Challenges for the realisation of the Foundation Fieldbus Technology potential

Kees van Geel - Shell Global Solutions Int.

Shell Global Solutions International - SGSI

Who we areWho we are:An international technology service provider, supplying innovative technical, safety and environmental solutions primarily to the worldwide Oil & Gas industry

The HagueAmsterdam

Rijswijk

Thornton

Houston

Singapore/KL

Hamburg

Some 4000 staff based in:Some 4000 staff based Some 4000 staff based in:in:

FF Project Implementation Support facilities

• FF Implementation Support Team – 7 global staff GSES • FF Implementation Support Packages ( Technology awareness package, Consultancy for technology decision, Practical project implementation support, Design Guidelines)

•Capture first operational experience after 12 – 18 months; input to:

lessons learnt and guideline improvement

Foundation FieldbusStandard technology used for all greenfield Shell projects

• Available on the market 10 years

• In Shell first used 8 years ago

• Now used in Capital projects as standard technology for 3 years

V i s io nD e v e lo p m e n t

T e st in gS ta n d a rd

E a r ly A d o p t e r s

B ro a dP ro je c ts U p -t a k e

S u p p o r t fu n c t io n s& G u id e lin e s ,

T ra in in g

P ro j e c t s E x p e r ie n c e s

L e s s on s L e a rn t

T e c h n o lo g y a c c e p t a n c ea n d u p - ta k e

20051995 2000

Generic Benefits from FF technologyProject Phase Operational

Phase• Reduced Project Capex

• DCS & Field devices• Field infra structure• Civil/Buildings - footprint

• Engineering, Design, Construction

• Design eff by standardisation• Fast configuration

• Installation, Commissioning• Cable installation• Fast commissioning

• Reliability, Availability• Diagnostics, Self-check• Control in the Field

• Throughput & Quality• Accurate control

• Operations• Reduced manning• Remote operations

• Maintenance• Fact based and pro-active

• Safety• Less people in the field• Less transport of people

FF projects list – Jan 2005 Up-date

Size confirmedProject # FF I/O RFS date Type Status FF-SupplierP-LNG 20000 Gas New building BODCSPC Nanhai 16500 Chem 2005 New building Des ign & Com m YokogawaQatar GTL _ SMDS_Phase 1 12010 Gas 2008 New building FEED HoneywellQatar GTL _ SMDS_Phase 2 10257 Gas New building Technology choiceNAM GLT 10727 Up On-going Re-ins trumentation Technology choice YokogawaVarious SPDC 5000 Up New building Des ignNorco Olefins 4800 Chem Re-ins trumentation Des ign & Com m YokogawaSakhalin Downstream LNG 4600 Gas 2006 New building Des ign & FAT YokogawaHoudini 4300 Ref 2009 New building BODDeerpark HC 3000 Ref Re-ins trumentation Operational EmersonNorco Refinery 3000 Ref 2004 Re-ins trumentation Start-up EmersonSakhalin Ups tream _Offshore 2080 Up 2006 New building Detailed Des ign & FAT YokogawaSPDC Bonney Oil Terminal 1750 Up Re-ins trumentation Early Des ign, MAC selec tionMalampaya 1600 Up New building Operational EmersonDeerpark CC 1500 Ref Re-ins trumentation Operational EmersonPDO Yibal 1500 Up Re-ins trumentation Operational EmersonBukom HCU 1400 Ref Re-ins trumentation Operational YokogawaPDO Fahud FCS 1000 UpSUK Bac ton Oil Terminal 1000 Up Re-ins trumentation Des ignSCAN AOS 600 Ref New building Operational FoxboroRefidomsa 600 Ref Re-ins trumentation Operational Emerson

FF projects list – Jan 2005 Up-date (cont/2)

Ormen Lange 0 Up 2006 New building Technology choice ABBPernis Smeerol ie Ref Re-instrumentation Technology choiceChine W est P ipeline Up New building Technology choiceChina Kela Up New buildingBBL Up New building Technology choiceSchoonebeek Up Re-instrumentation Technology choicePernis Steiger Ref TestSCOT Rejuvinat ion Ref Re-instrumentation BODCorrib Up 2005 New building Detailed Design ABBPernis Marathon Ref Test HoneywellMoerdijk ChemStanlow Ref Test

Totals 120767

Deerpark CC 1500 nov-01 12202Expro BAR 150 dec-01 12352 dec-02PDO Qaharir Production Stn. 120 jan-02 12472 sep-02PDO Musallim Expansion. 50 jan-02 12522 jul-03BSP Egret 150 jan-02 12672PDO Marmul-A Production Stn. 100 jan-02 12772 dec-02Norco Refinery 3000 jan-02 15772PDO Nimr Deep Water Disposal. 100 feb-02 15872 feb-03PDO Rima Deep Water Disposal. 100 mrt-02 15972 mrt-03PDO Govt' Gas Plant Expansion. 400 apr-02 16372 jan-03CSPC Nanhai 16500 mei-02 32872SUK Bacton Oil Terminal 1000 aug-02 33872Norco Olefins 4800 aug-02 38672Chine West Pipeline aug-02 38672BSP CW 125 sep-02 38797Deerpark HC 3000 sep-02 41797NAM GLT 10727 sep-02 52524SMDS Qatar sep-02 52524 35796,00PDO Marmul-G Production Stn. 300 okt-02 52824 okt-03 37987,00Refidomsa 600 dec-02 53424 2003/04Various SPDC 5000 jan-03 58424

FF Technology up- take in Shell Projects

010203040506070

1998 1999 2000 2001 2002 2003

Thou

sand

s

Time - Years

# FF

dev

ices

Nanhai

GLT

Norco Olefins

FF Technology Up-take in Shell Projects

2005: 120k I/O

FF I/O’s per Project Type

JAN 200450 Projects101150 FF I/O’s

FF IO's per Type

Unclear4%

Greenf ield59%

Re-Instr37%

Test0%

57 Projects120767 FF I/O’s

FF IO's per Type

Unclear3%

New66%

Re-Instr31%

Test0%

FF I/O’s per Application Sector

57 Projects120676 FF I/O’s

FF IO's per Appl SectorUpstream

30%Chem21%

Ref15%

Gas34%

FF IO's per Appl SectorUpstream

25%Chem18%

Ref12%

Gas45%

Jan 200450 Projects101150 FF I/O’s

Projects per Supplier

57 Projects120676 FF I/O’s

# Projects per Supplier

ABB4%

Honeyw ell13%

Foxboro2%

Emerson22%

Yokogaw a20%

Not decided39%

Jan 200450 Projects101150 FF I/O’s

# Projects per Supplie r

ABB4%

Honeyw ell8%

Foxboro2%

Emerson24%

Yokogawa22%

Not decided40%

FF IO per Supplier

57 Projects120676 FF I/O’s

Jan 200450 Projects101150 FF I/O’s

FF IO's per Supplier

Not decided28%

Yokogaw a36%

Emerson10% Foxboro

0%

Honeyw ell26%

ABB0%

FF IO's per Supplier

Not dec ided36%

Yokogaw a41%

Emerson12%

Foxboro1%

Honeywell9%

ABB1%

Definitions/1• Assets – all hardware available at a producing site

that has an impact on production availability and on production efficiency.– Specifically this will include process vessels, piping, process

control and automation system, electrical systems, rotating equipment, monitoring systems and tools, inspection systems and tools.

• Asset Management – the work process targeting optimum utilisation of Assets.– Specifically this will include work in the Project Phase –

system configuration and downloading, fast commissioning, trouble shooting – and work in the Operational Phase –effective planning and execution of maintenance, optimum operation.

Definitions/2

• Asset Management Systems – Systems that contain tools and provide input for plant staff –production planners, technologists, operators, maintenance staff – to assist in Asset Management.– Specifically this will include functionality for effective and

efficient Operations, i.e. to maintain planned availability and to optimise the performance of production facilities

– technical, financial, strategic

– Proper set-up of AMS should start in Project Phase

The Vision & the Expectation

Promises from Industry:Open System Architectures with FF technology will

provide

Enabling Platform for Operational Excellence andReduced Capex and Opex

– Time & cost effective automation project execution– Enable fast commissioning– Provide improved reliability/availability– Enable unmanned operations– Enable remote operations support– Enable pro-active maintenance schemes

Reality• Foundation Fieldbus is not much more then an

infrastructure• Currently asset management in DCS is instrument

asset management – Still stuck in development of basic applications– No platform for application developments

Challenge:• Move data into information• Working together of Supplier & Users to

develop applications

Contributing AMS elements – utilisation

ProcessUnitOptimisation

ProcessUnit/EquipmDiagnostics

ProcessInterfaceDiagnostics

DeviceDiagnosticsB

asic

A

dvan

ced

Type of Diagnostics InformationOn Process Unit utilisation

On basic Process Unit functioning

On Device utilisation

On basic Device functioning

Multiple input model, incl $$ info, reliability/stress relations to determine value/cost relation ship

Catalyst flow risk, Wrong temperature profile (all multi-input & model); pro-activeapproach is essential

Transmitter drift detected, Plugged Impulse line, Valve performance deterioration

Failure with sensor, A/Dconv, memory card

ProcessUnitOptimisation

ProcessUnit/EquipmDiagnostics

ProcessInterfaceDiagnostics

DeviceDiagnosticsB

asic

A

dvan

ced

Type of Development Action Type of Diagnostics Party Party Info

Production planner + Technologist, Automation Contractors

Technologist, Automation Contractor

Instrument Engineer/Automation Contr

Device Supplier

Targets for economical optimisation

Alert plus suggestion on action. Routing and action Criticality dependent.

Alert info plussuggestion on action & timing, SAP

DetailedDev. Diagnostics Data à SAP

Info toTechnologist

Operator

Operator/ Maint. Org.

Instrument Maintenance Organisation:Pro-active info

Traffic light to Op; Auto WO gen in SAP D

ata

In

form

atio

n

So

lutio

n

Str

ateg

ic

Opt

ions

ProcessUnitOptimisation

ProcessUnitDiagnostics

ProcessInterfaceDiagnostics

DeviceDiagnosticsB

asic

A

dvan

ced

Type of Development Action Type of Diagnostics Party Party Info

Production planner + Technologist. AC

TechnologistandAC

Instrument Eng. Automation Contr (AC)

Device Supplier

Advice for economical optimisation

Alert plussuggestion on

Alert info plussuggestion on action & timing

DetailedDev. Diagnostics Data à SAP

Info toTechnologist

Operator

Operator

Maintenance Organisation

Auto WO gen in SAP D

ata

In

form

atio

n

So

lutio

n

Str

ateg

ic

Opt

ions

Issue

• Little consistency in Vendor/User approach to AM• Little input from User Technologist/Process Engineers

– Different Departments– Little interest in perceived instrument/asset management(maintenance

issues)– Different priorities

Challenge:• Move instrument data into process unit information• Working together of Supplier & Users to develop

process/unit applications

A way forward• Vendor and User Engineers working together more

closely on AM requirements/ packages– Can this be done in an industry platform (FHI, WIB, IEC)– Can Users agree on generic requirements

• Vendor to develop “standard” AM building blocks around process equipment with Users– Requires Users to accept testing at another companies site– Willingness of users to invest in tests

• User friendly AM building blocks will make it easier for Technologist input and idea generation

• Implementation as a standard during design

Risk of doing nothing

• Getting stuck; FF based AM remains basic• Technology not used• Perception will remain AM = SAP• Lot $$ to loose for Users

Thank you for your attention