implementation of foundation fieldbus (ff ...indianoil.in 23rd nov’2012 copyright© indian oil...

Copyright© Indian Oil Corporation Ltd.

IMPLEMENTATION OF

FOUNDATION FIELDBUS (FF) TECHNOLOGY

IN IOCL REFINERIES

Atish Chakrabarty

Dy. General Manager (Projects)

Indian Oil Corporation Ltd. [email protected]

23rd Nov’2012

http://iocl.com/index.asp


Leading Fortune “Global 500” company in India in

the year 2011–12 for the 13th year in succession.

Ranks 83rd by revenues (exceeding INR 4 Lac cr./ US$ 80

billion).

Ranks 22ND largest petroleum company in the world.

Global Standing of IOCL

Within the country

Refining share : 31%

Market share : 49%

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IndianOil R&D Pipelines

Refineries Marketing

Indian Oil Corporation Ltd.

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Installed capacity - 65.70

Under Implementation -15.0

Digboi 0.65

Haldia 7.50

Panipat 15.0

Paradip 15.0

Koyali 13.7

Mathura 8.0

Barauni 6.0

Guwahati

(Figures in MMTPA)

CPCL(Manali) 10.5

BRPL 2.35

1.0

CPCL(Narimanam) 1.0

Refineries

4



l DUBAI

l MALAYSIA l MAURITIUS

Overseas Offices

Subsidiary Companies at

Mauritius

Sri Lanka

Regional Offices at

Malaysia

UAE l SRI LANKA

Globalisation Initiatives

5



Punch Cards

Second Generation Systems

Third Generation Systems/ Dedicated telecommunication systems

Relational Database Management Systems & SCADA

PC based Control systems

Programmable Logic Controller/ Distributed Digital Control Systems

Advanced Process Control

Project Manthan

Implementation of SAP

FF Implementation for Process Control

1967 / 68

1972

1977 / 78

1988

1991 / 92

1991

1994

1996

2000

2006 / 2010

History of Information Technology/ Process Control in IndianOil

6



Automation & Control in Refinery

Automation & Control in Pipeline

Automation & Control in Marketing & product

distribution

Automation & Control Initiatives

7



State of Art refinery design to maximize value addition

considering demand in the refinery supply zone

Process designed to refine a wide variety of crude oils

including comparatively economic crudes such as heavy, sour

and other opportunity crudes

Refinery to produce high value added products such as

Polypropylene, Food-grade Hexane and solvents in addition to

LPG, Naphtha, Petrol, Diesel, Aviation Fuel, etc.

Future ready refineries - diesel / petrol of Euro IV quality

‘Zero Bottoms’ refineries

State of the Art Refineries

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Planning

Level

Execution

Level

Control

Level

ERP-SAP (Enterprise Resource

Planning) MES

(Manufacturing

Execution System)

FF based DCS &

SIL 3 ESD system

(Distributed Control System

Emergency Shutdown System)

Field Instrumentation

Copyright © HPCL-Mittal Energy Ltd.

APC (Advanced Process Control)

Control Levels in IOCL Refineries

9



Evolution of FF Technology Implementation in IOCL Refineries

Refinery Year of

implementation

Areas of implementation

Panipat

Refinery

2006 FF implemented in ETP and other non-

process units for open loops only.

Gujarat

Refinery

2010 FF implemented during Residue upgaradation

project execution for open loops only.

Digboi and

Guwahati

refinery

2010 FF implemented during MS quality

upgradation project for open loops only.

Barauni

refinery

2010 FF imeplemented during execution of

Hydrogen unit and MS quality upgradation

project for all open loops and non-critical

closed loops.

Paradip

refinery

Under

implementation

FF under implementation in the whole

complex of 15 MMTPA refinery for open loops

and non-critical closed loops. 10



SYSTEM SIZE- APPROXIMATE FOR PARADIP REFINERY DCS

TOTAL NUMBER OF FOUNDATION FIELDBUS SEGMENTS = 2100 NOS.

TOTAL NO. OF FF LOOPS = 10000 NOS.

TOTAL NOS. OF FF CLOSED LOOPS = 2000 NOS.

TOTAL NOS. OF FF OPEN LOOPS = 8000 NOS.

TOTAL NOS. OF 4-20 mA / HART DCS LOOPS = 37000 NOS.

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DCS Sizing based on FF



Field JB HART

I/O

subsystem

with IS

barriers

FF JB with

field barriers Field JB Field JB

ESD-SIL3 F&G-SIL3

Data Highway

MCR

SRRs

FIELD

RACK ROOMs & MAIN

CONTROL ROOM (MCR)

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Controlling Methodology



Control Room

SURGE PROTECTOR

Field Junction box with Fieldbus Barriers

Field

Foundation Fieldbus Topology

Redundant FF-

H1 interface

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Foundation Fieldbus topology

DCS Field Instrument

Spur

Trunk


../../../D630-D Drive/FF DOCUMENTS/FF Presentations/FieldConnex Modular Presentation/FieldConnex HighDensity Power Hub en.ppt

../../../D630-D Drive/FF DOCUMENTS/FF Presentations/FieldConnex Modular Presentation/FieldConnex Surge Protector en.ppt


Fieldbus concept followed in Process units for all Open loops and non-critical closed loops

Max. two closed loops are considered per segment ,Coexistence of open & closed in same

segment

High Powered Trunk with Field Barriers concept is implemented

(Power Supply capability is minimum 350 mA at 25 VDC)

Control on wire concept is not implemented to avoid process instability.

Fieldbus junction boxes with field barrier assembly placed in SS316 Housing

18AWG Trunk Cable with a loop resistance of 44 ohms/K.M is generally used and based on

segment validation by system supplier, 16 AWG is also used.

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FF implementation Philosophy



Not more than 3 field barrier assemblies are considered in one segment per FFJB

Chicken Foot Topology

Minimum 25% spare connections for field devices are provided in each segment

Each spur is Intrinsically Safe & galvanically isolated from trunk

Fieldbus terminator & surge protector provided for each segment

LED indicator for each spur short circuit

In general, Max. Trunk Cable Length + Spur Cable Length – 1900mtrs. However, based on

segment validation for some cases with less number of devices, length of cable is more than

1.9KM.

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FF implementation Philosophy..contd



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Typical 3 Barrier FFJB in a segment



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Operational Excellence using FF

Experiences – During Installation & Commissioning

Cost savings achieved by

Reduction in cable cost

Faster completion of cable laying work

Less number of terminations

Reduced cable ducts/ trays.

Faster completion of loop checking and validation

Faster uptime of instruments

Less number of cabinets required

Less space required for control room due to lesser cabinets

Reduced erection & commissioning efforts.



Experiences – During Commissioning and Operations

Benefits of Interoperability.

Lesser time for instrument installation/ modification

Easy access to device information

More information available for field devices

Re-ranging from DCS is easy and faster

Advance information, alarms on impending failure

Easy trouble shooting

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Operational Excellence using FF



Proper flow of information about the installed systems across the globe.

Inclination of buyers towards existing & proven technology for comfort.

Cost of ownership of new technology.

Gap in understanding on provenness & dependability.

Sharing of Report on Failure Analysis with Diagnostic and overall

impact.

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Challenges & Opportunities for Buyers & Sellers



Thanks for your cooperation

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implementation of foundation fieldbus (ff ...indianoil.in 23rd nov’2012 copyright© indian oil...

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