DCS Migration Acetic Acid Plant Sterling s Experience. Assistant Manager Control Systems Group

Transcription

1 DCS Migration Acetic Acid Plant Sterling s Experience Dennis Yieh Assistant Manager Control Systems Group 10 February 2010

2 Sterling Chemicals Overview Corporate headquarters in Houston Sterling Chemicals, Inc. is a North American producer of selected petrochemicals used to manufacture a wide array of consumer goods and industrial products. Our primary products currently consist of acetic acid and plasticizers i and we benefit from long-term requirements contracts with BP Amoco Chemical Company and BASF Corporation for these products, respectively Our petrochemicals facility located in Texas City, TX, is strategically located on Galveston Bay and offers approximately 160 acres for future expansion by us, or by other companies that can benefit from our existing infrastructure, facilities, management and operations expertise com/ 2/15/2010 2

3 One of the lowest cost acetic acid facilities in the world Based on BP Chemicals proprietary carbonylation technology, or Cativa Technology Rated annual production capacity expanded in 2009 to 1.2 billion pounds through low-cost debottlenecking opportunity We sell all of our acetic acid production to BP Amoco Chemical Company pursuant to a long-term production agreement that expires in 2031 Acetic Acid Plant Overview 2/15/2010 3

4 System: Fisher Provox system (now owned by Emerson): Acetic Plant DCS Background 5 controllers, 4 workstations with dual monitors, 2500 I/O Commissioned around mid 1995 Control network Proprietary Decnet based Slow speed (2 to 5 MB) Proprietary configuration and control software (VMS based) Issues: Received obsolescence notification from vendor : no support after 2012 Shrinking Provox knowledge base Costly spare parts and availability DEC VAX with VMS configuration server some parts are no longer available and others are difficult to find for the particular model we have Expensive to add I/O, especially for remote field instruments 2/15/

5 Migration Challenges All systems must be re-configured to our plant Downtime required regardless of migration strategies Downtime production loss earning loss The more downtime the more costlier of the migration When to migrate? When acetic plant turnaround (2009) most cost effective Missing the turnaround window the next one will be 2012, increase risk Shutdown just for migration most costliest (production loss must be accounted) Desire to minimize re-wiring to reduce field and engineering re-work costs Migrate in pieces or all at once? HMI replacement solutions require use of two systems to make changes Controller only replacement leaves I/O change out for later Some solutions require new control cabinets How much capital investment? Users must be trained on new system 2/15/2010 5

6 What Do We Want? Proven low cost migration solution with minimal downtime and risk Easy to configure and troubleshoot with rich control functions Ease of integration to manufacturing execution and enterprise systems, e.g. APC, plant asset management Open architecture with ease of expansion and flexibility Control network with high availability and reliability Good support infrastructure and expertise Lowest life cycle cost with continuously current philosophy 2/15/2010 6

7 Why We Chose Invensys Invensys has the lowest cost and migration option that minimizes downtime Based on detail evaluation of 3 vendors migration solution (including OEM) Minimum downtime - no rewiring, retained all field wiring, I/O cabinets, terminations and power supplies Warranties existing racks, power supplies, and termination assemblies as new system True fault-tolerance system from controller to I/O modules High available and reliable control MESH network Integrating existing Modicon PLC into HMI is a matter of getting system connectivity and importing existing Wonderware based graphics saves engineering time and money Invensys has Continuously Current philosophy maintaining support for products. No Dear John letters Potential to integrate Avantis system and gain additional maintenance functionality 2/15/2010 7

8 Project made up of two parts Sterling Project Scope 1. Migrate Acetic Provox control system 2. Expand migrated system to operate new Process Water Collection and Treatment system (plant wide) Part 1: Migration of Acetic Provox includes: Part 2: Installing new single-mode fiber loop (west plant) and MESH switches Replacing 1,200 Provox SR90/SRx I/O Installing 140 new redundant smart Foxboro I/O (200 series) Interfacing 15 RS232/486 Modbus devices (1600 soft I/O) Converting regulatory control configuration Converting 81 customized complex control o strategies es instruction sets (Function Sequence Table) Installing 7 operator workstations with either dual or quad screens Converting 114 graphic displays Revised Treatment t System: Installing new Foxboro smart I/O (I/O cabinets spread out in 3 different locations) Interfacing 10 Ethernet Modbus devices (110 soft I/O) New display graphics New control logic for ph control 2/15/2010 8

9 New System Architecture 2/15/2010 9

10 Project management System engineering Develop project function specification Human interface configuration (graphic displays) Control configuration Foreign device interface configuration Fiber MESH network design Historian configuration and interface to PI Documentation Bill of materials System architecture Invensys Service Scope Power & grounding Cabinet electrical and layout drawings SAMA control logic drawings Factory acceptance test Construction and onsite service Dismantle and install Operator Consoles Disconnect and install cabling between marshalling and new I/O cabinets Loop check and commissioning Training i 2/15/

11 Project Schedule Major Milestone Date Master Supply and Professional Services Agreement signed Nov 10, 08 Purchase order issued Nov 13, 08 Project kick-off meeting at Invensys Houston office Dec 5, 08 Engineers and technicians configuration training Dec 8 12, 08 Issue functional design specification for both migration and process water Jan 27, 09 Engineering review meeting Mar 24 26, 09 Design and database for migration freeze Mar 31, 09 Foreign devices (Modicon and Phoenix PLC) communication testing and review new cabinets layout at Invensys Houston staging area Apr 21 22, 09 Operator training Apr 21 23, 09 May 5 7, 09 2/15/

12 Project Schedule Major Milestone Date Factory Acceptance Test May 11 19, 09 Equipment delivery to site May 29, 09 Provox DCS power down and begin migration installation Jun 11, 09 Migrated new system power up for loop check out and commissioning Jun 17, 09 Loop check out and commissioning complete Jun 28, 09 Complete Acetic plant turnaround and start up Jul 10, 09 Migration project complete Jul 31, 09 Begin Revised Treatment System project loop check out and commissioning Aug 10, 09 Complete Revised Treatment System project Sep 18, 09 2/15/

13 Lesson Learned Do due diligence on different vendors migration strategy and select the one that best meet your business condition and plan Invensys is the right choice Choose the right people for the project team: Process engineer and supervisors I/E project engineer and designer I/E maintenance supervisor and technician DCS engineer and technician Control configuration accurate and up-to-date information Updated P&ID s, logic diagrams and process control description Most current configuration database Verify accuracy of tuning parameters conversion Graphic displays Involves the right operator to get input Review each existing display and clean out those no longer use Understand the functionality of the new graphic software and its implication Define display, alarm and user security functions clearly Training both formal and during loop checkout and commissioning Factory acceptance test no short cut, well planned and executed 2/15/

14 Results Well executed migration project Completed in 7 months with great engineering support and services from Invensys Plant started up as scheduled with no incidence or trip due to DCS issue Project cost met budget within contingency Significance saving compares to bulldoze solution Control system performance Eliminated need for writing customized control instructions set for complex control strategy Eliminated confusion between valve and control action; loop drawings and configuration are consistent Ease of configuration from simple to complex control strategies Robust foreign device interface to work well with Serial or Ethernet devices Controllers and I/O modules perform robustly MESH network performs flawlessly and reliably Improved hardware and software maintenance Robust system tools for ease of hardware devices troubleshooting; minimizes downtime With Invensys Continuous Current philosophy, InFusion ECS software allows incorporation of new technologies as they evolve 2/15/