CHARMED Upgrading the UT Pickle Separations to DeltaV v11

CHARMEDUpgrading UT Pickle Separations

to DeltaV v11 with integrated

CHARMS

CHARMEDUpgrading UT Pickle Separations

to DeltaV v11 with integrated

CHARMS Dr. Frank Seibert – University of Texas

Mark Nixon – Emerson Research Manager

PresentersPresenters

Frank Seibert, University of Texas at Austin

Mark Nixon

Research Manager

Austin, Texas

AbstractAbstract

This presentation follows the modernization of the UT Pickle Research Center in Austin, TX. The project includes an upgrade to CHARMS IO (electronic IO) and S-Series controllers, installation of new junction boxes, upgrade of graphics, conversion to rack mounted PCs and Servers, and modernization of the control room. The presentation follows the planning and execution of the project from initial planning, through execution, to commissioning, to taking the project on-line.

Separations Research Program, University of Texas at AustinSeparations Research Program, University of Texas at Austin

The Separations Research Program was established at the J.J. Pickle Research Campus in 1984

This cooperative industry/university program performs fundamental research of interest to chemical, biotechnological, petroleum refining, gas processing, pharmaceutical, and food companies.

CO2 removal from stack gas is a current focus project

Undergraduate Students

Research Areas

• Distillation

• CO2 Absorption/Stripping

• Liquid-Liquid Extraction

• Oil Extraction from Algae

• Verification of Separation Processes

• Scale-up/Trouble-Shooting

HarvestingFiltration

Settling

Water

BiofuelsProcessing

Concentration

Preparation

Lysing

Extraction

Biomass

Coproducts

Algae Production

Biodiesel

Biogas

JP-8

Ethanol

Feeds

Fertilizers

Others

Sunlight

TimeMake-up water

UT Program

Simplified Algae Oil ProcessSimplified Algae Oil Process

Nutrients

CO2

Algae Oil ExtractionAlgae Oil Extraction

Recovery of submicron oil drops from slurry Solvent selection Extraction process – two options Feed: flocculated or de-flocculated? Preliminary material/energy balances and economics

Open Algae and UT Proprietary

CO2 Capture ProcessCO2 Capture Process

Absorber

Gas Acc

Condenser

Liq Acc

Feed Tank

Blower

Stripper

CrossExchanger

Trim Cooler

Air 12% CO2

CO2 Makeup

GasOutRecycled

CO2

Lean AmineRich Amine

350 acfm

15-20 gpm

20-60 psia

1450 Btu/lb CO2

52-93% Removal

SRP CO2 Capture Pilot PlantSRP CO2 Capture Pilot Plant

10

Gas Capacity, m3/min = 25

Solvent Capacity, liter/min = 130

Inlet CO2 Composition, mol% =1-20 Capabilities: - Solvent Screening - Packing Performance - Effect of Absorber Inter-cooling - Solvent Regeneration

Variations - Evaluate Process Dynamics - Evaluate Heat Exchangers - Model Validation

Absorption ColumnAbsorption Column

Column Diameter, cm = 42.8 Packed Height, cm = 600 Pressure, bar = 1 Windows for Observation Inter-cooling Capability Extensive Temperature

Measurements

Stripping ColumnStripping Column

Column Diameter, cm = 42.8

Packed Height, cm = 600

Pressure, bar = 0.2-4

Provides for Flashing Feed

Windows for Observation

Kettle Reboiler

Shell and Tube Condenser

Plate and Frame Cross Exchanger

11 bar Saturated Steam

10 C Chilled Water

Skid Fabrication – Initial StageSkid Fabrication – Initial Stage

High Temperature Two-Stage Flash SkidHigh Temperature Two-Stage Flash Skid

High Pressure Flash Stripping SystemHigh Pressure Flash Stripping System

Absorber Intercooling OperationAbsorber Intercooling Operation

Scope of the upgrade ProjectScope of the upgrade Project Upgrade to DeltaV v11 and AMS

– Replace M series with S series controllers & IO

– Two standard DeltaV JB’s w/ RCIOC’s & CHARMS

– Retrofit one of existing JB’s with RCIOC’s & CHARMS

– Upgraded Fieldbus

– Added WIOC

– Upgrade PROplus, Application Station & Workstations to Windows 7

– Update Displays

– Added new Switches Upgrade Control Room

– Remove existing overhead utility piping and abandoned conduit

– Add new wall to separate operators from equipment room

– Move analyzers to single cabinet and relocate

– Upgrade lighting and install suspended ceiling in Operator room

– Add new Operator room furniture

Upgrade continued…Upgrade continued…

Workstations and Servers – Rack Mount– Four DELL Workstations (Operator Stations)– One DELL Server (Application Station)

Three Redundant CIOCs 181 CHARMS

– AI, AO, DI, DO, RTD, Thermocouple

Two sets of Redundant S-Series Controllers 41 S-Series Cards

– AI, AO, DI, DO, Serial, FF

CO2 SkidCO2 Skid

Five Rosemount 3095 Flowmeters Two Rosemount 3051 Level Transmitters One Micromotion Coriolis Flowmeter Two Micromotion Viscometer Six Fisher DVC Valves One Rugged PC configured as a ProPlus (for local

interface & commissioning).

ScheduleSchedule The work at-site

started in late April and completed in mid-July

The physical plant was down for 3 weeks

Operators worked out of temporary control room for the duration

Previous System – Classic IO, FF, HARTPrevious System – Classic IO, FF, HART

JB11 Marshalling CabinetJB11 Marshalling Cabinet

Analyzers & ComputersAnalyzers & Computers

Cabinet 1 (before)Cabinet 1 (before) Redundant MD Controllers Mix of IO Cards

– AI, AO, DI, DO

– Thermocouples, RTDs

– Serial

– FF

WirelessHART Fisher valves, Rosemount

pressure, flow, and level instruments

Micromotion flow meters Rosemount Analytics pH Analyzers

Cabinet 1 (after)Cabinet 1 (after)

Redundant S-Series Controllers S-Series IO Cards

– AI, AO, DI, DO 24 VDC, DO 120/230VAC, Fieldbus, Serial

Redundant UPS Systems Redundant 24 VDC Power Assembled enclosures off-site and

dropped into site during switchover

Upgraded SystemUpgraded System

System PreferencesSystem Preferences

Ref: Ed Center S-series Electronic Marshalling Configuration

Connecting a CIOCConnecting a CIOC

When you first connect a decommissioned CIOC to the Control Network it will automatically appear in the Decommissioned Nodes category.

Ref: Ed Center

Identifying a CIOCIdentifying a CIOC If multiple CIOCs are connected at the same time an

Identify feature allows you to flash the LEDs on the CIOC to match the name to a specific CIOC.

Ref: Ed Center

Commission The CIOCCommission The CIOC The CIOC can be commissioned by dragging and

dropping it on the I/O Network.

Drag ‘n Drop

Ref: Ed Center

Commission The CIOCCommission The CIOC The commissioned CIOC appears with the auto-sensed

CHARMS.

Ref: Ed Center

CIOC DownloadsCIOC Downloads The illustration below shows CIOC commissioned and not

assigned to any controller.

Ref: Ed Center

Auto-sense CHARMSAuto-sense CHARMS Electronic Marshalling allows you to change I/O types

easily without re-wiring.

Ref: Ed Center

UT – Expanded IO NetworkUT – Expanded IO Network

Controller shown with assigned IO from JB’s and WirelessHART Gateways

IO Network shown with autosensed CICO’s

JB1 ExpandedJB1 Expanded

CHARM PropertiesCHARM Properties

Individual CHARMs can be

enabled/disabled

Each CIOC can be assigned to up to four

controllers

Each AI CHARM can be configured with or

without HART

Filtering can be enabled on each analog

input

Var 02 PDT901.PV% UTR000000AB-EX01.datAW PRESS HI RANGE 06/29/2010 09:45:00

Time Series

0.00 50.00 100.01 150.01 200.02Sec

4.091

4.119

4.146

4.174

4.201%Span


Power Spectrum (FFT)

0.005 1.005 2.005 3.005 4.005Cycle/Sec

0.0002

2.4365

4.8727

7.3090

9.7452Variance (E-6)

0

16

33

49

65% Variance

De-Trend=No, Win=None, Seg=0


Auto Correlation (FFT)

0.00 1.54 3.07 4.61 6.14Sec

-1.0

-0.5

0.0

0.5

1.0


Power Spectrum PeaksDe-Trend=No, Win=None, Seg=0

Lower Threshold: 4.681E-7, Change Threshold: 5.617E-7

Total Variance: 1.917E-4% Total P-P 2 Sigma

Peak Freq. Period Shape Variance Amplit. Remain.1 0.49878 2.0049 4 7.229 0.010530 0.0266742 7.235E-3 138.22 -3 4.901 8.671E-3 0.0270063 0.66502 1.5037 3 2.965 6.744E-3 0.0272804 0.022089 45.271 2 1.748 5.178E-3 0.0274505 3.9520 0.25303 1 0.8673 3.647E-3 0.0275736 0.13733 7.2818 1 0.8476 3.606E-3 0.027576**Truncated**

Example Process Noise (related to VSD’s)

NOTE: For additional information refer to Workshop: 118 - Guidelines for

Setting Filtering and Module Execution Rates

Enabling FilteringEnabling Filtering

DiagnosticsDiagnostics

Status of CIOC (in this case named by JB)

Can also view diagnostics of individual CHARMS

AMS – CHARMSAMS – CHARMS

AMS - FieldbusAMS - Fieldbus

WIOCWIOC

Ethernet To DeltaV

(redundant)

WIOCs

(redundant)

24V DC

(redundant)

RS485 and power to 781

Control Room (traffic patterns)Control Room (traffic patterns)

Control Room (design)Control Room (design)

Control (artist drawing)Control (artist drawing)

Control RoomControl Room

Moved back in…Moved back in…

Things learned along the wayThings learned along the way Have knowledgeable person on-site at all times Tags must be carefully tracked Keep a virtual machine handy with previous system

configuration on it It is very easy to move DST assignments between controllers

– utilize the split window view on Explorer and drag/drop DSTs between destinations

Use controller upgrade utility to double check version information

Use autosense to double check CHARM types Use diagnostics to look for wiring & calibration issues Use AMS to quickly check FF and HART devices

Business Results AchievedBusiness Results Achieved Flexibility. With CHARMS IO UT can easily add and

remove devices in the field and move configuration between controllers without being limited by where wires are terminated.

Supporting multiple projects. It will be much easier to run parallel tests. The improved control room layout makes it much easier for operators to run their portion of the tests.

More data. Upgraded servers makes it easier to hold on to more data.

SummarySummary

CHARMS IO provides UT with considerable project flexibility. The new control room layout and upgraded servers provides UT with much a better environment to run concurrent projects, collect data, and provide reports for their customers.

We appreciate you taking the time to attend our session. We would like feedback on the presentation or your own experiences.

Questions?

Where To Get More InformationWhere To Get More Information

Emerson Exchange 2010– Workshop: 168 - DeltaV Development Systems in a

Virtualized Environment– Exhibit: Virtual CHARMS IO Simulation Demonstration -

Advanced Control Booth– Workshop: 118 - Guidelines for Setting Filtering and Module

Execution Rate – Ed Svrcs: 13-555 - DeltaV S-series Electronic Marshalling

DeltaV Literature– Product Data Sheet: DeltaV Virtual CHARMS IO Simulation– Books On Line v11– Visit www.emersonprocess.com/smartwireless

http://www.emersonprocess.com/smartwireless

CHARMED Upgrading the UT Pickle Separations to DeltaV v11

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Transcript of CHARMED Upgrading the UT Pickle Separations to DeltaV v11