Foundation fieldbus technology secco 0306

Foundation FieldBus Technology Application in The Ethylene Project of SECCO (900,000 Tons Per Year)

General Assembly Feb. 28 – March 1, 2006 Shanghai, China © 1999 – 2006 Fieldbus Foundation 1 Foundation FieldBus Technology Application in The Ethylene Project of SECCO (900,000 Tons Per Year) (February 28 of 2006) SECCO Senior Engineer Wu Guoliang General Assembly Feb. 28 – March 1, 2006 Shanghai, China © 1999 – 2006 Fieldbus Foundation 2 1. Summary of SECCO 900,000 tons per year ethylene project SECCO 900,000 tons per year ethylene project is a joint-venture which is constructed by SINOPEC, SPC and BP。 This Project is a intergrated petrochemical complex which owns the largest scale, latest technology, supreme automated system integrated level in the world at present. The gross investment of the project is about $ 2.700 Billions. All ten plants, public utility and auxiliary factilities of SECCO 900,000 tons ethylene project were put into commercialized operation on Jun 29th of 2005. It indicated the success of adopting FF fieldbus technology in modernized large-scale integrated petrochemical industry factories. General Assembly Feb. 28 – March 1, 2006 Shanghai, China © 1999 – 2006 Fieldbus Foundation 3 Summary of Automatic Control System The whole factory consists of 15 satellite control outstations and are respectively placed in each production plant，public utility and auxiliary facilities. Various kinds of control system cabinets are installed in every satellite control outstations and a set of operation station with engineering station is also set up. All of these are designed by explosion proof structure level. The outmost satellite control outstation is about 2, 500 kilometers away from central control room. Signals from all satellite control outstations to central control room adopt dual-redundant optic-fibre cable for communication. The whole factory sets up a central control room. The operation and control management of all production plants, public utility and auxiliary factilites are centralized. The whole factory automatic system includes: DCS/FCS, SIS, FGS, AMS, ADAQ, MMS, EMS, APC, OPT, OTS, CCTV etc. The whole factory automatic control system scale： DCS I/O 141809 SIS I/O 9487 total： 151296 General Assembly Feb. 28 – March 1, 2006 Shanghai, China © 1999 – 2006 Fieldbus Foundation 4 Central Control Room（3/4 Parts） General Assembly Feb. 28 – March 1, 2006 Shanghai, China © 1999 – 2006 Fieldbus Foundation 5 The summary of instruments and devices of SECCO ethylene project: Field instruments and devcies totalized 54025 units. FF fieldbus devices have 14375 units which account for 26.6%. Total loops are 8200. Total tag numbers are 168,000. FF fieldbus network segments are 2473 and each of them are averagely connected to 5.8 units FF fieldbus devices. Field junction boxes are 5300. General Assembly Feb. 28 – March 1, 2006 Shanghai, China © 1999 – 2006 Fieldbus Foundation 6 2 . The advantages of FF fieldbus FF field bus control system is a kind of plant field network control system. It is a new technology combined by information technology, computer network and control system. The advantages are shown as below: 1. FF fieldbus have the attributes of openness and interoperable. 2. FF fieldbus device is intelligent and self defined function. 3. FF fieldbus control function is highly decentralized. 4. FF fieldbus is the totally digitalized technology with high accuracy and reliability. It has established strong foundation for the future application of digital technology in the control system. 5. FF fieldbus installation materials and communication workload can be greatly reduced. 6. FF fieldbus system provides means for the decreasing devices’ life cycle costs. General Assembly Feb. 28 – March 1, 2006 Shanghai, China © 1999 – 2006 Fieldbus Foundation 7 1. FF fieldbus have the attributes of openness and interoperabilty The key attribute of field bus devices is interoperability. To do this, each fieldbus device must has a device description (DD) file which provides description to make the control system or main machine understand the data meaning in the devices. DD file is similar to a device driver. As long as a PC is installed this driver program, it can recognize and operate the device, such as a printer. Fieldbus foundation has provided DD files for all standard function modules and converter, and supporters can use them. At the same time, supporters also can add their own characters, such as the device calibration or diagnostic capabilties man-machine interface definitations. General Assembly Feb. 28 – March 1, 2006 Shanghai, China © 1999 – 2006 Fieldbus Foundation 8 2. The intelligence of FF fieldbus device Fieldbus devices with microprocessor placed in the field devices have the abilities of digital computation and communication. One pair of transmition lines connects to many sets instruments and transmits many signals in dual direction. If we add the sensor measure, compensation calculatation, engineering processing and control functions in the fieldbus device, it can also complete basic control functions. For FF device, if the measurement range is not to exceed the sensor maximum measurement range, we only need to change XD-SCALE and OUT-SCALE in the AI block. This is much more convenient that the traditional 4-20mA transmitter which have to use standard signal generator to change and vertify the range of the transmitter. General Assembly Feb. 28 – March 1, 2006 Shanghai, China © 1999 – 2006 Fieldbus Foundation 9 The fieldbus control system is a truly distribution control system such that control functions can be distributed to the field devices. For example the main PID control block can be set in the transmitter and the secondary loop can be set in the valve positioner. In that case, it can help to reduce the communication load between DCS and field instruments, simplify the system architecture, reduce the virtual communication chains and improve reliability. 3. High decentralization of the Control System General Assembly Feb. 28 – March 1, 2006 Shanghai, China © 1999 – 2006 Fieldbus Foundation 10 4D igital information technologies have developed rapidly and establish the foundation for the application of digital technology in the future Compared with anolog signal, FF digital signal has strong anti-interference ability, high accuracy, small transmission error and hence it improves system reliabilty. With the development of digital technology, a variety of powerful field devices and function blocks are emerging. The whole digitalization of fieldbus has laid a strong foundation for its application.