Foundation Fieldbus at Suncor Firebag. Where s the Value?

Transcription

1 Foundation Fieldbus at Suncor Firebag Where s the Value?

2 Wes Meger Director Stonehaven Quality Controls Ltd. Control Systems Lead for Suncor Firebag Operations >28 years of oilfield experience. 2

3 Legal Notice This presentation contains certain forward-looking statements, including statements about Suncor's growth strategy and expected future production, operating and financial results that are based on Suncor's current expectations and assumptions. The forward-looking statements, identified by words such as targets, strategy, estimates, pending, plans and objectives, are not guarantees of future performance. Actual results may differ materially as a result of risks, uncertainties and other factors, such as changes in general economic, market, regulatory and business conditions; fluctuations in commodity prices and currency exchange rates; the successful and timely implementation of capital projects; the accuracy of cost estimates; labour and material supply issues; and uncertainties resulting from potential delays or changes in plans, among others. See Suncor's current Annual Report and other documents Suncor files with securities regulatory authorities for further details, copies of which are available from the company. The forward-looking statements speak only as of the date hereof and Suncor undertakes no duty to update these statements to reflect subsequent changes in assumptions (or the trends or factors underlying them) or actual events or experience. Unless noted otherwise, financial information is for the most recent quarter or year end. A boe conversion ratio of six thousand cubic feet of natural gas: one barrel of crude oil is based on an energy equivalency conversion method primarily applicable at the burner tip and does not represent a value equivalency at the wellhead. Accordingly, boe s may be misleading if used in isolation. 3

4 Suncor Energy at a Glance Integrated energy company - upstream, refining, & marketing, pipelines and wind power Market capitalization $42 billion (US$38 billion) Original and single largest investor in the Athabasca oil sands Production capacity of nearly 300,000 BOE/day More than 5,000 employees Sustainability: benefiting all stakeholders Standardized on Foundation fieldbus for all new projects ($10B over next 6 years) 4

5 5

6 Black Gold Athabasca Deposit > 42,000 km billion barrels in place 30 billion mineable reserves 142 billion in-situ reserves 6

7 Mining 7

8 SAGD In-Situ 8

9 Firebag Land Position Area extent: 1180 km 2 Independent estimate: ~ 10B barrels 9

10 10

11 11

12 Why use Fieldbus? Total Installed Cost Savings (TIC) Reduced wiring Smaller footprint Faster commissioning Total Lifecycle Cost Savings (TLC) Instrument diagnostics Predictive maintenance 12

13 Expert Opinion Suncor had no previous FF experience What did the experts think? It s too risky to put all those end devices on a single pair of wires!!! Engineering is more complex, thus more costly!!! There are too many calculations!!! There are too many limitations!!! It s too complicated to learn. Engineering staff will need extensive training, and field staff will need to be network experts!!! It s too expensive!!!!! It won t work!!!!!!!! 13

14 The Validation Process Interest in Fieldbus Benefits of TIC Benefits of TLC Gather data on Benefits Investigate Risk Use FF on Pilot Y Successful Vendor FAT testing Y Successful SAIT Stress Test Y Test FF during Pilot Startup Commissioning! Training! Operations! Vendor Presentations Other Users Papers, etc. N N N Reject Fieldbus & Use Classic Instrument N FF Testing Validates Savings & Risks Y Use Fieldbus On Firebag Commercial Phases 14

15 SAIT Testing Stress test the Host and FF Provide hands-on experience with live system SAIT - accredited training, lab, neutral testing site and resource for other vendor equipment Validate design-normal conditions # of devices, cable lengths, voltages, timing Test design guidelines for FF commercial application Explore the limitations and failures abnormal conditions Devices with/without DD files Connect and disconnect components Excessive terminations, instruments, voltages Cross segment communications and control Remove host, terminator, short circuits, etc 15

16 Stress Test Results Control works well on segments as per design guidelines Process control is maintained with loss of host using controlin-the-field Disconnect and reconnecting devices has no adverse effect Short circuits act as anticipated Failure modes are as anticipated Stress Test successful and validated FF use for commercial operation Final grade A- 16

17 Pilot Commissioning Pilot - unique approach Conventional 3 men, 48 hours, 48 devices Fieldbus 2 men, 24 hours, 109 devices Results FF devices in 1/6 the time Troubleshooting wiring is very simple Firebag Phase 1 Estimate (conservative).25 hr/trans hr/valve = $57,750 17

18 SIFT Testing (System Integration Function Test) Cannot be done the old way MIMIC simulation software that can interface to host directly and will simulate Fieldbus I/O and devices along with control-in-the-field. Suncor used this product for both Stage 1 and Stage 2 to test configuration and graphics prior to system leaving for field, > 95% debugged. MIMIC has being enhanced to include DeviceNet and Profibus. 18

19 Commission Results Stage FF devices, 275 control valves 1320 Conventional signals 150 AI, 45 AO Late May to late August, person crew 5.7 per day Power down checks Commission to system Function check Verify HMI indication and alarms Ran post-installation valve signatures to identify installation errors Commissioning is faster Field staff picked up FF easily with little training All staff want to work FF commissioning when choice available E/I Techs needed to adapt way of thinking go to console first Stage 2 results very similar utilizing approx 400 HART devices. Faster due to utilization of software in central console. 19

20 Stage 1 & 2 Positives Generally acknowledged that 75% of all start-up delays directly relate to instrumentation and controls. Firebag Stage 1 & 2 E/I not only did not cause any delays, but were easily on schedule throughout commissioning. Faster start-up = earlier production = $. 20

21 Start-up Results 50% of devices require checks with 70%+ (no problem found) Operators are learning the plant. When they don t understand what is happening they tend to doubt the instruments. Troubleshooting is much faster Many activities reduced from 90 min. to 10 min Operating plant needs hot work permit for entry Permit operator not available 20 people lined up for permit With FF most troubleshooting is successful from the console with no permit required 21

22 Vortex meters Production pads are 3.5 km from the plant CCR lower flow rates were required during start-up 40 meters could all be re-configured and low flow cutoff removed from the CCR with no travel required Corriolis meter Ease of observing the health of instrumentation by observing the right & left coil voltages and live zero value MOV Motor Operated Valves (MOV) on feedwater pumps and tanks have analog values in addition to on/off Operator can select desired valve position for testing or abnormal operation 22

23 Start-up Negatives 8 10 electronics failures HI_Lim parameter on one type of vortex Less functionality in FF configuring EDDL to solve? No factory valve signatures on vendor packages Heat related issues with power conditioners, breakers and motor monitoring equipment Failures on two multi-port connectors 23

24 Temperature Issues 24

25 Turnaround Valve signatures resulted in only 8 of possible 32 valves being pulled and serviced. Had time to do signatures on all critical 1 valves, identified 1 that required immediate attention. Able to easily complete all necessary tasks and respond to emergency work 25

26 Too Risky? Chicken foot topology field device wire, FF or 4-20, identical if cut Home run cable more catastrophic event (many instruments) Reliability of FF and 4-20 identical with control-in-host Reliability of FF increases with control-in-the-field Redundancy of power conditioners is recommended 26

27 Engineering is more complex? Segment layout more complex. Not really that hard, use HAZOP process if necessary. Point/tag configuration is more time consuming (more parameters + more options). Additional engineering costs 10% but can be mitigated (offline config, libraries) Engineering drawings and database input is less. Engineering drawings savings 40% for segment drawings over conventional loop drawings, simply from less terminations 27

28 Too Many Calculations? Use calculations and tools to develop guidelines for normal system design Use calculation tools to check extreme applications Allow the host system to calculate and optimize the macrocycle for normal operation. Manual intervention only for special or complex applications 28

29 Too Many Limitations? Limits include: # of devices, # of VCRs, power distribution, voltage drop, signal attenuation, and signal distortion All host Fieldbus systems are not created equal Develop guidelines early for # of devices, types, function block locations, topology, and this will allow for ease of engineering while meeting all limitations Firebag used 12 devices, 4 valves, 50 meter spur, 1100 meter homerun, control-in-the-field, PID in the valve etc. 29

30 Too Complicated to Learn? Fieldbus training at different levels 1 hour overview Multi-week Fieldbus technical training Owner and EPC staff all need FF training Minimal training for most involved Detailed training for small design & support group of specialists Accredited FF training SAIT/LeeCollege/Foundation Vendors and websites Relcominc.com/Plantweb.com/Fieldbus.org 30

31 Too Expensive? Suncor Firebag Foundation Fieldbus vs. Conventional 4-20 ma Design Basis 1200 devices with 280 control loops Stage 1 Fieldbus savings Instrumentation Wiring Control System Terminations Construction Rework Loop Drawings/ Engineering Total FF Savings Cdn $ +480, ,831 +4, ,900-27, ,555-57,136 A (+) number represents added costs and a ( ) number represents a savings. 31

32 Going Forward Firebag Maintenance Strategy Value Based Maintenance Value Based Maintenance is the strategy to improve the reliability of systems and equipment by managing the risks associated with each based on safety and economics. Value = Benefit derived Cost of Implementation The main objective is to identify the items that are potentially critical with respect to EH&S and production and analyze them with Failure Mode and Effect Analysis. Specific failures are targeted and solutions are applied, thus lowering the consequence and or frequency. 32

33 Preventative vs Predictive Preventative Maintenance is inherently inefficient; Must be scheduled to repair problems before they occur, usually end up conservative. Labor and materials are utilized whether necessary or not. Effectiveness is reduced if scheduled too late. Predictive Maintenance (Condition Based Maintenance) is a plan to predict failures before they occur; Requires frequent monitoring, trending and analysis of critical parameters. Predictive monitoring adds no value until information is analyzed and action is taken. 33 Should trigger Preventative Maintenance.

34 Valve Example % Efficiency Process Upset Valve Failure % VALVE WEAR REPLACE VALVE (HIGHEST COST) REPAIR VALVE ADJUST VALVE (LOWEST COST) HIGH NORMAL WEAR / DECAY LOW NORMAL WEAR / DECAY PROACTIVE ZONE REACTIVE ZONE 34 TIME > Equipment Fault Process Upset Loss of Efficiency Range

35 Implemented FF Alert HMI graphic Using Bad_PV parameter for automatic failover Valve signature baselines Travel Deviation Cycle Counter Valve Signature Step Response Dynamic Error Band Drive Signal Output Signal etc... Configuration Status / Alerts Diagnostics Calculations Electronics Failure Sensor Failure Process Condition Configuration Warning RTD Drift RTD Life Estimation etc Electronics Failure Sensor Failure Process Condition Configuration Warning Plugged Impulse Lines etc... ph Electrode Aging Glass Electrode Failure Reference Electrode Failure Reference Electrode Coating Reference Electrode Poisoning etc... Electronics Failure Sensor Failure Reverse Flow Empty Pipe Calibration Error Process Condition Configuration Warning etc...

36 Potential Transmitter Diagnostics Device health Plugged sensing lines Sensor failure, etc. Control Valve Diagnostics Device health Travel deviation Packing friction, etc. Machinery Diagnostics Motor-pump health Vibration Cavitation, etc 36

37 Potential for Headache Transmitter Diagnostics Device health Plugged sensing lines Sensor failure, Control etc. Valve Diagnostics Device health Travel deviation Packing Machinery friction, etc. Diagnostics Motor-pump health Vibration Cavitation, etc Transmitter Diagnostics Device health Plugged sensing lines Sensor failure, Control etc. Valve Diagnostics Device health Travel deviation Packing Machinery friction, etc. Diagnostics Motor-pump health Vibration Cavitation, etc Transmitter Diagnostics Device health Plugged sensing lines Sensor failure, Control etc. Valve Diagnostics Device health Travel deviation Packing Machinery friction, etc. Diagnostics Motor-pump health Vibration Cavitation, etc Transmitter Diagnostics Device health Plugged sensing lines Sensor failure, Control etc. Valve Diagnostics Device health Travel deviation Packing Machinery friction, etc. Diagnostics Motor-pump health Vibration Cavitation, etc Transmitter Diagnostics Device health Plugged sensing lines Sensor failure, Control etc. Valve Diagnostics Device health Travel deviation Packing Machinery friction, etc. Diagnostics Motor-pump health Vibration Cavitation, etc Transmitter Diagnostics Device health Plugged sensing lines Sensor failure, Control etc. Valve Diagnostics Device health Travel deviation Packing Machinery friction, etc. Diagnostics Motor-pump health Vibration Cavitation, etc Transmitter Diagnostics Device health Plugged sensing lines Sensor failure, Control etc. Valve Diagnostics Device health Travel deviation Packing Machinery friction, etc. Diagnostics Motor-pump health Vibration Cavitation, etc 37

38 Future Interfacing with CMMS use FF to trigger workorders FF alerts triggered by devices Software application filters based on priority and reliability data Filtered alerts passed on to CMMS with diagnostic message and remedy Utilize OpenO&M Many potential uses CMMS can raise priority on increased frequency CMMS can issue follow-up workorder on calibration failures CMMS can issue follow-up workorder if new device not suitable 38

39 Future Statistical Process Monitoring Resides in device ms scan time Can detect flutter on a furnace or boiler flame Can it detect steam/water hammer? 39

40 Summary Suncor Firebag Operations (field and management) still very much committed to realizing benefits of fieldbus technologies. Resources allocated for planning and implementation, and to set standards for future phases. Working with Vendor to piggy-back on other end-user experiences. 40

41 Questions? 41