Bechtel - PPT (1) - Foundation Fieldbus Technology PDF

General Assembly, Antwerp, 27-28 Feb 08
2008 Fieldbus Foundation

Execution of World Class Petrochemical Projects,
using Foundation Fieldbus Technology
David S. Lancaster, P.E.
Control Systems Chief Engineer
Houston
----------------------------
Richard Mills
Control Systems Supervising Engineer
London
Bechtel Oil, Gas & Chemical Inc.
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Execution of World Class Projects
Execution of a project using Foundation Fieldbus as the
preferred communication protocol is challenging enough,
whatever the size of the project. Implementation of very large or
World Class Mega Projects also requires the involvement of
multiple EPC offices in different continents or even multiple EPC
contractors.
In addition, system suppliers will use their international
resources; there will be multiple packaged equipment vendors,
and many hundreds or even thousands of skilled and semi-
skilled workers at jobsites and off-site fabricators such as
module yards.
What are the differentiators that ensure project success?
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Close cooperation between the End User, EPCs and Suppliers is a
key factor in identifying the sometimes overlooked details that can
come to light at the end of a project, causing problems and delays.
Among the issues we will consider are:
! Evaluation and selection of devices, wiring components,
wire/cable make up and characteristics
! Development of tools and standards to support the design
! Implementation of Foundation Fieldbus on the selected Host
! Installation, testing and commissioning tools and procedures
! Training for design, implementation, installation, testing,
commissioning, start-up, and maintenance for Engineering,
Construction and Maintenance personnel
This presentation will address these issues, showing where they
were encountered and how they were resolved, on recent Mega-
Projects, drawn from Bechtels global experience.
4
TBD
Emerson
Honeywell
ABB
Yokogawa
Honeywell
Honeywell
Invensys
Host
420 Houston Brass LNG
505 New Delhi, Shanghai Houston LNG Projects
682 Richland,
Washington
U.S. Dept of
Energy - WTP
2800 Houston, New Delhi, Beijing, KL,
Shanghai, Milan, Madrid,
Yokohama, Taipei
Reading
(BSF JV)
Shell/CNOOC -
CSPC Nanhai
10185 TOTAL
1600 New Delhi, Shanghai, JVs with
other EPCs
Houston Motiva CEP
678 Calgary, New Delhi, Toronto,
Edmonton, Montreal, Shanghai
Houston Shell - Scotford
Upgrader
Expansion Unit 1
3500 Houston, Frederick, Shanghai,
New Delhi, Toronto, Portsmouth,
Mumbai, Jamnagar, Paris
London Reliance - JERP
Segs Secondary Offices Primary Office Project
EXPERIENCE BASE:
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Background:
5 years ago
! Early adopters. Novel technology
! End User / Manufacturer lead the way
! Small Projects
! Involved Customer specialist teams
! Customer "pull"
Today
! Routine technology
! Customers look to contactors for expertise
! Mega Projects
! General engineering teams. Customer may have no
experience
! Industry norm
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What Does It Take To Do a Mega Project?
!Multiple offices & Time zones
!Multiple countries and continents
!Training, training, training
!Multiple Technical Evaluations (how does it
all fit together?)
!Multiple suppliers, supplier offices
!Standardization - Clear, concise instructions
!Coordination
!Follow-through
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What are the extras at each stage of a project
that ensure Certainty of Outcome?
1. EARLY IN THE PROJECT
(Front End Design)
2. DURING PROJECT DESIGN
(Detailed Design)
3. IMPLEMENTATION
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"#EARLY IN THE PROJECT:
! Overall vision expectations (realistic? achievable?)
! Brainstorm
Installation savings (schedule and cost)
Engineering (tools, schedule and cost)
Diagnostic tools (will they be useful & used during the
project lifecycle)
Maintenance (how to use FF to its greatest advantage)
! Installation
! Maintenance
! Operations
! Enterprise
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! FFB evaluation is it right for the project?
! What benefits are expected
! Are they realistic based on experience
! Can they be realized by the Project
! Can they be realized on schedule
! What problems are expected, Can they be
resolved
! Should we use a different FB
! Should we use conventional
technologies
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! Training
! Plan for all phases (design, system
implementation, installation, commissioning,
operations)
! Implement appropriate early training (include
O&M, management etc)
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! Implementation Basis:
! Prepare sound, clear design basis
! Follow that basis
! Keep current with the technology
BECHTEL Oil, Gas & Chemical Inc.
ENGINEERING CONTROL SYSTEMS
ENGINEERING DESIGN GUIDE
IMPLEMENTING FOUNDATION
TM
FIELDBUS
TECHNOLOGY
3DG-J41D-00009, Revision 001, 31 Jan, 2008
Prepared by: A. D. Boquiren
Checked by: R. D. Mills
Approved by: D. S. Lancaster
Reason for Issue: Issued for Use
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! Host Selection:
! FF Capability
! FF Experience
! Ease of use
! Integration of Asset Management System
! Diagnostics available
! Simulation capability for design and FAT
! Local support capability
! How easy to change to new DD revision?
! Other?
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! Component Selection:
! Meets area class requirements?
! How does it work individually?
! How does it work with other devices?
! How easy to configure?
! Experience, does it perform as published?
! Proven track record?
! Many others
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! Interoperability Testing:
! At the EPCs facility
! At the Host Supplier
! Project Office or Centre Of
Excellence
! Integration Tools between Offices
! Integration with suppliers
! Work Processes
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$#DURING PROJECT DESIGN:
! TRAINING (MORE, DETAILED)
! Engineering
! Construction
! Owner/End User
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! RISK ASSESSMENT RULES AND REVIEW
! Basis for Risk Assessment
! FF Final Control Element Process Severity
Ranking Matrix
! FF Final Control Element Risk Assessment
Philosophy
! Single Failure of Final Control Element
! Normal Failure mode of Final Control Element
! Number of Devices per Segment
! Diversity and redundancy
! Client expectation, perception of risk
! Balance between availability and reliability
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! SEGMENT LOADING RULES AND REVIEW
Segment B
Segment A
Discretionary
Utilities should be
separate from process
A and B services should be
separate
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! SEGMENT LOADING RULES AND REVIEW
! LAS / Control Philosophy
! Resource availability (VCR, time)
! Audit
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! SHIELDING / GROUNDING (EARTH) DESIGN
! Determine shield termination design for
Conventional and Foundation Fieldbus
installations they may be different
! How are unused (spare) conductors for Trunks
and Spurs terminated
! Which ground (earth) is used Instrument
(clean), Power, AC?
! Are Surge Protection Devices used? To which
system are they grounded?
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! SURGE PROTECTION DESIGN
! Different philosophies on surge protection (end users / EPC vs
manufacturer) is it really needed?
! What you are really trying to protect?
! What is the risk?
! Is the process area properly bonded and grounded?
! Are the FF signal lines physically isolated from the plant
and process ground system?
! Is the FF Segment shielding properly grounded?
! Are the FF devices and support devices CE compliant
(EMC requirement provides a 2kv surge test)?
! Is the cost for surge devices justified?
! Will implementation of surge protection impact
availability?
! How does FF protection integrate with other system
protection?
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2. DURING PROJECT DESIGN:
! METHODS (TEMPLATES)
! Do they work with the devices selected?
! How easy or difficult are they to configure (drag
and drop vs. keyboard entry)
! Are there any quirks or special considerations
! Review all options and defaults for selected
devices
! What are the unknowns before Commissioning
and Startup?
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%#IMPLEMENTATION:
! Training
! Construction
! Commissioning / Startup
! Owner/End User
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%#IMPLEMENTATION:
! Review Field Changes
! Was a Risk Assessment Review done?
! Were segment design guidelines followed?
! Were installation practices adhered to?
! What effect will downloading the new device
have on the existing segment?
! When is the appropriate time to implement the
change (can Operations be affected)?
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%#IMPLEMENTATION:
! Host System Performance
! Are execution times as published?
! Does the HOST slow down or have any other
adverse effects due to loading?
! How useful are the system diagnostics?
! Are any new DD revisions required available?
! Any unanticipated problems?
! If planned software revisions contain significant
changes, is there a plan for implementation?
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%#IMPLEMENTATION:
! Diagnostics Training
! What is displayed and what does it mean?
! What needs to be done if.?
! How can we do....?
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%#IMPLEMENTATION:
! Maintenance Methods
! What are the tools and equipment required?
! How is a device disconnected and reconnected
correctly?
! What happens in a download?
! How to use remote diagnostics
! What is a valve signature and what does it
mean?
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%#IMPLEMENTATION:
! Operations how to optimize the use of FF
! What parameters are available?
! What do they mean?
! How can combinations of parameter values be
used to indicate how the process is behaving??
! How to best used advanced diagnostic tools now
available?
! How can valve diagnostics be used to verify or
enhance performance
! Development and use of diagnostic reports
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%#IMPLEMENTATION:
! Review installation
! Maintenance of shields
! Bending radius of cable
! Grounding
! Are all devices supplied with expected DD
revision?
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Summary
! Todays need for Mega Projects requires an
extra effort to ensure Certainty of Outcome
! Owners / End Users, Contractors and the
Suppliers must be willing to provide that
effort
! Traditional design methods and execution
are not enough
! Thinking out of the box is required to
ensure success but must stick to the rules
once set
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Summary
! Product Maturity
! End Users and Contractors have developed
"Standard" solutions
! Need for manufactures to update Spec
Sheets/guidelines to work with new products
! Still developing installation standards /
assemblies, use new products on project
! Not yet fully mature as a technology
! Products evolve over Project lifecycle
! Similar requirements for all projects, Mega
Project makes best practice and early
application essential
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General Assembly, Antwerp, 27-28 Feb 08

2008 Fieldbus Foundation

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