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General Specification for the FPSO PLC Operator Configuration Software Upgrade P

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发表于:2004/10/18 15:30:00
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General Specification for the
FPSO PLC Operator Configuration Software Upgrade Project
CACT-OG, FPSO-Nanhai Faxian, Southsea, P. R. China

Table of Contents


1.0  Introduction
2.0  Requirement of CACT-OG
2.1  Work Scope
2.2  General System Definition
2.3  Overview
2.4  FPSO Operator PLC Upgrade
3.0  Design Description

3.1  Implement New Adding Process Control Loops Data Remote Monitor by Configured into PLC and new Operator Stations.
3.2  Other Instrument Function to PLC also in parallel with original Ronan Annunciator Panel
3.3  Adding Fire & Gas Alarm to CCR and Rear Control Room
3.4  Adding Fire Alarm to CCR and Rear Control room
3.5  I/O point list

1.0  Introduction

This specification covers the general requirements & design contents for the FPSO Operator Interface PLC Software Configuration work on FPSO NAN HAI FA XIAN located in the Huizhou Field, P.R. China.

The description of FPSO production process flow:All fluid from HZ21-1 and HZ26-1 is entering the slug catcher V-400.and then one part fluid  enter into HZ21-1 section three phase separator (Production Separator) V-200, Other fluid enter the HZ26-1 section three phase separator (Production Separator) V-600. Oil out of V-200 enter the treater V-210 ,that is separated and degassed ,dewatered and then to the FPSO oil tanker. the HZ26-1 section is the same to the HZ21-1 section.

The work scope described as below according to the design task sheet FPSO Operator Interface PLC Software Configuration work from the CACT.

General overview of instrument automatic control actualities of FPSO:
A suit of Rockwell PLC5 control systems has been used on the FPSO for production control and shutdown functions. This PLC system is mainly used as the ESD system. Conventional board mounted pneumatic controllers are used for process analog loop control. The only operator indication of process and shut down (alarm) status is a Annunciator panel and a bypass switch panel installed on the present systems.

In order to optimize instrumentation process control and improve control system reliability and safety, which needed to add several new process analog control loops by use of electronic instruments, some new alarm & shutdown I/O points, a suit of new A-B 1771 I/O rack which include some analog input (AI) modules, analog output (AO) modules, and other functional modules, DH+ network, two suits of CRT-based operator stations which will work in redundancy with each other, also include two sets of monitor and control software.      

Work scope include:
--- Add existing board mounted analog controller loops signals into PLC control system, and add their functions to the new operator stations. (12AI+12AO)
--- New process analog control loops and digital I/O points add into PLC control system. (6AI+6AO+2DO)
--- Add some digital input and output points in the FPSO production area to the PLC configuration and add operator graphics: 10DI
--- Make some alarm and shutdown signal points that annunciated on the FPSO Master Panel in parallel with the new CRT-based operator station.
--- PLC system update, add a new PLC AI&AO modules rack.
--- Update new Field instruments in order to implementing remote monitor and control
--- Update new Field instruments in order to implementing remote monitor and control

2.0  Requirement of CACT-OG

2.1  Scope
This document will establish the basis for the engineering and design philosophies of the process and equipment control, protection, and shutdown systems. These systems will be employed for the operation of the offshore platform.
Work scope include:
--- Add existing board mounted analog controller loops signals into PLC control system, and add their functions to the new operator stations. (12AI+12AO)
--- New process analog control loops and digital I/O points add into PLC control system. (6AI+6AO+2DO)
--- Add some digital input and output points in the FPSO production area to the PLC configuration and add operator graphics: 10DI
--- Make some alarm and shutdown signal points that annunciated on the FPSO Master Panel in parallel with the new CRT-based operator station.
--- PLC system update, add a new PLC AI&AO modules rack.
--- Update new Field instruments in order to implementing remote monitor and control

2.2  General System Definition
The systems in this specification will be functionally designed to perform their defined functions. These systems will be totally integrated to provide seamless control and protection functions for offshore FPSO facilities. The systems will be designed with proper level of redundancy for their particular application. In general two basic functionally different systems will be provided at each of the facilities mentioned above.
The system, a Process Control System (PCS) will be implemented to perform process control, process equipment shutdown, metering, data acquisition, and the other process related functions. This system will be based on Programmable Logic Controller (PLC) system, DH+ communication protocol network and Operator Interface Station (OIS) technology. Also, this system work as a Facility Protection System (FPS) will perform personnel and equipment safety monitoring, interface with fire and gas detection, manual and automatic emergency detection, and all associated shutdown functions. This system will be based on the Programmable Logic Controller (PLC) technology.  The FPS will operate together with PCS at each facility.
The two systems will be integrated at each facility such that common operator interface stations and data communication systems can be used by both systems. The communication between the various platforms is expected to be implement via subsea optical fiber cable.
These systems will be designed with proper level of redundancy to provide very high level of availability and minimizing downtime. This could be accomplished by use of redundant units or components, and software configurations.

2.3  Overview
The PCS and FPS systems for each facility of this project shall be based on the proven PLC & CRT based OIS technology. Each system shall perform all of the necessary functions to monitor and control oil processing facilities at the FPSO Nan Hai Fa Xian. It shall initially consist of CRT based operator interface and engineering stations, PLC system control processors, alarm and report printers, DH+ data highways will implement communicate with each OIS and PLC main racks to provide data gathering, changing and monitoring production states of all facilities. Hard disk storage devices in OIS system implement production process data input and output interfaces to PLC main racks, I/O sub-chassis, and field detecting instruments and control valves/ shutdown valves located at the process equipments.
The primary functionality for FPS system is to provide data gathering, process control, sound and flash alarming, alarm logging, production report generation, and operator interfacing for process operation.
The system shall be designed such that it can display all required process variables and functions on the color CRT terminals. These graphic displays shall mimic the physical equipment connections on multiple, easily accessible screen graphics. The number of the screen graphics and their content shall be defined during detailed engineering. Ability to control process set points, and equipment start/stop functions shall be provided to the operating personnel from the operator interface CRTs.  
The system shall be able to provide gathering of data for designated process variables. This data may then be manipulated for conversion to engineering units, gas, oil and water measurement calculations, or for performance of other pertinent mathematical functions. The results of these calculations and or the raw data acquired may be required to be displayed on the operator interface terminals, archived for future processing, or printed out on the system printers. In addition the system shall be capable of manipulating such data to provide the operations department with various periodic or on demand production, alarm, maintenance, and other reports.
The system shall be able to perform control functions such as open and closed loop control, sequence or logic control, and it should be capable of implementation of advanced control techniques.
The system shall notify the operations personnel audibly and visually about abnormal conditions in the process. The alarms shall be logged on the alarm printer, communicated to the operator by on screen display, and archival stored in the system for future retrieval. The detected alarm condition should also activate a audible horn/buzzer as will be defined later. The system shall automatically display the actual alarm condition description, time of occurrence, and alarm values on the bottom of the CRT. The CRTs shall display the highest priority alarm condition occurrence with the most recent one being shown on all screens. The system will have the capability for multiple alarm level prioritizations, and a separate alarm listing screen for several hundred alarm occurrences.
The system shall be able to retrieve the production data stored during the operations of the facility, and to manipulate that data to provide the operations personnel with production reports. These reports may be required on periodic basis (shift, daily, monthly, yearly, etc.) or on demand.
In cases where process systems employ redundant trains and equipment, the input/output hardware configuration shall be such that a single I/O card failure associated with those systems will not cause a process upset and shutdown be generated.  The control system shall be designed such that they provide an operator warning or a fail-safe shutdown of equipment upon end device failure. The input/output circuit design shall be of the fail-safe type (current flow or pressure continuity for normal operating conditions).
Experienced technicians via a portable computer with configuration programs shall easily make the programming changes in the system. Access for software changes shall be password or key protected to eliminate unauthorized access. The software changes involve both the analog loop control logic and set point changes. These two functions should have different means of access or a multiple level password protection scheme. The system shall allow for easy documentation of software in a format acceptable to field personnel. The documentation shall include full description of the control program including the field inputs and outputs, program control logics.
The Control System software shall have the following capabilities as a minimum:
*Color graphic displays
*Dynamic screen data and dynamic graphic display refresh
*Multiple operator interface station
*Communication driver capabilities
*Ability to integrate collected data into commercially available Spreadsheet for data manipulation and custom report generation
*Historical and trending curve diagrams archiving
*Ability to communicate with other computer systems for automatic production data transfer
*Multilevel alarm generation capabilities and reporting
*Multilevel configuration and operator access password protection
*Ability to add or delete control points on line without total system configuration
2.4  FPSO Operator PLC Upgrade

The PLC will be installed in the Control Room located on the Nan Hai Fa Xian F.P.S.O. (Floating, Production, Storage and Offloading) Production Control Room. The PLC system includes two parts. One part consist of new added two suits of redundancy OIS, the operator can monitor the production process data, displaying alarm and shutdown signals, other part is original existing manager station. Original manager station can be used to change and debug program data or configuration, which can only be operated by skilled program engineer. All of upward computers installed Windows 2000 operating system and Rockwell RS View32 software, configured dual network cards, dual DH+ data communication network, also with network printer. Second part consists of two suits of Redundant PLC main chassis (include modules functioned as CPU, backup communication, and power supply), 1#, 2# and 3# remote sub-chassis (include modules functioned as remote I/O adapter, analog and digital I/O and power supply), and A-B remote I/O links. 3# remote sub-chassis is new added, which include modules employed analog control loops input and output.  
Analog control loops
The field analog measuring instruments are transmitting signals such as pressure, temperature, liquid level, and flow rate into PLC AI modules, via calculation by configure PID or other complex control function blocks in PLC CPU and OIS facilities, then output signals from PLC AO modules to control actuator/valve positions.
Contact I/O points
Fire and gas field manual pushbutton emergency conditions alarm and shutdown functions for the facility functionality. Alarm occurrences be archived in the.  
3.0  Design Description

3.1  Implement Existing Process Control Loops Data PLC Monitor

The existing board mounted controller loop will be add to the PLC. But the controller will be remained. Its signal (from field transmitters,4~20mADC) will be wired to the new PLC rack. its wiring terminal is TB-11.
●  Oil Level of Slug Catcher V-400             (LIC-V401)
●  Oil Flow of Oil Inlet from V-400 to 21 Skid   (FIC-V401)
●  Oil Flow of Oil Inlet from V-400 to 26 Skid (FIC-V402)
●  Water Level of Slug Catcher V-400 (LIC-V403)
●  Pressure of Slug Catcher V-400 (PIC-V402)
●  Water Level of Production Separator V-600 (LIC-V602)
●  Pressure of Production Separator V-600 (PIC-V602)
●  Oil Level of Treater V-610 (LIC-V611)
●  Pressure of Treater V-610   (PIC-V611)
●  Pressure of Production Separator V-200 (PIC-V202)
●  Oil Level of Treater V-210     (LIC-V211)
●  Pressure of Treater V-210 (PIC-V211)      

3.2  Implement Field Instruments Remote Control

Now some loop is still local pneumatic control loop. So this time these loops will be upgraded to remote control loop. It must be add some new  electrical transmitters or switches instead of the original pneumatic instrument. And then the new cable is be added too.
●  Oil Level of Production Separator V-600 (LIC-V601)
●  Water Level of Treater V-610  (LIC-V612)
●  Oil Level of Production Separator V-200 (LIC-V201)
●  Water Level of Production Separator V-200 (LIC-V202)
●  Water Level of Treater V-210   (LIC-V212)
●  Water Level of Flare Scrubber V-240 (LT-V241)
●  Two Contact Output to the Local Air-driven Pumps(LY-V241A, LY-V241B)

3.3  Other Instrument Function to PLC                                
3.3.1   Some solenoid reset signals to the PLC
●  Gas Inlet Valve                              
●  SDV-T451 Slug Catcher Water Valve                        
●  SDV-V201 Slug Catcher Oil to 21 Valve                      
●  SDV-V601 Slug Catcher Oil to 26 Valve                    
●  SDV-V611 Oil to Tank                                      
●  SDV-T211 Oil to Tank
3.3.2   Pushshut signal to PLC(4 contact output)                              
●  Pushbutton SDV-Z211 Oil from Mooring Swivel to 21 Skid      
●  Pushbutton SDV-Z212 Oil from Mooring Swivel to 21 Skid    
●  Pushbutton SDV-Z601 Oil from Mooring Swivel to 26 Skid    
●  Pushbutton SDV-Z602 Oil from Mooring Swivel to 26 Skid    


3.4  Adding Fire & Gas Alarm to CCR and Rear Control Room

●  Fire common alarm point adding into PLC, also connected to cargo room.
●  Gas common alarm point adding into PLC, also connected to cargo room.
●  Gas 20% LEL alarm point in new deckhouse connected to PLC DI module.
●  Gas 40% LEL alarm point in new deckhouse connected to PLC DI module.
●  Fire alarm point in new deckhouse connected to PLC DI module.
●  Shut down alarm point in new deckhouse connected to PLC DI module.

3.5   I/O Point List
See You
Best Regards
Mac.Lu
Engineering Mgr.
IEC Engineering Service Inc. (IECES)
惠州艾迪斯技术咨询服务有限公司
Website:www.sinoiec.com
E-mail:Mac.Lu@126.com
Tel: +86 135 3170 6967(HZ),136 9285 5615(GSM)
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