Clelio Alves of Petrobras General Assembly Presentation

1. Foundation Fieldbus
Technology:
“ JUST ONE CASE”

2. “ JUST ONE CASE”
CLELIO GUIMARAES ALVES.:
Control, Automation & Instrumentation Senior Specialist
PETROBRAS-PETRÓLEO BRASILEIRO S.A.
Downstream- Investment Programs- Technical Support
Admitted in: Feb, 1986 in REDUC-Refinery
I/C Maintenance Support Division: 15 years
New Projects Division; 10 years
Downstream Premium Projects: since Oct, 2010
Graduation: Eng. Electronics
Specialization: Project Management
Baccalaureate: in Semiotics

3. “JUST ONE CASE”
Project: HDS-Carteira de Gasolina
Reduc-Refinery, Rio de Janeiro-Brazil
Start (FEL-I): 2005
Conclusion (Start-up): March-2011
Specs:
•FCC- Naphta FEED 4500 m3/d
•FCC Battery-limit direct to HDS Process unit.
•Licensor: AXENS

4. “ JUST ONE CASE”
 FEL-II to FEL-III: decision for the use of the FF Technology:
 Project Manager, Sponsor, Final Client (Operators)
 Supported by the Licensor
 Pros: (in 2006)
-EPC: reduction in materials & HH, Inteligent Instruments (more information).
-Maintenance: prediction
-Advanced Control: indicated by the Licensor- U$ 1MM per year in Profits
-Better response (PID´s running in the field)
-Accuracy
 Cons:
-Instruments and Cabling: more expensive
-Service: expertise in FF Technology by EPC team
-Review in Loop tests: new procedures
-Review in Schedule: Commissioning, Loop tests, etc.

5. “ JUST ONE CASE”
 FEL-III (FEED)
 FEED scope
 FEED deliverables
 Before Phase IV:
 Generation of “Specific Documents”:
 MD for FF specs, including Cables
 MD for EPC contract: Automation Chapter
 MD for Integrator-Contract, included in EPC scope
 LD for Specific FF deliverables (documents) by “Detailing Eng.”
 RL´s for: Commissioning, Loop-tests, Start-up procedures

6. “ JUST ONE CASE”
 General Project Criteria:
 12 Devices per H1 segment-maximum
 10 Devices instaled per H1 segment
 03 Field-barriers per H1 segment
 12 Spurs= 10 installed + 02 spares
 Voltage calculation for 12 Devices
 Microcicle Calculation for 12 Devices
 1000ms for Microcicle time(maximum) per H1 segment, indicated by Licensor
 Acceptable: 02 Control valves per H1 segment
 Connectors in the Fieldbarrier and Cable-glands in the Instrument
 ITK-4.5 (minimum)
 DCS: ABB IIT, Devices: Multiple Suppliers (PETROBRAS Vendor-List)
 Control Valve Criticity FF Loop Analisys Report
 Procedures and Calculations by CENPES
 Participants: CENPES (MC), Operators, Automation Experts, EPC, Ext. Consultant.
 Results: 58% of Loops accepted PID running in the Field (Valve Positioner).

7. “ JUST ONE CASE”
 Testing Procedures:
 Instruments Set-up (in the Bench)
 DCS parameters, configurated previously, should not modify “bench set-up”: loss of
Certification
 Dynamic Test for FF devices “in the Bench”:
 Procedures consolidated with “Integrator”
 Reports as Standards for Tests
 General Criteria:
>Cable maximum lengh cut for H1
>Cable maximum lengh cut for Spurs
>Simulate each H1, in the bench, with all devices and cables to test
Voltage and Microcicle values to certificate each H1 segment
>Consolidation of Voltage and Microcicle Memory Calculations.
 DCS parameters, configurated previously, should not modify “bench set-up”: loss of
Certification

8. “ JUST ONE CASE”
 Testing Procedures(Cont):
 Procedures for Connectorization
 Connectorization should be performed in a clean enviroment, never in the field/
site.
 Static test for Cables plus Connectors, in the bench.
 “Dynamic” test for Cables plus Connectors instaled in Trays in the field.
 Loop Tests:
 Faster, accurate
 Reports “from the Bench” as a reference to Field results
 Consolidate: Voltage and Memory Calculations- minumum deviation
 Use of FF signal Wave Form pictures in the Reports comparing bench to site
values.
 Composition of a File containing information for each Device in each H1
segment with all Devices.
 Acceptance procedure: file to be approved before and after tests.

9. “ JUST ONE CASE”
 Important Aspects:
 Are EPC´s prepared to support a project in FF(2012)?
• Certification for Automation Engeneers
• DCS Suppliers are prepared to develop a project in FF?
• Very Important: include a FF Certified Integrator in the EPC Contract.
• Interoperability: DCS versus Instrument Suppliers.
• Internet:
FF Website and Instrument Suppliers Website
 DCS Suppliers shall “open doors” to other Instrument Suppliers.
 DCS Suppliers shall “work close” to EPC´s
 PID running in the Field is not a “Monster”.

10. And Finally
It was “Just a Case”
Thank You