Malaysia End-User Seminar11 November 20091
Building PETRONAS Capability Through Fieldbus Testing
ZULKARNAIN DARUSPrincipal Engineer
Group Technology SolutionsPETRONAS
Malaysia End-User Seminar11 November 20092
INTRODUCTION
• FOUNDATION Fieldbus (FF) is 10+ years in the market but utilization in PETRONAS is low.
• Installation based in PETRONAS:– PPMSB: 1500 + 200 = 1700+ devices– PFK: 200+ devices– NPK: 800+ devices– Carigali:
• SUPG-B: 290+• SUJT-C: <100• SUDP-A: 200+
• GTS believes that FF can bring– Cost savings– Online asset proactive / preventive maintenance
• BAJT-H • KNPG-B• KNJT-C etc
Malaysia End-User Seminar11 November 20093
CURRENT ISSUES WITH FIELDBUS IN PETRONAS
• Level of competency for O&M personnel– Different tools– System software competency required
• Hardware issues– Field barrier failure– H1 card failure– Device drop out for no apparent reason
• To address these issues and start building PETRONAS capability in fieldbus system, GTS and UTP collaborated and…
Malaysia End-User Seminar11 November 20094
UTP FOUNDATION FIELDBUS LAB
• Lab was set up in Aug 2008
• Officially launched by Rector of Universiti Tekonologi PETRONAS (UTP) in Nov 2008
Field instrument rack: 25+ devices
Host stations
Host controllers: 4 systems
Malaysia End-User Seminar11 November 20096
FIELDBUS SYSTEM ARCHITECTURE IN UTP
P+F Power Conditioner
EWS AMS
MTL Power Conditioner
ROSEMOUNT YOKOGAWA
P+FFOXBORO
HONEYWELLE+H
FISHER
YOKOGAWAFOXBORO HONEYWELL
EWS EWS EWS PRM
EMERSON
• 2 segments of 300m and 500m type A cable
• Field barrier from MTL and P+F
}
Malaysia End-User Seminar11 November 20097
DELIVERABLES AND ASPIRATIONS
• A report on results from interoperability testing that will serve
as reference for FF in PETRONAS.
• A revised PTS on FF system.
• Working group who are well-versed on all aspects of FF system
• A test facility to verify fieldbus host interoperability and provide
user guidelines for each Host.
• Training and skill certification facility within 2 – 3 years for
engineers and UTP students on FF system.
• A test platform for R&D activities for UTP especially in areas of
Instrumentation & Control and Control Strategies.
Malaysia End-User Seminar11 November 20098
TEST DONE SO FAR…
Basic Test (Sept 08 – May 09)
• Findings– Problem with block instantiation leads to commissioning problem
– Field device communicator can’t communicate with all devices
– Wizards to perform some tasks may not necessarily available
– Not all system can restore device original configuration automatically
– In trouble if address of device inadvertently changed to out-of-scanned
range
– Some devices are polarity sensitive
Malaysia End-User Seminar11 November 20099
NEXT TEST TO BE COMPLETED…
Stress Test• Fully loaded segment
• Failure recovery
• Cable constraint: using other industrial standard instrument
cable
• Control in field including tuning
• Segment design tool
• Back up LAS
• etc
Malaysia End-User Seminar11 November 200910
FIELDBUS CERTIFICATION PROGRAM
• Intended for PETRONAS staff
• Staff shall be certified before they can work with Fieldbus system in
PETRONAS
• Training to be conducted by UTP
• Typical syllabus:– Comparison between fieldbus and conventional 4-20mA– System architecture– How to design fieldbus segment– Safety concept– Device communication layer– DD, LAS and macrocycle– Maintenance and troubleshooting
• Intention to open course to public in 5 years time
Malaysia End-User Seminar11 November 200911
Distinctive
Com
petitive
Financial Year
• A testing facility that will be used to verify
other Hosts and devices’
interoperability based on PETRONAS
standard and provide user guidance
Base
• A future training and skill certification facility
within 2 – 3 years for engineers and UTP
students who will be working on fieldbus
system
• A test platform for R&D activities for UTP
especially in areas of Instrumentation &
Control and Control Strategies
A PETRONAS Technical Standard on Foundation Fieldbus
system
Working group who are well-versed on the
fieldbus system in term of operation and
maintenance
2009/2010 2010/2011 2011/2012
Diagnostic capability enables real-time asset management, simplifying routine maintenance and supporting predictive maintenance
2012/20132008/2009
DEVELOP TECHNICAL
GOVERNANCE.
FOCUS ON GROUP
COMPENTENCY
UNFOLD & ACQUIRE
ADVANCED DIAGNOSTIC FEATURES
TRAINING CENTER FOR FIELDBUS TECHNOLOGY
FIT-FOR-PURPOSE TESTING FACILITY
Stress test validates the accuracy of systemic specifics, through simulation of variables for robustness in process automation
VALUE ADDING PLATFORM FOR R&D
A report on results from interoperability
testing that will be the reference for
Foundation Fieldbus system in PETRONAS
Continuous testing to stress fieldbus
system and explore its diagnostic
capability
Conduct Basic Test and Extended Test (basic operation and exploratory test) on all Hosts Completed
FOUNDATION FIELDBUS TESTING ROADMAP