviation Valve signature Overshoot / Undershoot stem travel

25 Maintenance Practices in Digital World Plant level Communication: 25 Advance diagnosis module Issue with FF: Common issue in Electrical wiring (loose wire strands, water ingress, faulty devices, EMC, etc..) Bus topology connects multiple devices Serial communications signal One fault can affect several devices Available tools are for conventional technology Tools lacks ability to visualize Fieldbus related signals Locating the problem is difficult and time consuming many devices in one loop; interoperability) Field Bus installation Tools to commission, Supervise & trouble shoot (signal distortion)

26 Maintenance Practices in Digital World Plant level Communication: Measurement & Online Solutions: Identify kind of failure & guided actions Grounding, Software, hardware & wiring problem Highlight Problem with help User configure warning & Alarm alerts before segment fails Commissioning tool Digital Oscilloscope function (Lost telegram) Log of each event at DCS / HMI 26

27 Maintenance Practices in Digital World Process Level Diagnosis: Vendor s Solutions Impulse line chocking ph sensor deteriorated Coating on probe of magnetic pickup Shedder bar not vibrating due to internal or external reasons High temperature around the devices Controllability problem due to process fluctuation Inappropriate step taken by Operator (SP not followed) 27

28 Maintenance Practices in Digital World Communication & Networking: Asset Management ETHERNET Proprietary BUS HIS HIS HIS EWS HART Control Net Mod Bus PROCESS FIELD BUS OmROn AB PLC Device Net R I/O Optic Fibre TCP IP Local start / stop Panel with indication Touch panel 28

29 Maintenance Practices in Digital World Communication & Networking: Communication Peripheral Device Health: Camera Video Surveillance Enterprise Network Redundant Link Dual Homing Wireless Transmitte r Secure Access to Enterprise Network HiPER Ring Secure Access to Plant Floor Provision for current & Future Demands of the Industry like wireless integration, Security against Hacking & Spy worm etc. Network Traffic Control Integration of several industrial networking standards Cabling, Software Management, System Integration, Installation and Maintenance. Configuration of secure and reliable Networks in highly sophisticated i Industrial environment 29

30 Maintenance Practices in Digital World Communication & Networking: Measurement & Solutions: Camera 30 Video Surveillance Enterprise Network Redundant Link Dual Homing Wireless Transmitte r Secure Access to Enterprise Network HiPER Ring Secure Access to Plant Floor Communication Peripheral device Health Deterioration indication & replacement Bus cable termination quality Replacement of Cable on Physical health information Bus cable rerouting if interference is noticed Redundancy alert of Device Active / failure Updating the Anti virus, Firewall software High h temperature t alarm in & around the devices

31 New Concept: March towards Maintenance to Management 31

32 New Concept: Engineering System & Products Field Bus Foundation 32

33 New Concept: Engineering Practices Develop and Establish Good Engineering g Practices Avoid Unnecessary hardware requirement in the segment Advice client for Appropriate level of redundancy, only based on FMEA Design based on higher CAPEX saving and Safety in operation Advice client for vendor independent right choice of products Minimum cost of conversion for engineering having analog design (HART) to FF design 33

34 New Concept: Engineering Practices Use of SAP / Intool / Other Instrument engineering g design software integration with system software by DCS vendor for FF projects Directly downloading design data from Intool / Design software to system software for reduction in engineering time Develop good knowledge of FF products available in the market Update with Foundation Field Bus system and its developments Provide high fidelity documentation and training advice 34

35 New Concept: Software & Hardware Tools Development of software tool to provide advance information of deterioration by analyzing the degradation indexes which is determined based on the long term gathered data. Provide accurate information for spare parts requirement / management Provide information for the lead time between failure and first alarm initiated by the system Accuracy in failure identification / information Affect of surrounding condition affecting the process elements to increase the life of control element 35

36 New Concept: Software & Hardware Tools Auto device recognition and one stork configuration from off line engineering software tool Develop / encourage using more function blocks in device to reduce load on macro cycle time Signal / Noise reader: Handheld / DCS & report generator Universal Low cost FF Laboratory test instruments Noise control: originating from one spur (device) & traveling to entire segment 36

37 New Concept: Developments in FF Final release of ESD system specification for SIL system Flexibility to use more number of devices in each segment Reduction in function block execution time Reduction in Non schedule time in macrocycle Reduction in loss of cyclic communication data Tool for understanding loss of data transmission to improve process control Tool for verification of execution time of function blocks defined in macro cycle 37

38 New Concept: Macro Cycle Macro cycle time is divided in Cyclic Communication and Acyclic Communication 38 Cyclic / Scheduled Communication Function Block scheduling Function Block execution Gap between messages Acyclic Communication Alarms / Events Maintenance / Diagnostic Information Program Invocation Permissives / Interlocks Display Information Trend Information Calibration and configuration

39 New Concept: Macro Cycle Cyclic / Acyclic Communication Based on Function block requirement macro cycle time is allocated Macro cycle Limits the number of devices in one segment to accommodate loops based on execution requirement Pressure and flow loops are considered as fast loops Level,, Analyzers, Temperature and others are moderate or slow loops Function block execution time depends upon device manufacturer technology 1 sec macro cycle total time is considered good for better process indication / control in most of application 250 ~ 300 ms cycle time for fast loops like pressure / flow control Around 40 ~ 50% time is given for other Acyclic Communication 39

40 New Concept: Macro Cycle Limitation with less time allocation for Cyclic / Acyclic Comm. Acyclic Communication limits the number of devices in each segment Higher Acyclic time leads to poor performance and generate process disturbance Lower Acyclic time increases the device configuration time during commissioning Lower Acyclic time increases the calibration time of valves Valve signature of each valve takes more than 15 min, which makes impossible for maintenance engineer to take valve signature before and after shutdown Development for new maintenance management solutions and its implementation Limitation it ti for configuration and trouble shooting 40

41 New Concept: Macro Cycle New Proposed JS-Macro cycle definition: A.Use Macro cycle for Cyclic / schedule communication for process control function blocks B.Use Wireless communication for Acyclic / Non scheduled data communication 41

42 New Concept: Macro Cycle Gain from new Hybrid Product: Cyclic and Acyclic data shall get appropriate time for job execution More number of devices can be added in segment (CAPEX benefit) Acyclic time in macro cycle shall be limited to critical abnormality alarms only Both activities shall be independent and parallel to each other Better flexibility More diagnostic features are possible to be developed in system Configuration and calibration shall be faster even in plant running Performance will further improve if we use control on wire Audit trail management will be easy More Multiplexers l can be added d / optimize i in each segment 42

43 New Concept: Macro Cycle Gain from new Hybrid Product: Use of Foundation Field bus for control and wire less for Acyclic data communication will help to remove bottlenecking in performance Hybrid product shall encourage vendors to develop many more features and added advantages in future Two way communication to be provided (reading and writing) Great help during commissioning of device dx/dt will increase (X data, t time) No additional hardware needed for analysis Control valve signature will take lesser time Enhance parallel trouble shooting and efficiency calculation Gathering data without affecting good operation and fine control OPEX saving shall now become a reality 43

44 New Concept: Macro Cycle with Hybrid hardware ETHERNET HIS HIS / AMS EWS BUS dx/dt New Concept Hybrid model (FF with wireless) 44

45 Thank You 45 For more technical Information on Hybrid system concept please contact: Jasbir Singh i