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 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+ • BAJT-H • SUJT-C: <100 • KNPG-B • SUDP-A: 200+ • KNJT-C etc • GTS believes that FF can bring – Cost savings – Online asset proactive / preventive maintenance Malaysia End-User Seminar 2 11 November 2009
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… Malaysia End-User Seminar 3 11 November 2009
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 controllers: 4 systems Host stations Malaysia End-User Seminar 4 11 November 2009
Malaysia End-User Seminar 11 November 2009 PARTICIPATING VENDORS DEVICES POWER HOST HUB 5
FIELDBUS SYSTEM ARCHITECTURE IN UTP YOKOGAWA EMERSON FOXBORO HONEYWELL EWS AMS EWS EWS EWS PRM • 2 segments of } MTL Power Conditioner P+F Power Conditioner 300m and 500m type A cable • Field barrier from MTL and P+F YOKOGAWA FOXBORO E+H ROSEMOUNT FISHER P+F HONEYWELL Malaysia End-User Seminar 6 11 November 2009
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. Malaysia End-User Seminar 7 11 November 2009
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 Malaysia End-User Seminar 8 11 November 2009
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 Malaysia End-User Seminar 9 11 November 2009
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 • Malaysia End-User Seminar 10 11 November 2009
FOUNDATION FIELDBUS TESTING ROADMAP � A PETRONAS � A report on results • A future training and • A testing facility that • A test platform for R&D skill certification facility from interoperability will be used to verify Technical Standard on activities for UTP within 2 – 3 years for other Hosts and Foundation Fieldbus testing that will be the especially in areas of Distinctive engineers and UTP devices’ system reference for Instrumentation & students who will be interoperability based Foundation Fieldbus Control and Control � Working group who working on fieldbus on PETRONAS system in PETRONAS Strategies are well-versed on the system standard and provide � Continuous testing to fieldbus system in user guidance VALUE ADDING term of operation and stress fieldbus system and explore PLATFORM FOR R&D maintenance its diagnostic FIT-FOR-PURPOSE capability TESTING FACILITY Competitive TRAINING CENTER FOR FIELDBUS UNFOLD & TECHNOLOGY ACQUIRE ADVANCED DEVELOP DIAGNOSTIC TECHNICAL FEATURES GOVERNANCE. FOCUS ON GROUP Base COMPENTENCY Diagnostic capability enables real-time asset management, simplifying routine maintenance and supporting predictive maintenance Stress test validates the accuracy of systemic specifics, through simulation of variables for robustness in process automation � Completed Conduct Basic Test and Extended Test (basic operation and exploratory test) on all Hosts 2010/2011 2009/2010 2011/2012 2012/2013 2008/2009 Financial Year Malaysia End-User Seminar 11 11 November 2009
Malaysia End-User Seminar 11 November 2009 www.fieldbus.org 12
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