6 implementing ff in kgd-6 gambhir

8/12/2019 6 Implementing FF in KGD-6 Gambhir

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2011 General AssemblyMumbai, India

Implementation of FF in KGD6

Harvindar Gambhir/MadhuriAllika

Vice President/Manager

Reliance

Place Company

Logo Here


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1994 2011 Fieldbus Foundation2

KGD6-General informationOnshore Gas Plant and Offshore Platform.

Distance between them is 25KM.Master Control system used for Well Controls.

FF technology for Control.

IS design

Total no of DCS/ECS controllers: 68, distributed

over 12 buildings


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Integrated Control system block Diagram

SUBSEA CONTROL CENTRE HOOFFSHORE PLATFORM

Data Transfer to HO(via Fibre)

CENTRAL CONTROL ROOM (CCR)Distributed Control System (DCS)

Emergency Shutdown System (ESD)

Sub-sea Control System(SCS)

Fire & Gas Detection (F&G)CCTV System

M05M0

9

M07

M06

M04

M03

Safety Guarding System(ESD, F&G CCTV)

BACKUP CONTROL ROOM

BACK-UPCOMMUNICATION

(MICROWAVE )

FIBRE OPTIC LINK

SCADA for pipeline

Emergency Shutdown System (ESD)Fire & Gas Detection (F&G), CCTVSystem

F I B R E

OP T I C L I N K

R E D

U N D A N T

ON SHORE TERMINAL


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IO CountSystem Conventional

(including HART)FF Serial

DCS 7500 1300 135000

ESD 3600

FGS 1200

220 FF Segments

250 Cabinets (including System, Marshalling,

Server, Network and PDB cabinets)

Few critical control loops taken on HART


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FF General ChallengesDURING DESIGN PHASE

Grouping of devices --Quantity of Devices,Location of devices, loop criticalityCritical Valves

H-1 RedundancyMacro cycle Execution TimePower ConsumptionSegment Length


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SolutionUpfront collaboration of design with Consultantand System vendor to avoid design problems.

DCS supports EDDL (Electronic Device

Description language) & FDT (Field device

Tool). So field devices --vendor independent.

Used High Power Trunk concept.

4 H1 segments per interface Card, so reduced

cabinet foot print.


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SolutionUsed DCS Vendor interoperability test lab in US

and Mumbai for upfront device type testing and

creation of templates.

Training for all Project, O&M personnel.

Used Advance Diagnostic module

One Team of RIL(Project, Constr, Maintenance)

& DCS vendor during implementation.

Audits


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Design Pre-requisitesP&IDs

Plot Plan, 3D model

Area Classification

Foundation Field bus Specification (ProjectSpecific)

List of Critical Control LoopsControl Narratives (process control strategy)

I/O Lists


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Segment DesignSegment length (Total of the trunk and all the spurs)

Device Assignments to Segments

Critical Loops : Use of redundant H1 interface cards &

power supplies.

Primary and Backup LAS


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When a control loop has multiple inputs, all the input

devices shall be on the same segment.This shall also apply to Cascade loops where the

master/slave shall reside on the same segment.Transmitters on duty/standby pumps, assigned to two

different segments.

Segment Design


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The voltage at each device should not be less than

13 VDC. The minimum for any device to operate is 9

VDC. The additional 4 vdc provides for segment

growth.

Make sure the total current draw for all devices on

the segment is well within the capacity of the

segment power supply about 350 mA.

Segment Design


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KGD6 Design Features


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KGD6 Design Features

Maximum of 12 devices per segment.

Maximum 3 Control Valves per segment.

However installed 2 control valves in mostof the segments

Macro cycle for all the segments is

maintained at less than 1200 msec


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KGD6 Design FeaturesOnly 1 Fieldbus device per spur

Max segment(trunk + all spurs) length - 1600 m

Spur length - 90 m

All FF devices are Entity compliant

No Repeators


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The method of protection is a high power trunk Hybridconcept. This method uses Increased Safety (Ex e)

protection for the Field bus Trunk.

IS spurs by using field mounted 4 channel Field Barriers.

This implementation allows full access to the field devices

when they are energized inside the hazardous area.

The spurs are galvanically isolated from the trunk and from

each other, have spur surge protection.

KGD6 - Design Features


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KGD6 - Design FeaturesDCS system in KGD6 is I/A system.

Segment Allocation carried out by Engineering

Consultant and approved by RIL

Segment macro-cycle validation carried out by DCS

vendor and approved by RIL

Control functionality in DCS, not in field.

Primary FBM 228 module is acting as a link activescheduler; secondary FBM 228 module as back up LAS


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MacroCycle Calculation Tool


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FF JB

It may be installed in a Zone 1 T4 IIC hazardous area.

12 intrinsically safe spurs. EEx ia IIC spur connections. Bus powered

Fieldbus barrier modules replaceable under power in Zone1 hazardous area

EEx e trunk wiring connection

Integrated fixed fieldbus terminator

Compatible with Entity and FISCO field devices

Spur surge protection provided for extra safety


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Spur

Trunk

FCP270

FBM228

FF Segment Interconnection

ADM

23

I-JB

FP32 SurgeProtectors

FCS-835112-way JB


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ADM (Advanced Diagnostic Module)

809FMTL --for physical layer diagnostics

Installed on the base plate and providesdiagnostics of 8 segment.

Diagnostic information of FF devices is also

available in Asset Management System

through Block error parameter


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5-pair or 10-pair overall and individually shielded

Trunk cables from system cabinets to intermediate junction boxes located within the various plant areas

Single pair cable run between the Intermediate FFJ-Box and the FF Spur J-Box and to the devices

Cables and Grounding


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Earthing Arrangement


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Shield are cut and taped to avoid any possibility of inadvertentgrounding at the device end

Safety (case) ground of FF devices, Intermediate FF Junction

Boxes and FF Spur Junction Boxes are made at each

component.

Cables and Grounding


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Interoperability-Field DevicesDevices shall have a Check mark logo which signifies

that the device is approved by Foundation Field bus

Device shall be certified as passing the ITK 4.61 or

later

Latest version of DD (Device Description), CFF

(Common File format) files shall be provided by the

Seller.

Hand Held Communicator shall be upgraded at

regular intervals


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Interoperability-DCSEnsure DCS supplier with the FF solution have

been tested extensively

The Field bus Foundation does not give a tick

marking(Logo) for host systems.

Host Interoperability Support Test in accordance

with FF-569.

DCS FAT included verification of interoperability of

the HOST system with each type of FF Device


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Devices tested in FAT for InteroperabilitySr. No. Supplier Description Model

1 Emerson Radar Level Transmitter 5402AF

2 Emerson Radar Level Transmitter 5301FA

3 Emerson Radar Level Transmitter 5402AH

4 Emerson Radar Level Transmitter 5301HA

5 Emerson Pressure & DP Transmitter 3051S

6 Emerson Pressure & DP Transmitter 3051CD

7 Emerson Temperature Transmitter 644HF

8 Emerson Temperature Transmitter 3144PD

9 Emerson Coriolis Mass Flow meter 2700R

10 Emerson Vortex Flow meter 8800DF

11 Emerson pH Transmitter XMT-P-FF-10-73

12 Emerson FF Valve Positioner DVC 6000f13 K- Patents MEG Analyzers IT-RM-GP

14 Chemtrols O2 Analyzers 3020T-H

15 GE Sensing Ultrasonic Flowmeters GF868

16 GE Sensing Ultrasonic Flowmeters XMT868

17 Dresser Valves Displacer type Level Transmitter 12322-058


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Device Installation and CommissioningWhat we used to test, calibrate and configure?

HART 375- Used for Addressing, tagging &

Configuration of FF devices

MTL Relcom FBT 6- Used for segment parameters

and diagnostics

Beamex MC5: For Calibration, tagging , Addressing

and configuration

32


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Installation Practices

Some contents and photographs in

this section are from variousaudits conducted at KGD6 site.


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Bring the inner jacket through the cable gland into the JB. This is to make sure

the overall shield and any individual pair shield do not accidentally make contact

with the gland and the JB ground


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2011 General Assembly

Mumbai, India


Cable Termination in FF cabinet

Inside jacket removed close to the

termination points such that the min. am t. of

individual pair shield is exposed.

At the point where the jacket is

Removed, place a 2 heat shrinksection over the area to maintain integrity

and label the cable.

4 of the 5 Pair terminate at the FP32 Surge protectors. The extra Pair terminates to the

standalone Grounded terminations below the FP32s. Overall shield terminates to the

standalone Grounded terminations


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Cable Termination in FF cabinetEnsure that the shields

of individual pairs are

maintained.

Place sleeve over eachindividual pair shield drain wire

and the overall drain wire


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The shield drain wire must be cut back to

the shield foil and isolated under heat

shrink so it does not touch the instrument

case.

Cut the signal lines as short as possible to

make the instrument connection. Spare

wire has the possibility of getting caught in

the threads and cutting the insulation thus

shorting out the signal to the case.


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Lessons Learnt

Take care of grounding

Avoid sharp bends as same can distort the

shield and also may cause shorts.

Do not untwist the Twisted pair cable

Do not loop the FF wiring in the tray and in

cabinets

Turn off the barrier Terminators


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Lessons LearntEnsure that device addresses are unique and

between 18 and 247

To reduce Commissioning time each FF device

shall be pre-configured by the Device seller with

Device tag and Channel address setting.

While removing a live FF device formaintenance, take the device in OOS mode (Out

of Service mode) and then remove the device


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Dedicated specifications for FF implementation &FF cables

Ensure all field devices procured are type tested

Ensure all devices with FF check markTraining on installation and maintenance by experts

Ensure proper cable laying and terminations

Criticality study/Control risk assessment

Audit by FF expert, by experts within the company and by

DCS vendor experts. Implementation of audit points

Macro cycle verification

Snap shots of all segments for record ADM report

Summary -Implementation steps KGD6


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Consider using control in the field for non-critical loops.

As long as the segment retains power (and one device

has backup LAS), automatic control can be maintained

in the field devices.

Non-Redundant FF H1 cards can be used on all non-

critical segments; however a spare slot shall be left

adjacent to each H1 card to allow for redundant card inthe future if required.

Future suggestions


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Thank You

This presentation is dedicated tothe team comprising of :

RIL, Vendors, Consultants &Contractors

who made it happen

6 implementing ff in kgd-6 gambhir

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