Fieldbus Foundation PID & safety action

Ab de Muijnck AkzoNobel Chemicals bv Location Rotterdam Project Engineering

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Contents
Introduction Shin-Etsu VCM plant Safety action & PID control
Functionality Experiences Proposal

Discussion

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Shin-Etsu VCM plant and Today's situation

Shin-Etsu VCM Rotterdam plant built in 1970
Pneumatic instrumentation (3-15psi) 350 control valves 2000 analogue measurements 250 motors Foxboro spec200 (0-10V) Relays cabinets (24Vdc, 60Vac, 220Vac)

TDC3000 / TPS (20%)

Ventgas Incinerator ((A)MCs, 1991) 3rd Oxygen reactor (HPM, SMS, 1995) Re-instrumentation of safeguarding functions (SMS, HPM, 1998 - 2001)

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Time schedule regarding Fieldbus

Planning Re-instrumentation Fieldbus discussion (Q1/2 2002) System discussion (Q2/3 2002) Building 4th furnace Construction & Commissioning (2003) 110 Fieldbus devices Re-instrumentation Furnace A&B Commissioning (Q2 2004) 90 FF devices Re-instrumentation rest (summer 2004 200?)

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Re-instrumentation VCB
Motivation for re-instrumentation Expanding and rebottle necking capacity Process optimising Process and installation availability & reliability Operational aspects in Control room Maintainability and maintenance expenses

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VCM plant Rotterdam

Chosen options for re-instrumentation Fieldbusses
Foundation Fieldbus Profibus DP (motor control) Integrating with existing Honeywell TPS system

Honeywell Experion PKS

FF projects 4th furnace (110 devices) Revamp furnace A + B (90 devices)

Re-instrumentation stage 1

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Fieldbusses
Why Fieldbus Safety
Availability and reliability Higher process availability by diagnostic capabilities Lower Maintenance expenses Lower Investments cabling Multivariable devices: temperature multiplexors; Vortex, MassFlow, Valve positioners

Economics

Vendor independent Technology state of the art

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FF starting points
10 12 devices per segment Control in the Field Basic PID control in Valve positioners Non redundant system interfaces (except when Multi vendor Host:

Honeywell Experion PKS

Endress + Hauser, Emerson, FlowServe, Honeywell, PR electronics, Yokogawa

Devices ATEX Trunck: EEx e / nA Spur: EEx nL (non-incendive) Asset Management Diagnostic from devices
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Multi vendor
Temperature
Rosemount 644 PR electronics 5350 Rosemount 848 multiplexor

Flow
Yokogawa Digital YewFlow Vortex Endress + Hauser Promass 83 Micro Motion MVD 2700

Level
Endress + Hauser Prosonic M

Pressure
Yokogawa EJA100 Honeywell ST3000

Valve Positioner
Yokogawa YVP110 FlowServe Logix1410

Local Indicator
Rosemount 752

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Control in the field

Present status Simple control in the field possible Advanced/complex control in the DCS

FT001

VT001

AI
OUT IN

PID
OUT IN

AO
OUT

BKCAL_IN

BKCAL_OUT

H1 FF segment

FT 001

VT 001

V 001

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Shutdown action on control valves

Need for continuous control combined with discrete control Safeguarding Good operational practice safeguarding
24Vdc H1 FF segment air supply 4 barg

Requirements On initiating safeguarding the following has to happen: Output PID to a predefined safe value PID mode target to MANUAL During safeguarding not possible to operate PID At reset safeguarding: PID mode been left on MANUAL, ready for operations

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Experience
Control in the field using PID function blocks in valve positioners: FlowServe Logix 1400
LX1400_0502 LX1400_0601

Yokogawa YVP110
YVP_0303

Implementation: Setting TRACK_IN_D so the PID output follows TRK_VAL Target the mode to manual
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TRK_IN_D
Task: to control the output of PID block to predefined safe value By activating TRK_IN_D on PID block
TRK_IN_D: value and status discrete (index 66)

During TR_IN_D the PID mode block is pushed to LO (Local Override) The output follows TRK_VAL.VALUE

Problems According FF standard: TRK_VAL.VALUE can be a CONSTANT

FlowServe Logix 1400 does not meet standard TRK_VAL is connected to a DCS parameter

Control option No outlimit in Manual also valid in mode LO

OUT_LO_LIM and OUT_HI_LIM give limitation if TRK_IN_D
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MODE
Task: to arrange that when TRK_IN_D resets mode is left on MANUAL for normal operation Set GRANT_DENY.GRANT.OPER Set MODE.TARGET on MANUAL After resetting the TRK_IN_D the mode will been left on MANUAL for normal operation

Problems Complex Uses a lot VCRs

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Flowserve Logix 1400

Unwanted extra VCRs

DCS functionality

PID
TRK_VAL

safe value: -5%

safety: on/off

TRK_IN_D

GRANT_DENY.GRANT.OPER enable manual: 8

PUSH

MODE.TARGET

valve positioner

AI
OUT IN

AO

OUT

IN

BKCAL_IN

BKCAL_OUT

device

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Proposal
Simple and robust safeguarding function with minimum VCRs: Control option No OUT limits in Manual also in IMAN and LO new STATUS_OPTS selection: Target to Manual if TRK_IN_D TRK_VAL as CONSTANT

DCS or other filedbus device functionality

safety: on/off TRK_IN_D

PID

valve positioner

AI
OUT IN

AO

OUT

IN

BKCAL_IN

BKCAL_OUT

device

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Final remarks
This presentation gives no comparison between valve positioners; only the PID function block is compared Different manufactures have different interpretation on the standard functionality of FF function blocks
Flowserve Logix 1400 does not meet the FF specification on points 1 and 3 Yokogawa YVP110 meets the specification on this point

Need for the selection: Target to Manual if TRK_IN_D A strong request to al manufactures is made to follow the standard exactly and be sure that it works like that Encourage all user to exchange practical detailed experiences

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