Building PETRONAS Capability Through Fieldbus Testing ZULKARNAIN - - PowerPoint PPT Presentation

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Building PETRONAS Capability Through Fieldbus Testing ZULKARNAIN - - PowerPoint PPT Presentation

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Building PETRONAS Capability Through Fieldbus Testing ZULKARNAIN DARUS Principal Engineer Group Technology Solutions PETRONAS Malaysia End-User Seminar 1 11 November 2009 INTRODUCTION FOUNDATION Fieldbus (FF) is 10+ years in the market

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Malaysia End-User Seminar 11 November 2009

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Building PETRONAS Capability Through Fieldbus Testing

ZULKARNAIN DARUS Principal Engineer Group Technology Solutions PETRONAS

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Malaysia End-User Seminar 11 November 2009

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INTRODUCTION

  • FOUNDATION Fieldbus (FF) is 10+ years in the market

but utilization in PETRONAS is low.

  • Installation based in PETRONAS:

– PPMSB: 1500 + 200 = 1700+ devices – PFK: 200+ devices – NPK: 800+ devices – Carigali:

  • SUPG-B: 290+
  • SUJT-C: <100
  • SUDP-A: 200+
  • GTS believes that FF can bring

– Cost savings – Online asset proactive / preventive maintenance

  • BAJT-H
  • KNPG-B
  • KNJT-C etc
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Malaysia End-User Seminar 11 November 2009

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CURRENT ISSUES WITH FIELDBUS IN PETRONAS

  • Level of competency for O&M personnel

– Different tools – System software competency required

  • Hardware issues

– Field barrier failure – H1 card failure – Device drop out for no apparent reason

  • To address these issues and start building

PETRONAS capability in fieldbus system, GTS and UTP collaborated and…

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UTP FOUNDATION FIELDBUS LAB

  • Lab was set up in Aug

2008

  • Officially launched by

Rector of Universiti Tekonologi PETRONAS (UTP) in Nov 2008

Field instrument rack: 25+ devices Host stations Host controllers: 4 systems

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Malaysia End-User Seminar 11 November 2009

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PARTICIPATING VENDORS

POWER HUB DEVICES HOST

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Malaysia End-User Seminar 11 November 2009

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FIELDBUS SYSTEM ARCHITECTURE IN UTP

P+F Power Conditioner

EWS AMS

MTL Power Conditioner

ROSEMOUNT YOKOGAWA P+F FOXBORO HONEYWELL E+H FISHER

YOKOGAWA FOXBORO HONEYWELL

EWS EWS EWS PRM

EMERSON

  • 2 segments of

300m and 500m type A cable

  • Field barrier

from MTL and P+F

}

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Malaysia End-User Seminar 11 November 2009

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DELIVERABLES AND ASPIRATIONS

  • A report on results from interoperability testing that will serve

as reference for FF in PETRONAS.

  • A revised PTS on FF system.
  • Working group who are well-versed on all aspects of FF system
  • A test facility to verify fieldbus host interoperability and provide

user guidelines for each Host.

  • Training and skill certification facility within 2 – 3 years for

engineers and UTP students on FF system.

  • A test platform for R&D activities for UTP especially in areas of

Instrumentation & Control and Control Strategies.

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Malaysia End-User Seminar 11 November 2009

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TEST DONE SO FAR…

Basic Test (Sept 08 – May 09)

  • Findings

– Problem with block instantiation leads to commissioning problem – Field device communicator can’t communicate with all devices – Wizards to perform some tasks may not necessarily available – Not all system can restore device original configuration automatically – In trouble if address of device inadvertently changed to out-of-scanned range – Some devices are polarity sensitive

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NEXT TEST TO BE COMPLETED…

Stress Test

  • Fully loaded segment
  • Failure recovery
  • Cable constraint: using other industrial standard instrument

cable

  • Control in field including tuning
  • Segment design tool
  • Back up LAS
  • etc
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Malaysia End-User Seminar 11 November 2009

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FIELDBUS CERTIFICATION PROGRAM

  • Intended for PETRONAS staff
  • Staff shall be certified before they can work with Fieldbus system in

PETRONAS

  • Training to be conducted by UTP
  • Typical syllabus:

– Comparison between fieldbus and conventional 4-20mA – System architecture – How to design fieldbus segment – Safety concept – Device communication layer – DD, LAS and macrocycle – Maintenance and troubleshooting

  • Intention to open course to public in 5 years time
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Malaysia End-User Seminar 11 November 2009

11 Distinctive Competitive Financial Year

  • A testing facility that

will be used to verify

  • ther Hosts and

devices’ interoperability based

  • n PETRONAS

standard and provide user guidance

Base

  • A future training and

skill certification facility within 2 – 3 years for engineers and UTP students who will be working on fieldbus system

  • A test platform for R&D

activities for UTP especially in areas of Instrumentation & Control and Control Strategies A PETRONAS Technical Standard on Foundation Fieldbus system Working group who are well-versed on the fieldbus system in term of operation and maintenance

2009/2010 2010/2011 2011/2012 Diagnostic capability enables real-time asset management, simplifying routine maintenance and supporting predictive maintenance 2012/2013 2008/2009 DEVELOP TECHNICAL GOVERNANCE. FOCUS ON GROUP COMPENTENCY UNFOLD & ACQUIRE ADVANCED DIAGNOSTIC FEATURES TRAINING CENTER FOR FIELDBUS TECHNOLOGY FIT-FOR-PURPOSE TESTING FACILITY Stress test validates the accuracy of systemic specifics, through simulation of variables for robustness in process automation VALUE ADDING PLATFORM FOR R&D

A report on results from interoperability testing that will be the reference for Foundation Fieldbus system in PETRONAS Continuous testing to stress fieldbus system and explore its diagnostic capability

Conduct Basic Test and Extended Test (basic operation and exploratory test) on all Hosts

Completed

FOUNDATION FIELDBUS TESTING ROADMAP

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Malaysia End-User Seminar 11 November 2009

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www.fieldbus.org