End User Conf. Japan

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Fieldbus Foundation >>> Moving Ahead

A New perspective A New perspective ––

FF Contribution FF Contribution

and and

Future ChallengesFuture Challenges

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Essar Group - Mission

To create enduring value for customers and stakeholders in core

manufacturing and service businesses, through world-class operating

standards, state-of-the-art technology and the ‘positive attitude’ of our

people

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Overview

Promoted by the Ruia Family

Employs more than 50,000 people across 20 countries and over 150 offices

A well balanced portfolio of assets in manufacturing, services and retail

State-of-art facilities and technology

Global level of operations and strong business relations

Moving closer to customers and building strong brands

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Businesses

Essar Group

Shipping Ports & LogisticsSteel Energy Power Projects

Essar Steel Ltd4.6 MTPA integratedsteel plant

Essar Steel (Hazira)4 MTPA integrated steel plant (under implementation)

Essar Steel Orissa6 MTPA pellet plant(under implementation)

Algoma Steel, Canada4.0 MTPA integrated steel plant

Minnesota Steel6 MTPA pellet plant (planned)

1.4 billion tonne iron ore reserves

PT Essar Indonesia0.4 MTPA cold rolling complex

Essar Oil12.5 MTPA refinery complex

Over 1,000 retail outlets

Refinery expansion to 34 MTPA in two phases

Exploration & Production Assets E&P rights in valuable oil & gas blocks in India and abroad

Essar ShippingFleet of 26 vessels, DWT of 1.49 mn

Vadinar Oil TerminalTerminal facility of 32 MTPA – Liquid Cargo

Bulk TerminalDry bulk port facilities

Essar Oilfields A drilling company with 13 rigs

Essar LogisticsOwns and operates transshipment assets

Essar Power / Bhander Power1,015 MW combined cycle

Vadinar Power125 MW co-generation; expanding to 1250 MW

Essar Power MP1,200 MW coal based(under implementation)

Essar Power Gujarat1,200 MW coal based(under implementation)

Essar Power Jharkhand1,200 MW coal based(under implementation)

Essar Construction - Engineering- Fabrication- Construction

Fully geared to execute turnkey EPC jobs in India and overseas

Essar Offshore SubseaExpertise in marine construction

Global Supplies (UAE) FZEGlobal procurement company

Heavy Engineering Services

Project Management Consultants

Asia’s largest equipment bank

Communications

Vodafone Essar60 million subscribers

Essar Telecom Infrastructure3,500 telecom towers operational; 20,000 planned by 2010

The MobileStoreOver 1,300 outlets operational; 2,500 planned by 2010

Aegis - BPO30,000 people in offices in the Philippines, Costa Rica, USA and India

BPL MobileMore than 1.8 million subscribers

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Steel

Communications

Projects

INDIA ESSAR STEEL LTD4.6 MTPA integratedsteel plant

ESSAR STEEL (HAZIRA)4 MTPA integrated steel plant (under implementation)

ESSAR STEEL (ORISSA)6 MTPA pellet plant

OVERSEASALGOMA STEEL,CANADA4 MTPA steel complex

MINNESOTA STEEL, U S A6 MTPA pellet plant (under implementation)1.5 billion tonne of iron ore reserves

INDONESIA0.4 MTPA Cold Rolling complex

SteelFully integrated producer from iron ore to ready-to-market products

Essar Global

Shipping, Ports & Logistics

Energy

Power

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EnergyFrom rig to retail

EXPLORATION & PRODUCTIONOVERSEASVietnam: 1 offshore blockMadagascar: 3 onshore blocksNigeria: 1 offshore blockAustralia: 2 offshore blocks

INDIA4 onshore blocks and 1 offshore blockAssam, Raniganj and Mehsana: Onshore Ratna & R Series: Offshore

REFINING12.5 MTPA refinery, capacity being expanded to 34 MTPA in two phases

MARKETINGRetail: Over 1,000 retail outlets operationalBulk Marketing

Essar Global

Energy

Steel

Communications

Projects


Power

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PowerIndia’s first independent power producer

CURRENT OPERATIONSHazira 1,015 MW Combined Cycle Power Plants Jamnagar125MW Co-generation PlantVisakhapatnam25 MW coal based power Plant

NEW PROJECTS3,600 MW Power projects(1,200 MW each in Gujarat, Madhya Pradesh and Jharkhand )

Under development1,250 MW captive for Vadinar refinery

Essar Global

Power

Steel

Projects


Energy

Communications

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CommunicationsWhere ever you go, our network follows

CELLULAR JV WITH VODAFONEA major force in the industryOver 60 million subscribers

INVESTOR IN BPL MOBILE

AEGIS BPOCall Centres in USA, India, the Philippines and Costa Rica; total capacity of over 30,000 seats

TELECOM RETAIL STORES

ESSAR TELECOM INFRASTRUCTUREOver 3,500 telecom tower sites

Essar Global

Communications

Steel

Projects


Energy

Power

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Shipping, Ports & LogisticsEnd-to-end transportation logistics solutions

SHIPPING OIL TERMINALSBULK TERMINALSOILFIELDS SERVICESLOGISTICS

Essar Global


Steel

Projects

Energy

Power

Communications

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ProjectsOver 30 years of experience in constructions

INDUSTRIAL PROJECTS

CIVIL AND IRRIGATION PROJECTS

PIPELINES: ONSHORE & OFFSHORE

MARINE PROJECTS

HIGHWAYS AND EXPRESSWAYS

ENGINEERING CENTRES

HEAVY ENGINEERING SERVICES

GLOBAL SOURCING

Essar Global

Projects

Steel


Energy

Power

Communications

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Energy

RETAIL OUTLETS IN INDIARETAIL OUTLETS IN INDIA

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Energy

BASE REFINERY AT JAMNAGARBASE REFINERY AT JAMNAGAR

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From Rig to RetailEssar Oil is a fully-integrated oil company of international standard and scale

Energy

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EOL – Business Units

Marketing

Retail

Bulk

Exploration & Production

Exploration Blocksin India, Vietnam, Nigeria, Australia and Madagascar

Development Blocks

Coal Bed Methane Blocks

Grassroots

Refinery

in Vadinar

Refining

Energy

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E & P

Proven FieldRatna and R series with reserves of 500 million

barrels of oil

Exploration Blocks:

Oil Blocks: Mehsana, Gujarat, and Assam

CBM Blocks: Raniganj, West Bengal

Exploration Blocks in Australia, Madagascar,

Nigeria and Vietnam

Energy

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Refinery

12.5 MTPA capacity being increased to 34 MTPA in two phases

State-of-the-art technology and flexibility to handle diverse crude mixes

Capability to produce EURO III & EURO IV compliant fuels

Dedicated infrastructure include port, SBM, tankage, pipeline and power

Ideal location; close to source of crude and market

Energy

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Marketing

Network of 1,000 retail outlets

Presence on highways, rural and semi-rural areas in India

Premium fuel brands

Institutional sales through bulk marketing

Energy

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ROI ROI –– ImprovementImprovement

Increase ROI

ReducedProject Capital,

Installation &Commissioning

Cost

ReducedFeed stocks

Energy and UtilitiesMaintenance

wasteAbnormal Events

Increase Productivity

IncreasedYield

ConsistencyEquipment Capacity

Equip. Efficiency

Reduction of losses

ReducedUnscheduled Downtime

& Small stoppagesLow Maintenance time

Resources, Reliable History

Increase RevenueReduce conversion Costs

Reduce Capital Cost Increase Profitability

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Asset Wear Pattern:Asset Wear Pattern:AGEAGE

PROBEBLITY OFPROBEBLITY OFFAILUREFAILURE

PM Plan for time base proactive maint.

Electronic Instruments (transmitters, Sensors, Cards, FF accessories, Switching Hub, Operator /Touch Screen

F. Worst New

Rolling element bearingE. Constant Random Failure

Hydraulic & compressed air System

Random Wear

D. Best New

Control Valves (external affects)C. Slow Aging

Electro-mechanical items, Electronic components (positioners) give rise to infant failure at the left side of curve, while mechanical component give late life failure, (Internal failure of control Valves)

B. Bath Tub Curve

Failure of control Valves moving parts, Mechanical drive items (gear box, chain)

Time Base Wear

& Tear

A. Traditional view

EXAMPLESEXAMPLESType of AssetAsset

Maint.

GRAPHICAL REPRESENTATIONGRAPHICAL REPRESENTATIONDESCRIPTIONDESCRIPTION

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• Process devices start deteriorating and wear out from the minute it’s placed in service. Types of maintenance:

• Run to failure – No maintenance till device fail• Preventative maintenance – Based on schedule given by

equipment vendor or past history • Predictive maintenance – Based on future prediction of condition

of devices

Current Practices:Current Practices:Current Practices:

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Maintenance PracticesMaintenance PracticesMaintenance Practices

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Three- Level Diagnostics Module- “Abnormality Analysis”ThreeThree-- Level Diagnostics ModuleLevel Diagnostics Module-- ““Abnormality AnalysisAbnormality Analysis””

Operations

Loop

Device

Drift

µP

Externalinfluence

ElectronicsDefective

Sensor Drift

Level 1

Level 2

Level 3

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Maintenance Practices in Digital WorldMaintenance Practices in Digital WorldMaintenance Practices in Digital World

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Enterprise Enterprise NetworkNetwork

Operations

Loop

Device

Communication& Networking

Level 4

Drift

µPExternalinfluence

ElectronicsDefective

Sensor Drift

FF SensorsLevel 1

Level 2

Level 3

FF AccessoriesLevel 1A

Four - Level Management Module- “Abnormality Analysis”Four Four -- Level Level Management ModuleManagement Module-- ““Abnormality AnalysisAbnormality Analysis””

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Device LevelDevice Level

۩ FF Basic-to-LM device wizard“Safe” way to enable/disable

Backup LASProvides wizard to step

through sequenceInsures BLAS will

work when needed

Device Configuration:Device Configuration:

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Device Level (Sensing):Device Level (Sensing):

۩۩ Device Replacement by Operator۩ Replacement from Operator Station or Engineering Station۩ Auto replacement۩ Upgrading devices on-line

Device Replacement:Device Replacement:


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Device Level (Final Element):Device Level (Final Element):Asset Measurement & Solutions:Asset Measurement & Solutions:

• Effectiveness for diagnostic– Detecting inner valve failure

• Wearing of seat ring• Sticking the foreign object

– Detecting the failure by vibration• Moving from proper mounting position of positioner by

vibration.– Accurate analysis (No Human error)– Information available at Control room ( With Problem Description)– Stroke repetition– Hysteresis data, Input output deviation– Valve signature – Overshoot / Undershoot stem travel


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Advance diagnosismodule

Common issue in Electrical wiringCommon issue in Electrical wiring(loose wire strands, water ingress, faulty devices, EMC, etc..)Bus topology connects multiple devicesBus topology connects multiple devices

Serial communications signalOne fault can affect several devices

Available tools are for conventional Available tools are for conventional technologytechnology

Tools lacks ability to visualize Fieldbus related signals

Locating the problem is difficult and time consuming many devices in one loop; interoperability)Field Bus installationField Bus installation

Tools to commission, Supervise & trouble shoot (signal distortion)

Issue with FF:Issue with FF:Plant level Communication:Plant level Communication:


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Plant level Communication:Plant level Communication: Predictive maintenance:Predictive maintenance:

Advance diagnosismodule


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۩۩ Identify kind of failure & Identify kind of failure & guided actions guided actions Grounding, Software, hardware& wiring problem۩۩ Highlight Problem with helpHighlight Problem with help۩۩User configure warning & User configure warning & Alarm alerts before segment Alarm alerts before segment failsfails۩۩ Can be used as a Can be used as a Commissioning toolCommissioning tool۩۩ Digital Oscilloscope function Digital Oscilloscope function (Lost telegram)(Lost telegram)۩۩ Log of each event at DCS / HMILog of each event at DCS / HMI

Measurement & Online Solutions:Measurement & Online Solutions:Plant level Communication:Plant level Communication:


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Process Level Diagnosis:Process Level Diagnosis:

Impulse line chockingImpulse line chockingpH sensor deterioratedpH sensor deterioratedCoating on probe of magnetic pickupCoating on probe of magnetic pickupShedder bar not vibrating due to Shedder bar not vibrating due to

internal or external reasonsinternal or external reasonsHigh temperature around the devicesHigh temperature around the devicesControllability problem due to Controllability problem due to

process fluctuationprocess fluctuationInappropriate step taken by Inappropriate step taken by

Operator (SP not followed)Operator (SP not followed)

VendorVendor’’s Solutionss Solutions


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Asset Asset ManagementManagement

ETHERNET

Proprietary BUS

HARTHART

PROCESS FIELD BUS

Optic Optic FibreFibre TCP IPTCP IP

EWSEWSHISHISHISHIS HISHIS

Mod BusMod Bus

OmROn

DeviceDeviceNet R I/ONet R I/O

Local start / stopLocal start / stopPanel with indicationPanel with indication

Touch panelTouch panel

Control NetControl Net

AB PLCAB PLC

Communication & Networking:Communication & Networking:


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Provision for current & Future Provision for current & Future Demands of the Industry like Demands of the Industry like wireless integration, Securitywireless integration, Security against against Hacking & Spy worm etc.Hacking & Spy worm etc.

Network Traffic Control Network Traffic Control Integration of several industrial Integration of several industrial

networking standardsnetworking standardsCabling, Software Management, Cabling, Software Management,

System Integration, Installation and System Integration, Installation and Maintenance.Maintenance.

Configuration of secure and Configuration of secure and reliable Networks in highly reliable Networks in highly sophisticated Industrial environmentsophisticated Industrial environment

Camera


Dual Homing

HiPER Ring

Secure Access to Plant Floor

Secure Access to Enterprise Network

Wireless Transmitter

Video Surveillance

Redundant Link

Communication Peripheral Device Health:


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Communication Peripheral device Communication Peripheral device Health Deterioration indication & Health Deterioration indication & replacementreplacement

Bus cable termination Bus cable termination Replacement of Cable on Physical Replacement of Cable on Physical

health informationhealth informationBus cable rerouting if interference Bus cable rerouting if interference

is noticedis noticedRedundancy alert of Device Active Redundancy alert of Device Active

/ failure/ failureUpdating the Anti virus, Firewall Updating the Anti virus, Firewall

software software High temperature alarm in & High temperature alarm in &

around the devicesaround the devices

Measurement & Solutions:Measurement & Solutions:

Camera


Dual Homing

HiPER Ring

Secure Access to Plant Floor

Secure Access to Enterprise Network

Wireless Transmitter

Video Surveillance

Redundant Link


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MaintenanceMaintenanceto to

ManagementManagement

March towardsMarch towardsNew Concept:New Concept:New Concept:

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A. Engineering B. System & ProductsC. Field Bus Foundation

New Concept:New Concept:New Concept:

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New Concept: Engineering PracticesNew Concept: New Concept: Engineering PracticesEngineering Practices

Develop and Establish Good Engineering PracticesAvoid Unnecessary hardware requirement in the

segment Advice client for Appropriate level of redundancy,

only based on FMEAFMEADesign based on higher CAPEX saving and Safety

in operationAdvice client for vendor independent right choice of

productsMinimum cost of conversion for engineering having

analog design (HART) to FF design

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New Concept: Engineering PracticesNew Concept: New Concept: Engineering PracticesEngineering Practices

Use of Intool / Instrument engineering design software integration with system software by DCS vendor for FF projects

Directly downloading design data from Intool / Design software to system software for reduction in engineering time

Develop good knowledge of FF products available in the market

Update with Foundation Field Bus system and its developments

Provide high fidelity documentation and training advice

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New Concept: Software & Hardware ToolsNew Concept: New Concept: Software & Hardware ToolsSoftware & Hardware Tools

Development of software tool to provide advance information of deterioration by analyzing the degradation indexes which is determined based on the long term gathered data.

Provide accurate information for spare parts requirement / management

Provide information for the lead time between failure and first alarm initiated by the system

Accuracy in failure identification / informationAffect of surrounding condition affecting the

process elements to increase the life of control element

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New Concept: Software & Hardware ToolsNew Concept: New Concept: Software & Hardware ToolsSoftware & Hardware Tools

Auto device recognition and one stork configuration from off line engineering software tool

Develop / encourage using more function blocks in device to reduce load on macro cycle time

Signal / Noise reader: Handheld / DCS & report generator

Universal Low cost FF Laboratory test instrumentsNoise controlNoise control: originating from one spur (device) &

traveling to entire segment

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New Concept: Developments in FFNew Concept: Developments in FFNew Concept: Developments in FF

Final release of ESD system specification for SIL system

Flexibility to use more number of devices in each segment

Reduction in function block execution timeReduction in Non schedule time in macrocycleReduction in loss of cyclic communication data

Tool for understanding loss of data transmission to improve process control

Tool for verification of execution time of function blocks defined in macro cycle

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New Concept: Macro CycleNew Concept: Macro CycleNew Concept: Macro Cycle

Macro cycle time is divided in Cyclic Communication and Acyclic Communication

Alarms / EventsMaintenance / Diagnostic InformationProgram InvocationPermissives / InterlocksDisplay InformationTrend InformationCalibration and configuration

Acyclic Communication

Cyclic / Scheduled CommunicationFunction Block schedulingFunction Block executionGap between messages

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Cyclic / Acyclic Communication

Based on Function block requirement macro cycle time is allocatedMacro cycle Limits the number of devices in one segment to accommodate loops based on execution requirement

Pressure and flow loops are considered as fast loops Level, Analyzers, Temperature and others are moderate or

slow loops Function block execution time depends upon device

manufacturer technology1 sec macro cycle total time is considered good for better process indication / control in most of application250 ~ 300 ms cycle time for fast loops like pressure / flow control Around 40 ~ 50% time is given for other Acyclic Communication


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Limitation with less time allocation for Cyclic / Acyclic Comm.

Acyclic Communication limits the number of devices in each segmentHigher Acyclic time leads to poor performance and generate process disturbanceLower Acyclic time increases the device configuration time during commissioning Lower Acyclic time increases the calibration time of valvesValve signature of each valve takes more than 15 min, which makes impossible for maintenance engineer to take valve signature before and after shutdownDevelopment for new maintenance management solutions and its implementationLimitation for configuration and trouble shooting


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New Proposed New Proposed JSJS--Macro cycleMacro cycle definition:definition:

A.Use Macro cycle for Cyclic / schedule communication for process control function blocks

B.Use Wireless communication for Acyclic / Non scheduled data communication


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Gain from new Hybrid Product:Gain from new Hybrid Product:

Cyclic and Acyclic data shall get appropriate time for job executionMore number of devices can be added in segment (CAPEX benefit)Acyclic time in macro cycle shall be limited to critical abnormality alarms onlyBoth activities shall be independent and parallel to each other Better flexibilityMore diagnostic features are possible to be developed in systemConfiguration and calibration shall be faster even in plant runningPerformance will further improve if we use control on wireAudit trail management will be easy


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Gain from new Hybrid Product:Gain from new Hybrid Product:

Use of Foundation Field bus for control and wire less for Acyclic data communication will help to remove bottlenecking in performanceHybrid product shall encourage vendors to develop many more features and added advantages in futureTwo way communication is possible (reading and writing) during commissioning of deviceNo additional hardware needed


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Thank YouThank You

End User Conf. Japan

Business

Transcript of End User Conf. Japan