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Foundation Fieldbus Experiences in Shell

Bindert Douma; Senior Consultant Measurement, Instrument & Plant Automation

Presentation Outline

• Introduction - Foundation Fieldbus (FF)

• Benefits/Risks• Shell Group experiences• Summary

Shell Global Solutions

Houston

ThorntonRijswijk

Amsterdam/ The Hague

Kuala Lumpur

Calgary

Bangalore

Combining the operating experience of over 5000 staff with proven implementation skills and advanced technologies

• Over 50 years of implementing business and engineering solutions

• Diverse cultures and nationalities

• Continued investment in innovation

Measurement, Instrument and Plant Automation

Delivery Group located in The Hague (NL), Amsterdam (NL),Rijswijk (NL), Thornton (UK), Houston (USA), Calgary (Can), KL (Mal), Bangalore (India) ~100 staff.

Technical Services & Project Support primarily for Refinery, Up-stream and Gas businesses - both Shell and 3rd party customers.

Vendor independent advice & operational experience

R&D budget for development of new products & services.Working closely with Strategic Suppliers – 4 DCS suppliers.

Support for early implementations of new developments.Corporate Implementation Teams - key to success of new technology up-take

Technology - Traditional

Control - DCS

Process control:500 - 2000 measurement and control points per process unit

Up to 15000 - 25000 per plantSignal Cables 4-20 mA

Smart Computer talks to

dumbdevices

P

T

L

F

Process Unit

Technology – Foundation Fieldbus (FF)

P

L

F

Automation and

Display Systems

ProcessUnit

A digital, two-way multi-drop communication link among intelligent measurement and control devices, and automation and display systems.

LANSmart

Computer talks to

Smart devices

Vision & Expectation for FF

Promises from Industry:Open System Architectures with FF technology will provide:

Enabling Platform for Operational Excellence andReduced Capex and Opex

• Time & cost effective automation project execution• Enable fast commissioning• Provide improved reliability/availability• Enable unmanned operations• Enable remote operations support• Enable pro-active maintenance schemes

Our Route from Vision to FF Implementations

VisionDevelopment

Testing

Early Adopters

1996 2001 2003

Technology acceptanceand up-take

2005 2007

Relevance of End-user Testing• End-user testing has been important

- To provide feed-back on early Industrial developments - hardware, infrastructure

- To check basic interoperability- To build up own knowledge

• A representative test environment has been essential as technology demonstrator, to grow End-user confidence

• Testing is essential to evaluate End-user value - applications- Diagnostics- Asset Management- Overall integration

• A representative test environment is essential to provide training facilities

11Shell Global Solutions

Technology Up-take within Shell

EPM HW

NI Bus Mon.NI Config.

Yok.

bus supply (redundant)24 VDC

DCS-controllerI/O card(s)

DCS systems:

SmarEPM

Valtek

Foxboro

Yokogawa: CS3000; StardomEmerson: DeltaV 7.3Honeywell: Experion PKS R201, R300ABB: Industrial IT 800xA; under testFoxboro: IA system; under test

HW

29 devices:

Burkert

P&FE&H

H1-bus (1)

H1-bus (2)

Samson

Metso

H1-bus (3)

EPM

Yok.

P&F

FF Test Facility at SRTCA - Lay-out

Projects Experiences

Our Route from Vision to FF Implementations

VisionDevelopment

TestingStandard

Early Adopters

BroadProjects Up-take

Support functions& Guidelines,

Training

1996 2001

Lessons Learnt

2003

Technology acceptanceand up-take

2005 2007

FF DEP11Shell Global Solutions

Technology Up-take within Shell

EPM HW

NI Bus Mon.NI Config.

Yok.

bus supply (redundant)24 VDC

DCS-controllerI/O card(s)

DCS systems:

SmarEPM

Valtek

Foxboro

Yokogawa: CS3000; StardomEmerson: DeltaV 7.3Honeywell: Experion PKS R201, R300ABB: Industrial IT 800xA; under testFoxboro: IA system; under test

HW

29 devices:

Burkert

P&FE&H

H1-bus (1)

H1-bus (2)

Samson

Metso

H1-bus (3)

EPM

Yok.

P&F

FF Test Facility at SRTCA - Lay-out

Technology ready for

utilisation in Projects

FF Project Implementation from 2001 FF Implementation Support Team – 7 global staff

• FF Implementation Support Packages- Technology awareness package

• Consultancy for technology decision- Business Case analysis

• Practical project implementation support- URS, MAC selection, Design input, Design verification,

FAT/SAT, Trouble shooting, Training, PIR

• FF DEP (Design & Engineering Practice)- Safety requirements, topology, cable choice, cable routing,

redundancy, spare capacity, segment loading

• Capture first operational experience after 12 – 18 months; input to lessons learnt and guideline improvement and close the loop

Some specific Project experiences• Malampaya – New building; Up-stream - Early Adopter• Nanhai – New building; Large Chemical Complex• Norco – Re-instrumentation; Hydrotreater• BAR – Re-instrumentation; Offshore platform

Experiences from Malampaya -1Key-drivers• High Reliability/Availability• Future Unmanned Operations• Reduced Maintenance

Installation Details• 1600 FF devices, • > 80 % CIF,

Experiences from Malampaya -2Start up 2001

Capex Savings - compared to conventional systems

• Platform: + 22% - due to Eexi implementation(1)

• OGP: –13.5% - Eexd implementation

Main Benefit• High process availability - PCS reliability, CIF• Reduced manning – remote control, diagnostics• Fact based decision via all extra

information – diagnostics/asset management

(1) Would be different to date

Key-drivers• Create and infrastructure for ‘DCS anywhere ’• Create an infrastructure to enable efficient and cost-

effective maintenance planning & execution.

Installation Details• >13,000 FF devices, • 6036 segments• 16 FAR’s, • 3 CR’s • Start-up early 2006

Experiences from Nanhai – 1

Design• Conservative Design Guidelines

- GL: Max 8 dev/segment- Result:< 3 dev/segment

• For Process Automation, one PMC + 9 major EPC’s- Yet FF for most skid packages

• Design and design validation with INTools• 85% Yokogawa field devices – single vendor approach• At start-up no CIF

Experiences from Nanhai – 2

Commissioning• Useful Interoperability test at Yokogawa on all utilised Tx• 7-10 dev/day-team• Version problems with Tx in Packaged Systems

- Not clear to Yokogawa Tx were ordered for Nanhai Project

• Insufficient use of PRM- More training up-front

• No problems to implement basic control functionality

Experiences from Nanhai – 3

Experiences from Nanhai – 4

Unhealthy status FF devices

7%

4%

15% 14%

3%

6% 6%

1%

13%

0%

2%

4%

6%

8%

10%

12%

14%

16%

LOP

SMPO

EO/EG

Utilitie

s

HDPE

LDPE PP

Polyols

Logis

tics

Key-drivers• Replace obsolete system

- Re-instrumentation of 1980 constructed instrumentation and control of Gasoline Hydrotreater Unit

- From pneumatic system to Yokogawa CS 3000 DCS system

Installation Details• 1379 devices• 245 segments• Average 5.6 devices/segment

- min 2, max 12• No CIF• Hot cut-over

Experiences from Norco Olefins - 1

Design• January 2004: Start design and engineering• Clear functional spec up-front• FF Design Guidelines

Commissioning• 3 field teams, one CR team• On average 14 dev/day• January 2005: Cut-over completed

Experiences from Norco Olefins - 2

Experiences from Norco Olefins - 3

The End Result• Better process stability• Less nuisance alarms• Great DCS reliability• Better data quality

Experiences from Norco Olefins - 4

Experiences from Brent AlphaInstallation Details BAR

• 165 FF dev, • 24 segments,• Initially no CIF,• Commissioning 2002/03

Capex Savings - compared to conventional systems• No quantification available• No shut-down required for commissioning; commissioning per

wellhead; commissioning time 2h per well iso 24 h per well; less people needed

Main Benefit• No deferred production• Unmanned operations over night – control from Brent Bravo

Actual Project Implementation

Larger Systems have DCS, F&G, Safety Systems

Hart/Classic I/O

FF I/O

AS-I, DP, DeviceNet FF

Linking DeviceHSE-

FF device

Project Support• Where to apply FF - architecture

• How to apply FF – guidelines/DEP

Next steps in FF technology development

• Grow FF contents in Projects – increase % IO coverage- FF for SIS / Demo; development ongoing- FF for F&G / First products for testing available- (FF HSE for analyzers)

to better utilize FF technology benefits, both in Projects and in the Operational Phase.In this context FF SIS is a key initiative, strongly supported.

• FF SIS technology will grow the diagnostics coverage factor in operating facilities and as such support the Safety Compliance aspect.

Amsterdam SIS Demo

Smar Temperature

HIMA Logic Solver

Emerson Valve

Level Siemens

HIMA Logic SolverConfiguration Tool

Yokogawa Asset Management

Yokogawa BPCS

Level Magnetrol

H1 H1

Pressure E+H

Pressure Yokogawa

Pressure Smar

Westlock Positioner

SoftingLinkingDevice

SoftingLinkingDevice 123

Softing DeviceConfiguration Tool

HSEFCS

Configuration Runtime

Ethernet

Segment # →H1

RuggedCom Switch

P+F

Moore

MTL

Metso ValveNon-SIF

DO

RuggedCom Switch

HSE

HSE

SIF Protocol

H1

SIFSIF

SIF

2oo3

Strategy to Introduce New Technology

Technology pushTechnology pull/Solutions offering

• Create technology awareness; project sessions, seminars, workshops

• Assess benefits and risks; risk management plan

• Technology choice & management buy-in

• Provide implementation support incl. Risk ManagementUse Lessons learned from previous projectsTrack early operational experience

Summary• FF is widely used in Projects

• Company wide, both green field and brown field• Recommended standard for projects since 2001• Major up-take since 2002 - > 160,000 FF I/O’s in Projects• No more risk than traditional technology

• Great saving potential in Capex, but mainly in Opex

• Status of FF developments and application experience is different for various vendors

• Implementation Support Packages & FF DEP available

• Early and broad technology training is essential

• Ongoing development to broaden the FF applicability