Jasbir Singh. FFIC : Automation 2011 Mumbai Fieldbus Foundation

Transcription

1 Asset Management with Fieldbus Foundation Jasbir Singh

2 Essar Global Essar Energy plc* Essar Steel Essar Shipping & Logistics Essar Projects Essar Telecom Aegis BPO Business Essar Oil Essar Power (a) Upstream Total reserves and resources (incl. unrisked): 2,132 mmboe Significant ifi development and exploration upside in India and abroad Refining 14MMTPA capacity today; expanding to 20 MMTPA Securing international distribution/access to maximise margins Marketing c.1,370 retail outlets Increasing current capacity from 1,220 MW to 11,470 MW by 2014 Current operating plants Total capacity: 1,600 MW Plants under construction Total capacity: 9,670 MW Plants under development Total capacity: 1,800 MW Coal Blocks 450MT coal reserves across mines in India, Indonesia & Mozambique India Hazira Steel Complex 10 MMTPA integrated steel plant (b) Essar Hypermart Steel distribution chain North America Algoma Steel, Canada 4 MMTPA integrated steel plant Minnesota Steel Iron ore mine with resources of 1.4 bn tonnes & 4 MMTPA Pellet Plant Trinity Coal Block 188.6MT coal reserves across 6 mines in eastern Kentucky and southern West Virginia Indonesia P T Essar Indonesia 0.4 MMTPA cold rolling complex Essar Ports Operational Dry Bulk: 30 MMTPA Liquid: 46 MMTPA Under Construction Dry Bulk: 70 MMTPA Liquid: 12 MMTPA Essar Shipping Owns and operates 25 ships. One semi submersible rig and 12 land rigs. Fleet of lighterage and transhipment assets. 12 new ships and 2 new Jack Up rigs on order Essar Projects India Engineering Procurement Construction Fabrication Fully geared to execute turnkey EPC projects in India and overseas Essar Offshore Subsea Ltd Engaged in marine offshore construction Global Supplies FZE (UAE) (Essar owns 25%) Global procurement company Project Management & Consultancy Vodafone Essar 115 mn subscribers Essar Telecom East Africa GSM services in Kenya, Uganda, Congo (Brazzaville) Indus Towers (Essar owns 14%) One of the world s largest tower company 102,000 towers The Mobile Store Chain of over 1,300 retail outlets The Electronic Store Large format stores for Consumer Durables & IT products Aegis BPO One of the leading Global player in BPO and Service sector Caters to: Telecom Healthcare Financial services Travel & hospitality Consumer products Employee strength employees globally Integrated company spanning the oil & gas value chain Over a decade of experience in the Indian power industry Integrated, global steel producer International logistics provider to the steel, oil refining and power industries Provider of multi channel Leading EPC contractor with 40 year track record Significant player in the Indian telecoms industry CRM solutions to a blue chip, multinational l client base

3 Device Monitoring & Information Engineering g level information & Process Optimization Asset Management Operator information & control Advance Process Control &Ad Advance diagnosis, i DCS, Historical Data acquisition server Min ~ hours Secs Peer to peer Communication (Local Touch / Operator panels, Network & PLC Gateway) Field controllers Analog Devices, Transmitter, Recorder, Real time data acquisition server 1 sec m sec PLC to Field digital devices R I/O, Sensors, Drive control, AS-I FFIC : Automation Field Sensing 2011 Mumbai μ sec

4 Device Monitoring & Information Device in service Fault information Preventive Maintenance Predictive Maintenance Device Performance advance information Device & Process Diagnostic information

5 Device Monitoring & Information M A I N T E N A N C E Down time Operating Losses Product & Spares Inventory Manufacturing Cost Reduce Increase Product Yield Process Consistency Operation Reliability Equipment efficiency O P E R A T A B I L I T Y

6 Device Monitoring & Information Device Fault Alarm Device Diagnostic Information Process Failure / status Information

7 Device Monitoring o & Information o Device Fault Alarm Plant Sensors TI 4367 Plant Actuators Device Diagnostic Information FI 1211 LI 1167 Operations Personnel Process Failure / status Information

8 Device Monitoring & Information Business Development (Seamless Integration ) Advance Management APC & loop tuning Troubleshooting Continuous improvement Proc ess Performance diagnostic Device management Correction Preventive Maintenance Shutdown & Spares planning Predictive Maintenance

9 Device Monitoring & Information Asset Management with Technology: Increased reliability on software information Reduced dependability on people and the work process. Process improvement (get it performing) Maintenance optimization (keep it performing) Sustained performance of the most critical element for process control - the final control element. Minimize total downtime during shutdown Maximize MTBF

10 Device Monitoring & Information Corrective Maintenance (Reactive) Preventive maintenance (Schedule) Predictive maintenance (Condition Based) Performance Diagnostic Maintenance (Overall Reliability) S A V I N G

11 WHY ASSET MANAGEMENT IS IMPORTANT? Back up of device Historical Performance Comparison of Final element Service / Performance behavior Support to Semiskilled Operation and Maintenance personnel Improvement in skill set of maintenance staff Non dependence on individual s skill only Management with reduce experience level personnel Change in Input conditions of unit Change in production throughput Change in raw material New addition of complex processes and operation Flexibility of change management in the process demand from customer / quality

12 FINAL ELEMENT CHARACTERISTIC Stick slip Total stroke Stroke repetition Shut off count Valve travel distribution Shut off gap Ambient temperature Input/ Output deviation

13 FINAL ELEMENT CHARACTERISTIC (Signature) Software Diagnostic Features Profile Test Friction Test Comparison Trending Multiple Tests Multi-Dataset Analysis Batch Scheduling

14 FINAL ELEMENT CHARACTERISTIC (Signature)

15 FINAL ELEMENT CHARACTERISTIC (Signature) Signature (Multiple Graphs): Actuator Pressure Vs. Travel Actuator Pressure Vs. Time Valve Travel % Vs. Time Valve Travel Vs. Time

16 FINAL ELEMENT CHARACTERISTIC

17 FINAL ELEMENT CHARACTERISTIC (Act. Pr. Vs. Travel)

18 FINAL ELEMENT CHARACTERISTIC (Travel Vs. Input %)

19 FINAL ELEMENT CHARACTERISTIC

20 FINAL ELEMENT CHARACTERISTIC

21 FINAL ELEMENT CHARACTERISTIC

22 FINAL ELEMENT CHARACTERISTIC

23 FINAL ELEMENT CHARACTERISTIC

24 FINAL ELEMENT CHARACTERISTIC

25 FINAL ELEMENT CHARACTERISTIC (Step Response) Step response Graph of valve taken during commissioning

26 FINAL ELEMENT CHARACTERISTIC

27 FINAL ELEMENT CHARACTERISTIC

28 FINAL ELEMENT CHARACTERISTIC

29 FINAL ELEMENT CHARACTERISTIC

30 FINAL ELEMENT CHARACTERISTIC (Act. Pr. Vs. Travel) Signature graph of same valve taken after initial commissioning

31 FINAL ELEMENT CHARACTERISTIC (COMPARISON) Overlapping of two graphs of same valve taken at different interval

32 FINAL ELEMENT CHARACTERISTIC (COMPARISON)

33 FINAL ELEMENT CHARACTERISTIC (PST)

34 FINAL ELEMENT CHARACTERISTIC (PST)

35 FINAL ELEMENT CHARACTERISTIC (PST)

36 FINAL ELEMENT CHARACTERISTIC Over a period of time, control valve packing requires tightening depending on the packing material and wear and tear inorder to avoid fugitive emissions Output to valve

37 LOOP CONTROL CHARACTERISTIC (CONTROLLABILITY)

38 LOOP CONTROL CHARACTERISTIC (CONTROLLABILITY)

39 FINAL ELEMENT CHARACTERISTIC Software Report Analysis & Issues Need skilled / expert maintenance engineers to analyze / interoperate the Graphs Supplier supports / Training becomes essential for diagnostic analysis Signature is only possible during service outage of valve Dedicated engineer to use opportunity for signature during small stoppages Decision making for servicing / maintenance not easy for continuous and long running plant Difficulty for planning of long lead spares based on signature Signature of valves takes long time

40 Thank You Fieldbus Foundation India Committee 21 st September,