04-GNFC Implementation-Keval & Mannan...GNFC has implemented Field bus technology for first time in...

Topics

A. GNFC at a glanceB. What is FF?C. Hazardous Area ConceptD FF Design criteria of GNFCD. FF - Design criteria of GNFCE. Components at GNFCF. Block configuration of FF DevicesG. Advantages of FFgH. Problems faced by GNFCI Challenges for FF DesignersI. Challenges for FF Designers

A. GNFC at a glance1 Introduction

G j N d V ll F ili C L d

1. Introduction

Gujarat Narmada Valley Fertilizers Company Ltd.(GNFC), is a joint sector enterprise promoted by theGovernment of Gujarat and the GSFC in 1976Government of Gujarat and the GSFC in 1976.GNFC is in the field of manufacturing and selling offertilizers such as Urea Ammonium Nitrofertilizers such as Urea, Ammonium Nitrophosphate and Calcium Ammonium Nitrate underthe umbrella “NARMADA”the umbrella NARMADA .GNFC also manufactures industrial chemicals suchas Methanol, Formic Acid, Nitric Acid and Aceticas Methanol, Formic Acid, Nitric Acid and AceticAcid ,aniline and TDI.

A. GNFC at a glance2 An Overview

GNFC PLANTS and PRODUCT – AN OVERVIEW

2. An Overview

Acetic AcidCO + H 2Acetic Acid

Aniline

GNFC PLANTS and PRODUCT – AN OVERVIEW

Ammonia

M SU

Air M eth ISG GU

Syn Gas CO + H 2

NG

TDIM ethanol

PlantAir

Fuel Oil / LSHS

M eth II H 2H 2 + CO Aniline TDI

M ethanol

Tail Gas

Urea

Formic AcidCO 2

TDI

M ethyl FormateW N A

NH

Tail GasTail Gas

Form ic Acid

CN A I

AN P

W N A

CN A II

C AN CAN

NH 3NH 3

CN A I

AirConc NA

CaCO 3

CaCO 3

AN P CANRock

PhosphateAN M elt

AN M eltANP

A. GNFC at a glance2 An Overview

Sr Plant Installed Technology Supplier

2. An Overview

Sr. No

Plant Installed Capacity TPA

Technology Supplier

1 Ammonia 4,45,000 M/s Linde, M/s BASF, M/s Texaco M/s Haldor TopsoeTexaco, M/s Haldor Topsoe

2 Urea 6,36,000 M/s Snamprogetti

3 Ammonium Nitro 1,42,500 M/s BASFPhosphate

, , /

4 Calcium ammonium Nitrate 1,42,500 M/s UHDE

5 M th l 1 50 000 M/ ICI5 Methanol 1,50,000 M/s ICI

6 Acetic Acid 1,00,000 M/s BP Chemicals

7 Formic Acid 10,000 M/s Kemira OY7 Formic Acid 10,000 M/s Kemira OY

8 Weak Nitric Acid 2,47,500 M/s UHDE

9 Conc.Nitric Acid 66,000 M/s Plinke

10 Aniline 20,000 M/s Chematur

11 TDI 10,000 M/s Chematur

A. GNFC at a glance3 Project Overview3. Project Overview

GNFC has planned for setting up following project at GNFC Bharuch site at GNFC ,Bharuch site.

Weak Nitric Acid plant – WNA-II -C d Ni i A id l CNA IIIConcentrated Nitric Acid plant – CNA-IIIEthyl Acetate plant CPSU for power generationLNG based synthesis gas generationy g g

GNFC has also planned for setting up of TDI project at DAHEJ site.

Topics

A. GNFC at a glanceB. What is FF?C. Hazardous Area ConceptD FF - Design criteria of GNFCD. FF - Design criteria of GNFCE. Components at GNFCF. Block configuration of FF DevicesG. Advantages of FFH. Problems faced by GNFCI Challenges for FF DesignersI. Challenges for FF Designers

Topics


B. What Is FF ?

FOUNDATION Field Bus is a digital, Two way,Multi Drop Communication Link.It can be represented as a LAN for FieldDevices.FF is both open and interoperable, and it is anenabling technology that allows migration of

l f i fi ld d icontrol functions to field devices.The physical layer of FF is H1 bus having data

i i d f 3 25 kb & i d fi dtransmission speed of 31.25 kbps & is definedin IEC 61158-2 & ISA-S50.02 fieldbust d dstandard.

B. What Is FF ?

Various Architectures

Host HostHost

Trunk

Host

Trunk TrunkTrunkTrunk

J.B.S

SpursSpurs

Point to Point Daisy ChainBus With Spurs Tree/Chicken Foot

Topics


C. Hazardous Area Concept

There are four hazardous area concept availablefor FF.

1. Entity Concept

2. FISCO Concept

3. FNICO Concept (derived from FISCO)

4. High Power Trunk Concept. g o e u Co cept

C. Hazardous Area Concept1 Entity Concept

Established in Mid 1980’s used for

1. Entity Concept

Hazardous area.Entity concept assign safety parameters inEntity concept assign safety parameters inboth power sourcing and receiving devices.Intrinsic safe trunk and spursIntrinsic safe trunk and spursLive maintenance of trunk and spurs.Limitations:

Not more than 80 ma in Field hence Onlyy4 devices per segment for both IIC andIIB.No Physical Layer Diagnostic is available

C. Hazardous Area Concept2 FISCO Concept

Established in 1994 and used for

2. FISCO Concept

Zone 0-1-2 / Div-1 area.Provides more current to IS trunk

Power supply in control room

than entity conceptLive maintenance possible.

Trunk(IS)p

Limitations:Not more than 250 ma in field

IS safe field Wiring

Not more than 250 ma in field,Only 12 devices per segment forIIB.

Spurs

IIB.Not more than 110 ma in field,Only 06 devices per segment forOnly 06 devices per segment forIIC. IS safe field devices

C. Hazardous Area Concept3 FNICO Concept

Derived from FISCO concept, used for

3. FNICO Concept

Zone-2 / Div-2.Delivers more current than FISCO

Power supply in control room

Live maintenance of trunk and spursLimitations:

Trunk (non incendive)

Not more than 320 ma in field, Only16 devices per segment for IIB.

Ex n or IS safefield Wiring

Not more than 180 ma in field, Only10 devices per segment for IIC.

Spurs ( Non incendive)

All field devices shall be Non-incendive FNICO certified.

Ex n or IS safe field devices

C. Hazardous Area Concept4 High Power Trunk

In this concept the trunk does

4. High Power Trunk

In this concept the trunk doesnot limit energy, rather theenergy on spur connection to

Powersupply

gy pinstruments is limited.Delivers more current in field

Trunk non IS

than Entity/FISCO/FNICO.More number of devices than

Segment Protect

Entity/FISCO/FNICO.It is used for General purpose

Spurs IS

p pas well as for Hazardous areaalso.

IS Field Devices

Topics


D. FF - Design Criteria of GNFC

GNFC has implemented Field bus technology forfirst time in year-2008 in UREA plant duringPneumatic DCS conversion projectPneumatic-DCS conversion project .Being new technology for us, we have selected onlyfew open loop tags, which were additionally requiredp p g , y qfor monitoring in DCS (Earlier in field) asrecommended by Operation group.W h t id d CLOSED l bWe have not considered any CLOSED loop because:

New technology for GNFCLess familiarity with technology and didn’t have Less familiarity with technology and didn t have troubleshooting experience.At that time Less experience man power p p


Hi h P T k C tHigh Power Trunk ConceptMore number of devices per segment can beinstalled as we don‘t require Intrinsic safetyinstalled as we don‘t require Intrinsic safetyconcept because of all FF devices are in Zone-2.Longest cable length is possibleLongest cable length is possible.Exd IIB/IIC JBs used for Segment Protectors.Live maintenance of Trunk was not requiredLive maintenance of Trunk was not required.Possibilities of addition of more Tx in future.Overall cost benefit for implementationOverall cost benefit for implementation.


Host:2 number of non redundant FF I/O cards areused.

Power Supply Selection:For Optimum Integrity and availability redundantFor Optimum Integrity and availability redundantPower Supply was used.

Segment Protector:Segment Protector:Selected in such a way that it will reduces energysupplied to field devicessupplied to field devices.During Field Devices maintenance spurs fault dueto short circuit will not affect functioning ofto short circuit will not affect functioning ofsegment.

D. FF – Design Criteria of GNFC

Cable Selection:Cable Selection:Armored, Type A cable was selected forpreventing physical damage to the cable aspreventing physical damage to the cable aswell as avoiding use of Conduits.

Field Engineering:Field Engineering:Chicken Foot Topology is used.Junction Boxes with segment protectors areJunction Boxes with segment protectors areinstalled near to field devices for minimizingSpur lengthSpur length.Total 5 Trunks used to take care of moreSegment Protectors and to increaseSegment Protectors and to increaseavailability.


System EngineeringSystem EngineeringDevice configuration has been carried outthrough Yokogawa DCS FF device builderthrough Yokogawa DCS FF device builderand Filed bus Device management tool.All FF fi ld d i ll di t ib t dAll FF field devices are equally distributedfor optimum Segment Loading.Macro cycle of each segment has been 1sec.Single point grounding has been adopted.

Topics

A. What is FF?B. Hazardous Area ConceptpC. FF - Design criteria of GNFCD Components at GNFCD. Components at GNFCE. Block configuration of FF DevicesF. Advantages of FFG. Problems faced by GNFCyH. Challenges for FF Designers

D. Components at GNFC

HIS

AFV10D R d d t

Vnet/ip

1 0 HOST AFV10D Redundant controller,, YIL

ALF111 FF cards, non

1.0 HOST

redundant, YIL

2.0 power supply

3.0 H1trunk

J.B J.B

Spurs

4.0 Seg.

Protectorp

5.0 Field

Devices

D. Components at GNFC

Yokogawa DCS with FF IO card ALF1111. HOST

Yokogawa DCS with FF IO card ALF111Specifications:

A ALF111 k th Li k A tiAn ALF111 works as the Link ActiveScheduler (LAS) of H1 bus and transfersd t f /t fi ld d i f FFdata from/to field devices for FF.4 Segment Capacity.Current Consumption: 0.5 A max.

D. Components at GNFC2 Power supply

Turck Rack with Power supply

2. Power supply

Turck Rack with Power supplySpecifications:

DPC 49 MB RC:DPC-49-MB-RC:back plane for 8 module,Redundant host connectionRedundant power supplyDPC-49-IPS:Output current: 800 ma

DPC-49-IPS

DPC-49-MB-RCpComplete Galvanic Isolationfor H1 to H1 and H1 to power supplyfor H1 to H1 and H1 to power supplyHot Swappable

D. Components at GNFC3 H1 trunk

TYPE A Cable ( Procured indigenously )

3. H1 trunk

TYPE A Cable ( Procured indigenously )Specifications:

Multi Stranded, 2 wire, 0.8 mm2, 18AWG, 7 stranded ATC Cu shielded, typeA cable.It has been used for trunk as well asspurs.Electrical Parameters were selected asElectrical Parameters were selected asper IEC 61158-2:

D. Components at GNFC4. Segment Protector

Turck JRBS-49SC-8Specifications:

Switchable End TerminatorShort Circuit Protectionconfigurable for 30, 35, 45and 6O ma.Open Circuit Voltage: 33Vdc

End Terminator

D. Components at GNFC5. Field Devices

a. Temperature MUX CARD:Emerson 848T

Specifications:Configured for 8 Type K TCConfigured for 8 Type K TCEight independently configurableh lchannel

Less than 1.5 sec to read all 8Inputs

D. Components at GNFC5. Field Devices

b. Pressure TransmitterABB 2600T 264HS

Specifications:Accuracy:+/- 0 075%Accuracy:+/- 0.075%Link master capableOperating Current:10.5 maFault Current limit:20 ma

Topicsp

A. What is FF?B. Hazardous Area ConceptpC. FF – Design criteria of GNFCD Components at GNFCD. Components at GNFCE. Block configuration of FF DevicesF. Advantages of FFG. Problems faced by GNFCyH. Challenges for FF Designers

E. FF Device Blocks

Fi ld B

Resource Transducer Fi ld D i

Field Bus

esou ceBlock

a sduceBlock Field Device

FunctionBlock

Resides in Field DeviceBlock

Can be configured in host or in field

E. FF Device Blocks

A set of standardized blocks used to monitorA set of standardized blocks used to monitorand control process applications.Device blocks are interconnected over the FFDevice blocks are interconnected over the FFto implement an integrated control strategy.D i fi d i R Bl kDevices are configured using Resource Blockand Transducer Block.The Control Strategy is built using FunctionBlocks.

E. FF Device Blocks

ABB 2600T 264HSABB 2600T 264HS

E. FF Device Blocks1 R Bl k1. Resource Block

The resource block defines the physicalresources of the device.It contains manufacturer information,device identification, CPU and memoryyinfo.The block has no linkable inputs orThe block has no linkable inputs oroutputs.No data processingNo data processing.

E. FF Device Blocks1 R Bl k1. Resource Block

E. FF Device Blocks2 T d Bl k

Th t d bl k t i th t l

2. Transducer Block

The transducer block contains the actualmeasurement data.The transducer block includesThe transducer block includesinformation about sensor type,engineering units, linearization, reg granging, temperature compensation, anddiagnostics.

E. FF Device Blocks2 T d Bl k2. Transducer Block

Provides additional error codes like memory failure, electronics failure, output failure.

E. FF Device Blocks3 F ti Bl k

Function blocks within the FF device

3. Function Block

Function blocks within the FF deviceperform the various functions required forprocess controlprocess control.Function blocks can be built into FFdevices as needed to achieve the desireddevices as needed to achieve the desireddevice functionality.It can be located in host devicesIt can be located in host devices.

E. FF Device Blocks3 F ti Bl k3. Function Block

E. FF Device Blocks3 F ti Bl k3. Function Block

Mux Card FF block configuredMux. Card FF block configured in dcs

Topicsp

A. What is FF?B. Hazardous Area ConceptpC. FF - Design criteria of GNFCD Components at GNFCD. Components at GNFCE. Block configuration of FF DevicesF. Advantages of FFG. Problems faced by GNFCH. Challenges for FF Designers

F. Advantages of FF1 T h i l1. Technical

Automatic device detection prevents faultychannel connection.Diagnostic tools (e.g. segment checker,Advanced Diagnosis Module) are availableg )to find out any kind of problems like malfunctioning of tx, cable short circuit andimpedance change, end terminatordeterioration etc.

F. Advantages of FF1 T h i l1. Technical

New devices combine several sensors intoone device, several piece of information canflow over on pair of wire.LAS (Link Active Scheduler) control can be( )transferred to Field Device.Configuration of Field Devices from controlConfiguration of Field Devices from controlroom, hence quicker commissioning, fasterdiagnostics.diagnostics.

F. Advantages of FF1 T h i l

Less Spacing is required hence panels reduction faster

1. Technical

Less Spacing is required, hence panels reduction, faster commissioning.

Total 64 channelsTotal 64 channels

Total 133 channels( 29 PT and 13 mux.Still has spare 3 segment(30 channel segment(30 channel approx.)

Gnfc site, Urea plant

F. Advantages of FF1 T h i l

I t bilit

1. Technical

Interoperability:The capability for a device from one

f t t i t t ith th t fmanufacturer to interact with that ofanother manufacturer on a FF networkwithout loss of functionality.without loss of functionality.In GNFC

Host: Yokogawa DCSTechnical and Price Host: Yokogawa DCS

Power supply card: TurckH1 Bus: Associates Cable.

benefit.

H1 Bus: Associates Cable.Segment Protector: TurckTemp Multiplexer: EmersonTemp Multiplexer: EmersonTransmitters: ABB 2600T 264HS

F. Advantages of FF1 C i l

Benefit by implementation of Field bus for 133 points at

1. Commercial

Conventional Foundation FieldBUS

GNFC

US

No of Channel 133 42

Cables 396520 143000

Transmitter/muxcard

551000 1026160

N f FTA 38000 N t R i dNo of FTA 38000 Not Required

PS/Seg.Protector/Node

397570 158840

No of I/O cards 713050 125000

No Terminations 1596 596

Erection Cost 100000 36000

Total Cost 2196140 1489000

Topicsp

A. What is FF?B. Hazardous Area ConceptpC. FF- Design criteria of GNFCD Components at GNFCD. Components at GNFCE. Block configuration of FF DevicesF. Advantages of FFG. Problems faced by GNFCyH. Challenges for FF Designers

G. Problems Faced by GNFC

Problems Faced:Practically no problems related to FFy pwere observed during and aftercommissioning.gDuring Commissioning one transmitterwas not coming in line, hence itswas not coming in line, hence itselectronics module was replaced.Kick were observed in anotherKick were observed in anothertransmitter, after replacement oftransmitter problem got solvedtransmitter, problem got solved.

Topicsp

A. What is FF?B. Hazardous Area ConceptpC. FF - Design criteria of GNFCD Components at GNFCD. Components at GNFCE. Block configuration of FF DevicesF. Advantages of FFG. Problems faced by GNFCH. Challenges for FF Designers

F. Challenges to FF designers

Still REDUNDANT FF H1 Trunk is notStill REDUNDANT FF H1 Trunk is notestablished , hence Trunk failure will lead toall device disconnection with HOST.all device disconnection with HOST.Inability to add SEGMENT PROTECTORwithout interruptionwithout interruption.If user want to install few more devices on

t k th l t l l ti isame trunk, then complete recalculation isrequired to avoid any malfunction after

difi ti F th t i ti i t ll timodification. For that, existing installationshould be with perfect documentation.

H. Challenges to FF designers

LengthLengthIf field devices are at Host

longer distance thannumber of devices per

T1 Type A cable

segment will reduce.With Increase in number

Junction Box

of field devices the lengthof Spurs will Decrease.

S1 S2 Sn

Length = T1+S1+S2+ +Sn <= 1900 MLength T1+S1+S2+…+Sn < 1900 M


LengthgNo. of devices 1 device

per spur2 devicesper spur

3 devicesper spur

4 devicesper spur

1 – 12 120 m 90 m 60 m 30 m

13 – 14 90 m 60 m 30 m 1 m

15 – 18 60 m 30 m 1 m 1 m

19 24 30 1 1 119 – 24 30 m 1 m 1 m 1 m

25 – 32 1 m 1 m 1 m 1 m25 32 1 m 1 m 1 m 1 m


Problem reported by one user : In case ofProblem reported by one user : In case ofany terminator broken or Segment protectorfailure the behavior of that H1 bus becamefailure, the behavior of that H1 bus becameunpredictable.High power trunk concept is now FFHigh power trunk concept is now FFcertified or not?

THANK YOUTHANK YOU

04-GNFC Implementation-Keval & Mannan...GNFC has implemented Field bus technology for first time in...

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