FF technology application progress in China petrochemical industry

Foundation fieldbus technology application and progress
in China petrochemical industry

Rong Lin
Shanghai, 2013/03/14

September 2012
1 1
© 1994 – 2012 Fieldbus Foundation

1. Introduction

2. PetroChem Industry Trends and Challenges

3. Ff fieldbus technical and economic analysis

4. Ff fieldbus technology trends

5. The Ff fieldbus Example

6. Conclusion

September 2012
2 © 1994 – 2012 Fieldbus Foundation

1. Introduction
In the beautiful season of Spring returning to the good earth and all things recovering, the world-
remarkable Fieldbus Foundation Global Member and User Conference has come to China again.

The foundation fieldbus is recognized quickly in the world every year and its application has covered
such industries as oil, gas, petrochemical, electric power, paper making, pharmacy and so on. The installation of
the foundation fieldbus technology has reached the record-making level; globally, there are totally hundreds of
thousands of systems and millions of devices in service at present. Therefore, we may say that the foundation
technology has changed the future of industry automation, including the design mode of control systems. The
sufficiently rich information makes preventive maintenance possible.

The theme of this forum “In a World of Choices, FOUNDATION™ Brings it all Together” is consistent with the
development direction of “large, integrated, park-based, intelligent and clean” currently implemented by our
Chinese petrochemical enterprises. In particular, it’s of significantly practical value in the strategic deployment
of “establishing digitalized factories” implemented by Sinopec. The gradual promotion and application of Ff
technology in China has greatly improved the intelligentization level of the production of petrochemical.

We hope, by virtue of this “Conference”, the technical exchange and communication among the
production users, engineering companies, scientific research institutes and manufacturers from the process
automation field in Ff technology development and application can be greatly promoted. Therefore, I would like
to, on behalf of SEI Instrument Team, show our sincere acknowledgement to such end users, engineering
companies, scientific research institutes, manufactures as CSPC, SECCO, FREP, Yantai Wanhua and so on that
we cooperated and are cooperating with and that greatly promote Ff technology’s development in China, and the
experts and friends from FFCMC, CFFC, etc.!

September 2012

World Economy - the center of gravity from West to East

September 2012
4 4

China's sustained economic growth has contributed to the progress of the
petrochemical industry
The Daily Telegraph of UK reported on November 5, 2012: “China will become the largest economy in
the world by 2025”. This newspaper quoted a research report of Frost & Sullivan, a US authoritative market
research company. This report pointed out: “By 2025, China will become the largest economy of the world with
the nominal GDP up to USD 38 trillion”. Soon later, HSBC also issued a similar report.
Petrochemical industry, as foundation energy and raw material industry, has become an important pillar
industry in the development of national economy and plays an irreplaceable role in GDP contribution and
improvement of people’s life. In terms of oil refining, according to the latest forecast, the demand growth rate of
petroleum products in China in the 12th Five-year Plan period will be about 4.4%. According to the
Petrochemical Industry Development Program in the 12th Five-year Plan Period set out by the National Reform
and Development Commission, by 2015, the demand of crude oil in China will be 600MT/a and that of steam,
coal and diesel 360MT/a. During the 12th Five-year Plan, the oil refining capacity of China will increase by at
least 100MT and reach 670MT/a. Attention will be paid to the construction of more than ten 10MT level oil
refineries in Sichuan, Beihai, Quanzhou, Zhanjiang, Huizhou, Jieyang, Hainan, Zhenhai, Taizhou, Lianyungang,
etc.; by 2015, the predicted production capacity of ethylene will reach 27MT and the demand will reach 34~38MT,
with the gap of about 7-11MT. The demand growth rate of ethylene in China is about 5.1% and the attention will
be paid to the construction of nine MT level ethylene plants in Sichuan, Wuhan, Zhanjiang, Huizhou, Hainan,
Zhenhai, Taizhou, Lianyungang, Qingdao, etc..

September 2012

The momentum of petrochem industry - China is the world's largest
petrochemical market.
By 2015, the market demand will take up about 1/3 of the world’s demand and 1/2 of Asian demand.

China is the main driver of the global petrochemical industry.

Asia, MT World, MT

September 2012

Sustained growth of the petrochemical industry in refining capacity
The Oil Refining
China: The oil refining capacity continuously increase, but the growth Industry Development
speed is lower than that of ethylene production capacity. Program in the 12th
Five-year Plan Period
issued by the Ministry
of Industry and
Information
Technology requires
that:
The crude oil refining
capacity of China by
2015 should reach
about 600MT/a; the
demand of refined
petroleum products in
the incoming 5 years
should increase by
4.4% every year on
average and the fuel
demand by 2015
should be estimated to
increase from 245MT
in 2010 to 360MT.
September 2012

Sustained growth of the petrochemical industry in
The Alkene Industry
rapid growth of Ethylene production Development Program in
the 12th Five-year Plan
Period issued by the
Ministry of Industry and
Information Technology
Ethylene production capacity: will grow quickly in the requires that:
During the 12th Five-year
coming years. Plan period, the alkene
industry of China should
insist on the diversity of
raw materials and the
target is as follows: by
2015, the production
capacity of ethylene in
China should reach
27MT/a and that of
propylene 24MT/a. It is
predicted that the ethylene
demand in China by 2015
will increase by 5.1%
every year, up to 38MT/a.

September 2012

Petrochemical industry development trend: the production
capacities of oil refining and ethylene grow synchronously.
For example, in Guangdong, from 2008, Sinopec prepared to cooperate with Kuwait in joint venture form to construct an
integrated project of 15MT oil refining and 1MT ethylene capacity (Zhanjiang, Guangdong); PetroChina prepared to cooperate
with Venezuela in joint venture form to construct a 20MT oil refining project (Jieyang, Guangdong); CNOOC prepared to
continue the construction of the project of 12MT oil refining and 1MT ethylene (Huizhou, Guangdong), and such projects have
been initiated by now.

图1-1 中国大型炼油项目分布图
Figure 2-1 Distribution Map of China‟s Figure 2-2 Distribution Map of China‟s
Large Oil Refining Projects Large Ethylene Projects
Fushun
Fushun
Fushun
Fushun Fushun

Dushanzi
Dushanzi
Dushanzi
Dushanzi
Dushanzi DUSHANZI
Dushanzi FUSHUN
DUSHANZI Tianjin
Tianjin FUSHUN Tianjin
Tianjin
Tianjin
Tianjin

TIANJIN
QINGDAO
LIANYUNGANG QINGDAO LIANYUNGANG
Qingdao
Qingdao
Qingdao
Qingdao
ZHENHAI WUHAN
Wuhan
BYC

TAIZHOU Secco
SICHUAN Fujian
Fujian
Fujian
Fujian SICHUAN
Qinzhou
Qinzhou
Qinzhou
Qinzhou Huizhou
Huizhou Fujian Huizhou Zhenhai
ZHENHAI
Qinzhou Huizhou QUANZHO
TAIZHOU
U Fujian
BEIHAI HUIZHOU Maoming HUIZHOU FUJIAN
Hainan
Hainan
Hainan
Hainan MAOMING
JIEYANG
Hainan
ZHANJIANG HAINAN ZHANJIANG HAINAN

September 2012

Post-oil era is approaching
Marion King Hubbert, a famous US geologist, predicted in 1956, the turnout of the world petroleum
would reach the peak in certain time in the future, followed by petroleum turnout decrease and
supply shortage, namely, the beginning of the post-petroleum era. We may also think the day
where the turnout of the world petroleum reaches the peak is the day where the post-petroleum
era begins (e.g. after 2020 indicated in Figure 2-3).

产量 turnout
需求 demand
Oil Supply
石油供应量

1900 1940 1980 2020 2060 2100
时间/ 年
Figure 2-3 Schematic Diagram of World Petroleum Turnout September 2012
and Demand Trends

Post-oil era is approaching
The energy consumption structure comparison between China and the
world is as shown in Figure 2-4 and Figure 2-5:
能源比例
能源比例
煤
Coal 煤
Coal
7.8% 0.3% 1.0%
3.9%
石油
Oil 9.0% 28% 石油
Oil
18% 24.0%
天然气
Gas 天然气
Gas
70%
水电、核电、风电
Hydropower, 38% Hydropower,
水电、核电、风电
nuclear power, nuclear power,
wind power wind power
其它（太阳能、潮
Other (Solar 其它（太阳能、潮
Other (Solar
汐能等） tidal
energy, 汐能等） tidal
energy,
energy, etc.) energy, etc.)

Figure 2-4 China Energy Figure 2-5 World Average
Consumption Structure Energy Consumption
11
Structure September 2012

Two hot spots of the petrochem industry
One of hot spots: Coal to oil, coal chemical, Coal to gas and shale gas
exploration are flourishing, Coal to oil, coal chemical, natural gas chemical and biomass
chemical develop rapidly: Power
Heating
Generation

Natural Gas Industrial and domestic fuel Oil

GTL Gasoline Diesel

Transportation
fuel

Aviation Vessel
kerosene oil
Coal Biomass
CTL Petrochemical raw material BTL

Ethylene
Propylene Aromatics Other organic
chemicals September 2012
Figure 2-6 Diagram of Carbon-contained Energy Comprehensive Utilization

One of hot spots: Coal to oil, coal chemical, Coal to gas
and shale gas exploration are flourishing
BDO PTMEG, TH
F Coalbed Natural
Coke Calcium Acetylene
carbide gas/Shale gas gas
PVC
Coalbed gas, commonly called as gas, is
Coke oven Coal tar Crude Triphenyl a kind of new clean energy. The new
gas benzol /PX round of national coalbed gas resource
evaluation result indicates that the depth
Olefin of embedment of the 42 major gas-
Methane
MTO/MTP contained basins of China is 2,000m and
the shallow coalbed geological resources
Dimethyl are 36.8 trillion m3; therefore, China is the
Methanol ether
third largest coalbed gas reserve country
Acetic following Russia and Canada. In the
Glycol DMF acid Coalbed Gas Development and Utilization
Coal in the 12th Five-year Plan, the National
Energy Administration of China points out
Ammonia Urea that, by the end of the 12th Five-year
Plan, the turnout of coalbed gas in China
Gasification will reach 20-24 billion m3.
syngas Carbon Nitrate Ammoniu
monoxide m nitrate The result in the National Shale Gas
Resource Potential Survey, Evaluation
Hydrogen DMC/DPC Polycarbo and Favorable Zone Selection issued
nate recently by Ministry of Land and
PC
Resources of the People‟s Republic of
Indirect
China shows that, the shale gas
liquefactio
n geological resource potential of China is
134 trillion m3 and the recoverable
Naphtha Olefin
resource potential is 25 trillion m3. In
Direct addition, the greenhouse effect of coalbed
liquefaction
Gasoline gas emission is 21 times as much as that
oil
and diesel of CO2 emission! September 2012
13
Figure 2-7 Coal to oil and Coal Chemical Comprehensive Utilization Diagram © 1994 – 2012 Fieldbus Foundation

The second of hot spots:The rapid develop of fine chemicals
Tier 1-Inner Oil, Natural gas, Coal

Tier 2 9 basic chemical raw materials: ethylene, propylene, butene, butadiene, methane, butane, benzene, toluene and xylene

Tier 3 More than 90 derivatives

Hundreds of synthesized resin, synthesized rubber,
Tier 4-Outer synthesized fiber and other chemical raw materials and products.

Figure 2-8 Petrochemical Product Chain Hierarchical Graph

The seven major strategic emerging industries China mainly supports (i.e. energy saving and
environmental protection, new generation information technology, biology, high-end equipment
manufacture, new energy, new material and new energy automobile) all are closely related to fine
chemical industry.
According to the report of the website of www. chem.hc360.com, it is predicted that by 2015, the
output value of the fine chemical industry of China will reach RMB 1.6 trillion, double of that in 2008;
the self-sufficiency rate of fine chemicals of China will reach above 80%; therefore, China will enter
September 2012
the world fine chemical major countries and powers.

Challenges-Focus on Resource & Environment
1. Short crude oil resources and relying on imported crude oil for processing;
2. Inferior crude oil resources and difficult crude oil processing;
3. More and more remarkable supply and demand contradiction of oil refining and
petrochemical raw materials;
4. Fluctuating crude oil price, higher production cost and higher operation risk;
5. Stricter safety, energy saving, emission reduction, environmental protection
specifications and indices requirements;
6. The world-famous petrochemical companies establish plants in China, so the market
competition is furious;
7. The rapid development of the petrochemical industry in Middle East has brought more
and more furious competition;
8. The Coal to oil and coal chemical projects also face up the following special challenges:
1) Large water consumption and severe water shortage in the coal rich areas;
2) Large 3-wastes (waste water, waster gas and industrial residue) and severe environmental protection situation;
3) High project investment and key equipment needing to be imported;
4) Immature production technology and very high energy consumption;
5) High equipment maintenance cost;
6) Shortage of Coal to oil and coal chemical technicians;
7) Concentrated project distribution points and thus large market impact.
September 2012

Why FF?

Characteristics of Ff Fieldbus Technology
The fieldbus control system (FCS) is the new generation control system
after the distributed control system (DCS) and one important branch in the
program control field; however, it will not substitute DCS completely. FCS
has the following remarkable characteristics:
• FCS is of openness, interoperability and inter-usability;

• FCS has site equipment intelligence and functional autonomy;

• FCS has high functional decentralization (CIF);

• FCS has high accuracy and high reliability;

• FCS may save installation materials, reduce debugging load and shorten construction period;

• FCS has advanced diagnosis and predictive maintenance (AMS) function and thus may save
maintenance cost and reduce the cost for the life cycle of the system.

September 2012

Why FF?

Advancement and Necessity of Ff Technology
The fieldbus technology has changed instrument maintenance strategy, greatly decreasing non-planned downtime!

Traditional Brand new • Dedicated to developing one team consisting of operation, process
and maintenance personnel and with cross function;
maintenance maintenance • Eliminate fault sources;

strategy strategy
World-class
65% maintenances are corrective
maintenances, i.e. maintenances
after failures. The key is to take actions before faults rather than
30% maintenances are preventive after faults!
maintenances, i.e. regular
maintenances as planned.

5% maintenances are predictive Maintenance management trend
maintenances, i.e. the maintenances
conducted according to equipment
situation.

Corrective Preventive Predictive
September 2012

Why FF?

The fieldbus technology has changed instrument maintenance strategy, greatly decreasing non-planned downtime!

The key is to take actions where necessary, no need
doing too much!

63% instrument preventive maintenances are excessive, i.e. waste resources.
September 2012

Why FF?

Comparing with the traditional DCS, FCS has the following remarkable characteristics:

Characteristics DCS FCS RMKS
Transmission signal Analog signal or analog Fully digital signal
and digital mixed signal
Communication Unidirectional Bidirectional
direction
Connection mode Point-to-point Multi-node
Routine control Inside DCS controller- In site equipment-
Concentrated Distributed
Fault diagnosis Basic Advanced (with fault
forecast)
Measurement accuracy Average (≤0.2% FS) High (≤0.1% FS)
Measurement Few Many (more convenient
parameters for factory
informationization)
System capacity Configuration to be Plug & play, system * DD document
expansion revised and offline automatic identification needed.
installation
Interoperability Average Very good
Hardware quantity 100% 30%~50% According to ARC
report.
Cabling 100% 30%~50% According to ARC
report.
Installation cost 100% Approx. 91% (9% According to ARC
saved!) report.
Maintenance cost 100% Approx. 80% (20% According to ARC
saved!) report.
*Note: ARC is an authoritative consulting company in the international automation field.
September 2012

Why FF?

Investment Comparison between Ff Technology and
Traditional DCS Technology
Investment Step Decomposition Schematic Diagram
Investment1

DCS LAN

DCSControl Station
H1Bus interface cards
Investment 3
Investment 4
H1 FF Fieldbus Field wiring box
Power supply unit Terminator

Terminator
Investment 2
Non-Ex- FF structure
i

FF Bus instrumentation and adjust valve

Figure 3-1 Investment Decomposition Diagram of Ff Technology and
20
September 2012
Traditional DCS Technology

Why FF?

Investment Comparison between Ff Technology and Traditional DCS Technology
Fujian Refining and Ethylene Projects

In respect of FREP project, at the bid invitation stage of the main instrument
control contractor (MICC) and in the process control system (PCS) inquiry, it‟s
required the three bidders should have the quotation for the Ff technology
(Proposal 1) and the traditional DCS technology (Proposal 2); and it is required
that the utilization ratio of the FF segment should be 6 field devices on average
and adopt the domestically manufactured FF cables.
When cable investment is not considered, from Table 3-1, the quotations of the
three bidders for Ff technology (Proposal 1) all are higher than those for the
DCS technology (Proposal 2); when cable investment is considered (as per
domestically manufactured FF cable price), from Table 3-2, the quotations of
the three bidders for Ff technology (Proposal 1) all are a little lower than those
for the DCS technology (Proposal 2).
From the above investment comparisons, we may draw the following
conclusion:
When the utilization ratio of the Ff segment is 6 field devices on average and
adopts the domestically manufactured Ff cables, Ff technology investment
September 2012
21 (Proposal 1) is a little lower than the DCS technology investment (Proposal 2).

Why FF?

Economic comparison
Table 3-1 Investment Comparison between Ff Technology and Traditional DCS Technology (without cable)

September 2012

Why FF?

Economic comparison
Table 3-2 Investment Comparison between Ff Technology and Traditional DCS cTechnology (with able)

September 2012

Why FF?

Economic comparison

Conclusion
I. The overall investment with Ff technology adopted is a little less than that
with the traditional DCS system. Key factors to reduce project investment:
1. Increase the utilization ratio of segment to 6 devices or above.
2. Fully adopt domestically manufactured Ef fieldbus cables.
II. Benefits expected from the adoption of the Ef technology:
1. Saves engineering investment and speeds up project progress (CAPEX);
2. Can realize the preventive maintenance, increase maintenance efficiency and
lower maintenance and operation expenses (OPEX);
3. Has boosted plant digitalization and intelligentization level and thus facilitates
mean production and operation management;
4. May lower plant full life cycle cost and maximize corporate benefit.
September 2012


Ff Fieldbus technology keeps developing and perfecting

1） FDT/DTM development (AG-181 Rev3.1);
In March 2010, FF Foundation
2） Stricter host computer interoperability test (FF-569);
issued Version 3.1 of
3）Safety instrument function (SIF) application (FF-895,SIL3); FOUNDATION™ Fieldbus System
Engineering Guidelines(AG‐181)
4）Fieldbus advanced diagnosis function (FF-912); and later successively issued
several FF series codes. As the
5）Essential safety segment application research (AG-163); FDT technology is widely used on
field equipment, the new version
6） Quicker execution period (CIF stressed, non-period time
of such guideline has added the
increased); function that the MCS should
support the FDT/DTM standard in
7）Complicated control strategy application research (FF-892);
addition to EDDL.
8）Enhanced integration of DCS/Ff and AMS (NAMUR NE91);

9）f engineering application guide and project implementation
code version upgraded.

September 2012


Figure 4-1 Ff Communication Model
FF HI SIS

FF H1 FF HSE User layer

OSI-RM reference model User layer User layer IEC 61508

Application layer 7 Fieldbus message sub-layer FMS/FDA Fieldbus message sub-layer
(FMS) and fieldbus access sub- (FMS) and fieldbus access sub-
layer (FAS) layer (FAS)

Presentation layer 6 3-6 layers omitted IETF TCP/UDP 3-6 layers omitted
IETF IP
Dialog layer 5

Transmission layer 4

Network layer 3

Data link layer 2 H1 data link layer Data link layer H1 data link layer

Physical layer 1 IEC 61158-2@31.25Kbps IEEE 802. 3u @100 Mbps IEC 61158-2@31.25Kbps

26 User Layer based on IEC 61804 September 2012


Ff Development Trend
1. The instrument and control system based on Ff technology will develop
rapidly; Ff technology will become one important branch in the process
automation field but cannot replace the traditional DCS system completely.
2. Research the application demands of petrochemical users on Ff technology:
1） High security;
2） High reliability (robustness);
3） Good real time;
4） Good openness and interoperability;
5） Develops multiple complicated applications;
6） Develops multiple Ff field devices in line with FDT/DTM;
7） Develops AMS user functions;
8） Pays attention to the development of Ef configuration and application software and
boosts the embedment between software module and hardware;
9） Some travel test functions that may be used for safety interlock SIL loop, especially
interlock control valve;
10）Develops redundancy fault-tolerant Ef segment and related equipment;
11）Researches the interface between Ff technology and industrial wireless network
27
technology, etc.. September 2012


5.1 Ff Latest Application Case 1: FREP Bottleneck Removing Reconstruction
Project
Fujian Refining and Ethylene Project (FREP) is a large refining and chemical integrated project with the joint capitals
(25% each) of Sinopec, Fujian Province, ExxonMobil and AOC and fully completed and put into operation at the end of
August 2009.

Phase I Ef technology application:

By now, this project has been in operation for 3.5 years with the control systems (DCS, ITCC, PLC) operating stably
and flexibly, safe and reliably safety protection systems (SIS, FGS, MMS), other systems (OTS, RTDB, MES, ERP, etc.)
operating online and the automation system and information management system highly integrated. According to user
statistics, including Ef fieldbus and HART instrument, the perfectness ratio and utilization ratio of instruments both have
reached 99.8% (the regulations of Sinopec on equipment management: perfectness ratio and utilization ratio≥95%). As
the project has completely adopted intelligent instrument technology, the maintenance load on instruments has been
reduced greatly and all the maintenance personnel for the control systems and field instruments of the whole plant are
only 30% of those in normal case.

World-class large refining and chemical integrated project

September 2012


The Engineering Research and Application of the Integrated Automation System for
Large Oil Refining and Chemical Integrated Plant developed on the EREP project
obtained the first prize of Science and Technology Advancement 2010 under “Science
and Technology Award of Petroleum and Chemical Automation Industry”.

September 2012


5.1 Ff Latest Application Case 1: FREP Bottleneck Removing Reconstruction Project

A. Oil refining reconstructed portion: C. Chemical reconstruction portion:
Normal decompression devices Ethylene splitting devices reconstructed
reconstructed from 8MT/a to 10MT/a; from 0.80MT/a to 1.10MT/a;
New dry gas purification devices built; Gasoline splitting & hydrogenation
Hydrogenation and cracking devices devices reconstructed;
reconstructed to 2.50MT/a; Polyethylene devices reconstructed from
MTBE/butylene-1 devices 0.80MT/a to 0.90MT/a;
reconstructed. Polypropylene devices reconstructed
B. Newly built oil refining portion: from 0.40MT/a to 0.55MT/a;
New arene extraction devices built: PX devices reconstructed from
0.40MT/a; 0.70MT/a to 0.86MT/a.
New dry gas purification devices built; D. Newly built chemical portion:
New S-zorb devices built. New EO/EG devices built:
0.18/0.25MT/a;
New butadiene devices built: 0.06MT/a.

September 2012

5.1 Ff Latest Application Case 1: FREP Bottleneck Removing Reconstruction Project

The total investment of FREP is about RMB 31.6 billion (equivalent to USD 4.60 billion); and the total investment of
FREP2 is about RMB 6.0 billion;

FREP construction progress: The oil refining portion was completed and put into operation at the end of April 2008 and
the ethylene portion at the end of August 2009; FREP2 is planned to be completed and put into operation at the end of
2013;

The construction mode of FREP adopts PMC (FEED) +EPC and E+P+C while FREP2 adopts E+P+C; only EO/EG
device adopts EPC mode;

The whole plant has 11 process control systems (PCS), totally about 56,000 process I/O points and 180,000
communication I/O points; FREP2 has added 1 PCS (EO/EG device) and has totally about 10,000 process I/O points
and 35,000 communication I/O points;

The whole plant has totally 2 central control rooms (CCR), 11 local control rooms (LCR) and 26 field auxiliary rooms
(FAR); FREP2 has added 1 LCR (EO/EG device) and 5 FARs;

The main optical cables of the whole plant are 106km; FREP2 has added about 25km;

The whole plant has used 8,033 Ff and 8,229 Hart devices; FREP2 has added about 1,450 Ff and 1,500 Hart devices;
277 848T multi-way temperature transmitters (TT) are used, saving about 2,000 temperature transmitters;

On average, every FF network segment has about 5.3 instruments. If the number increases, more investment may be
further saved.

September 2012


5.2 Ff Latest Application Case 2: Wanhua Yantai Industrial Park Project
Project name: Yantai Wanhua Polyurethanes Co., Ltd. Wanhua Yantai Industrial Park Project

Construction site: Shandong Yantai Economic and Technologic Development Zone Port Chemical
Industrial Park

Project construction investment: RMB 27 billion

DCS points (estimated): Including but not limited to the DCS/Ff used by such devices as MDI devices,
coal gasification devices, nitrobenzene devices, propylene epoxide devices, acrylic acid and ester
devices, propane dehydrogenation devices, butanol devices, utilities and so on, the number of the
system I/O points is estimated to be 3,500 and the number of Ff devices is about 8,000. The total of
the I/O points of such systems as DCS/SIS/CCS/PLC and so on is about 50,000.
CCR category Area Device name DCS name Device No.
CCR1 A MDI device MDI 13
CCR2 B Coal gasification device GAS 11
CCR3 C Nitrobenzene device Aniline 12
H Utilities UT 01, 04
CCR4 D Propylene epoxide device 22
E Acrylic acid & ester device AA 24
F Propane dehydrogenation PDH 21
device

G Polylol device Polyol 23
I LPG and storage and LPG 05 September 2012
transportation


5.2 Ff Latest Application Case 2: Wanhua Yantai Industrial Park Project

Improvements from the previous projects:

1）Network segment utilization ratio has increased to 6~8 units/segment;

2）For the sequential control and interlock completed in DCS, Ff digital I/O coupler is
recommended;

3）For most devices, explosion-proof proposal is recommended; for some high-risk
devices (such as coal gasification, nitrobenzene and so on), the high-energy trunk +Field
Barrier segment may be adopted.

5.3 Potential Ff oil refining and chemical projects

1）CNOOC Huizhou Oil Refining and Chemical Project (Phase II): 12MT/a oil refining
+1MT/a ethylene;

2） Sino-Kuwait Guangdong Zhanjiang Oil Refining and Chemical Integrated Project:
15MT/a oil refining + 1MT/a ethylene;

33
3） Other projects. September 2012


5.4 Ff Implementation Points
1. Enhanced AMS Application in DCS/Ff
The predictive diagnosis function of AMS makes predictive maintenance possible. From user‟s
angle, this is the most attractive point of fieldbus. With such function, before FF field devices have
real failures, maintenance request information may be issued and the maintenance personnel are
reminded of conducting maintenance, thus greatly decreasing the non-planned halt times and
maintenance fees of devices. The specific implementation points are as follows:
1） Enhancing training. As the communication protocol between FF field equipment and control system
is different from the traditional instrument, its maintenance mode and method are different;
therefore, the training on the instrument maintenance personnel is necessary.
2） Version upgrade: The DD File of Ff field instruments should be updated and upgraded continuously;
comparing with the traditional routine instruments, when the FF field equipment is replaced, we
must consider the version of the DD File of Ff field equipment and whether it passes the HIST test
(Host Interoperability Support Test).
3） Field patrol and daily maintenance. Although one major advantage of fieldbus is “able to see one
„transparent‟ field in the control room”, it does not mean “take in everything in a glance” or no field
patrol is needed, and the advanced diagnosis function it has cannot achieve no maintenance daily,
for example, ambient temperature change, mechanical vibration, damp, dust, oil stain, etc., may
greatly affect the reliability of Ff field equipment.
September 2012

2. Control in Field (CIF)
The most important characteristic of Ff is that it hardly relies on control room equipment and the
control strategy may operate directly in the field equipment, namely, its field equipment has very strong
autonomy. This guiding ideology is directly reflected on the unique “function block” and “function block
connection” of the user layer. As a result, this needs the field equipment to provide function blocks as
many as possible so as to meet the process control demand of different application environment.
The users have a different angle to consider a problem from Ff developers; they do not focus on
technology advancement such as “fully digital signal”, “bi-directional and multi-point communication”,
“function block” and so on but pay attention to the benefits brought by these “advanced technologies” in
actual applications.
The research conclusion of the Fieldbus Foundation:
1） In respect of quick control loop, the control performance of the fieldbus on H1 is much better than 4-20mA;
2） In respect of pressure and flow loops, the control performance is 10-15% more improved than the loop
with 4-20mA signals;
3） In respect of the slow loop (50s or 1min), the control performance is not so advantageous;
4） In respect of P and PD control, the bus and the 4-20mA loop are the same in performance;
5） In respect of PI and PID control, the bus (CIF) is better than the 4-20mA loop in control:
14.8% is better for orderly disturbance;
29.3% is better for random disturbance.

September 2012


3. FF Network Segment Loop Allocation Principle- Fail-safe Design
1） To realize field control, all fieldbus devices on the same regulating loop should be allocated on the same segment;
2） The transmitter and regulating valve of the single regulating loop should be allocated on the same segment;
3） Only 1 key regulating loop is allowed within every FF segment (the failure of such regulating valve may lead to the
local halt of one process unit); no other regulating loops but monitoring loop are allowed;
4） 2 common regulating loops should be allocated within every FF segment and at most 3 common regulating loops
are allowed;
5） 6~8 FF devices or 1.5~2 FF locators (which have the maximum value) should be allocated for every FF segment
on average;
6） For the equipment with energy transmission (such as rectifying tower, reactor and so on), the instrument in
relation to heating equipment (such as reboiler) and the instrument in relation to cooling equipment (such
condenser) should be allocated in different segments;
7） The fieldbus device for the main process equipment (such as master pump) and the fieldbus device for the backup
process equipment (such as backup pump) should be allocated in different segments;
8） The equipment adopting multi-point measurement, for example, the reactor with multi-point temperature and multi-
point pressure measurement, should allocate the fieldbus devices equally in different segments;
9） The regulating valve and the switching valve of the fieldbus shall be configured as when the main control system
communication is faulty, the position of the valves is the same as that in case of gas source fault.

September 2012

6. Conclusion

1. To sum up, via the comprehensive analysis of Ff technology engineering application status quo and
development trend, it is fully necessary for large petrochemical projects to adopt Ff technology and such
technology is reliable, stable, advanced and workable and can save much debugging, startup time and
labor and increase instrument operation rate.
2. The application of Ff technology may greatly promote plant‟s intelligent production, maintenance and
management level and establish a good foundation for the whole-plant automation system and information
management system to realize integrated management and control.
3. The combined use of Ff technology and AMS may realize remote predictive maintenance, realize plant‟s
intelligent management, lower plant‟s maintenance cost and life cycle cost and heighten economic benefit
and social benefit.
4. The successful performance of Ff technology in large petrochemical projects must achieve 5-
implementation, i.e. “technology implementation, investment implementation, HR implementation, progress
implementation and management implementation”.
5. Although Ff technology develops very slowly at present in China, as such large oil refining and chemical
projects as Shanghai SECCO Ethylene Project, Nanhai Shell Ethylene Project, Caojing Bayer
Project, Fujian Oil Refining and Ethylene Project and so on have been smoothly put into operation, it
indicates that Ff technology has come to the new stage of large application in China. We believe, as the
Chinese economy further develops and the demand of petrochemical enterprises in China for advanced
production and technological innovation becomes increasingly higher, Ff technology will have great
development in China and even in the world.
In the end, wish this conference successful! September 2012
Thank you!

FF technology application progress in China petrochemical industry

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