Documente Academic
Documente Profesional
Documente Cultură
Overview
D G Sangawar
1
What is Instrumentation
Instrumentation is art and science of measurement
and control.
It makes available the necessary process information
[ indication / trending / status ] at a predetermined
destination in a predetermined form.
It also controls the parameter within a specified limits
/ at specified value.
Instrumentation provides a means to the plant
operator to operate the plant safely, continuously,
and consistently with optimum productivity.
It minimizes the human element in the plant
operation.
2
What is Instrumentation
Instrumentation provides handle for monitoring:
Health of the process,
3
Parameters Measured
The parameters encountered in a process
industry are:
Pressure
Level
Flow
Temperature
Quality of intermediate and finished products
- Physical
- Chemical
Speed/vibration/displacements for rotary machines
4
Parameters Measured
Every possible law of physics and chemistry
has been exploited to achieve accurate
measurement of the above parameters
All the field instruments/devices adhere to
Ingress Protection (IPnn) & Area
Classification norms
5
Evolution of Instrument Engg Field
Mechanical Engg Industrial Engg
Production Engg
Chemical Engg
Electronics Engg Elect & Telecommunication
Communication
Computers/IT
Electrical Engg
Mechanical Engg
Instrumentation
Electronics Engg
Computer/IT Engg
6
Evolution of Instrument Engg Field
“ Instrumentation and Automation” was
recognized as a separate branch of
engineering in between the two world
wars as the concept of mass production
came into vogue due to war efforts.
7
Changing Technologies
1. Indication local
2. Indication remote –
Pneumatic
Analog electronics
Digital electronics
Microprocessors (Configurable)
DCS & PLC (Programmable)
3. Recording
Paper-pen
Thermal charts
Trending
8
Changing Technologies
4. Exception reporting/Alarms
Local
Remote audiovisual – annuciators
Alarm logs
5. Control
Local instruments
Local panels
Plant wise control room
Centralized control room for number of plants
9
Changing Technologies
Transmission media
Pneumatic air pressure 0.2 to 1.0 kg/cm2 through
tubes
Electrical 4 to 20 ma through copper conductor
Digigtal signals through twisted / shielded pairs
Light signals through Fiber optic cables
Air waves – wireless
10
Changing Technologies
Connectivity
One to one
Multiplexing
Multidrop – bus topology
Networks
Logics
Switches
Relay
PLC
ESD
11
Changing Technologies
Hardware Base
Configuration Base
Software Base
12
Networks
CRITERIA STANDARD
RS 232 RS 422 RS 485 TCP/IP
TWISTED TWISTED TWISTED
MEDIA CO-AXIAL / F.O
PAIR PAIR PAIR
THEORITICALLY
MAX DIST. 50 FT 5000 FT 5000 FT
NO LIMIT
NO. OF TWO(POINT MUTI DROP MUTI DROP THEORITICALLY
DEVICES TO POINT) 256 NODES 256 NODES NO LIMIT
MAX SPEED 19.2 KBPS 906KBPS 10MBPS 10 TO 100 MBPS
13
System Components
Power supply ®
Central Processing Unit ®
Memory
Input Modules
Output Modules
Communication Modules ®
Bus/network ®
Programming terminal
Human Machine Interface
14
System Features
Redundancy
Fall back – primary/main – secondary/standby
Sharing – 50/50 – 100/0
Cold standby: If primary system fails, the
15
System Features
Redundancy (contd.)
Hot standby: Both primary and secondary are
16
System Features
Easy troubleshooting
Easy expandability
High availability – redundancy
High reliability – fail safe design
Self-diagnostic capability
Alarm handling & Sequence Of Events (SOE)
System security from unauthorised changes.
Hierarchical Presentation like Complex, Plant, Unit, Tag.
Historisation & data logging for ease of maintenance.
Each system has the capability to communicate with another
system in general and DCS in particular
17
Objectives of Control Systems
Operating personnel and Plant safety.
Simplified and Efficient Plant operation.
Automated stepwise start – loading – unloading – S/D
High Plant availability.
Easy and guided maintenance/diagnostics.
User friendliness for Engineering, Operation and
Monitoring functions.
Fast and accurate analysis.
18
Instrumentation Systems
DCS
PLC
ESD
F&G
MCMS
ATG
CTM
BMS
AMS – lab / online analyzers
CCTV & Security Automation
19
Distributed Control System
The distribution can be
- Functional (most commonly used)
- Functional + Physical
Operator window for interface with plant
Integrated in to a single site wide system.
Single window to operations makes plant more
manageable by reducing operator training by
supporting information from all the other control
systems.
20
Distributed Control System
Used for monitoring & control of regulatory level,
advance control & Optimisation.
Self documenting features like loop diagrams.
Redundancy is provided in all control processors &
communications.
Two to three operator console monitors are provided
per operator.
Provides detail History of plant with Alarm summary,
Trend displays, detail displays etc.
21
PLC System
PLCs are used for control & monitoring of packaged
equipment like compressors, fired heaters, water
treatment plants, back wash filters, etc.
Stand alone control system & also having considerable
facilities for centralised configuration & data monitoring.
Systems are redundant in processors, power supplies &
communications.
22
PLC System
Each PLC system has serial interface with DCS for
centralised data & status monitoring by control room
operators.
Both CPUs run the application programmes. Primary
CPU only controls the I/O & secondary CPU monitors
the I/O.
Windows based HMI software packages can be used for
stand alone control of the PLC.
23
Logics
Voting at I/O level to improve safety/reliability
1oo1 – Low on safety/low on reliability
1oo2 - High on safety/low on reliability
2oo2 - High on Safety/high on reliability
2oo3 - Highest on Safety/highest on
reliability
24
Emergency Shutdown System
Monitors & controls startup & shutdown of entire plant.
These systems are fault tolerant, Triple Modular
Redundant (TMR) with a high availability, self test & self
diagnostic facilities. Three CPUs solve logic parallely
and output is based on 2oo3 voting.
Sequence of events recording facility.
All ESD systems are connected to plant wide DCS.
Fail safe philosophy is adopted.
2oo3 logic is utilised in critical areas.
25
Emergency Shutdown System
26
Scan Time comparison for
DCS, ESD & PLC
27
Hazards in Refinery
Fire
Leakage of Toxic Gases
Leakage of Combustible Gases
Rise in Temperature
28
Atmospheric Air (20.8 % Oxygen)
HC
Inside
the Flange
Plant
equip-
ment
and Electrical
piping Equipment
29
Release of HC Atmospheric Air (20.8 % Oxygen)
HC
Inside
the Flange
Plant
equip-
ment
and Electrical
piping Equipment
HC
Inside Spark from
the Flange Lightening
Plant Hot Surface
equip- Spark Electrical Spark
ment
and Electrical
piping Equipment
HC
31
Fire and Gas Monitoring System
32
F&G Indicators
Stand alone indicator
Addressable LCD display
Dedicated F&G Work Station
Integrated DCS F&G Work Station
33
F&G Devices
Type Of Detector Service Location Alarm Setting
34
Machine Condition Monitoring
System
The system is used for monitoring health and protection
of the rotary machines.
The following machine parameters are normally
measured:
the vibration levels of the casing and / or the shaft
Velomitors
Accelerometers
RTDs
36
ATG
Types Of Tanks
• Cone Roof Tank (With or W/O N2 purging)
• Sphere
• Horizontal ( Bullet )
37
ATG Objective
Raw parameter measurements in tank
Level
Temperature – multi spot / single spot
Hydrostatic Pressure
Static Pressure
Water bottom
38
ATG Objective
Calculated Tank Inventory
Gross volume @ amb.
Net Volume @ amb.
Net standard volume @ 15 deg C.
Mass
Ullage
The above values are either calculated in TIS/DCS
39
Types of Tank gauging
Servo
Hydrostatic
Radar
40
Custody Transfer Metering System
43
Burner Management System
Heater trip logic is in general based on following
philosophy:
44
Analyser Management System
45
Analyser Management System
Sampling: It is the extraction of the process fluid and its
delivery to the analyser
46
Analyser Management System
Sampling Delay: It is the time taken by the sample in
reaching the analyser from the process.
47
Analyser Management System
Analyser Houses are located at strategic locations to
collect various samples required for analysis & reduce
the length of sample lines.
All analysers are connected to analyser management
system for collection of data.
The system
- monitors the healthiness of sampling system
- monitors the healthiness of analyser electronics
- trends the parameters
48
CCTV & Security Automation
CCTV system
is used for monitoring of flare stacks, General
surveillance ( loading /unloading , major equipment's
monitoring ), fire prone areas etc.
Time lapse video recording is provided for reviewing
history.
Security system
Used for access control
Automatic movement of gates
49
Controllers
One of the basic functions executed by
instrumentation system in process industry is
‘controlling the process parameter’. There may
be two types of controls:
1. Open Control Loop
2. Close Control Loop
50
Open Control Loop
Liquid In
Liquid
Out
In Out
Process
51
CLOSED LOOP
AUTOMATIC FEEDBACK CONTROL
Error
signal
Comparator
Feedback
52
PID/Regulatory Control
Proportional Action
output = K1 * e
Proportional + Integral Action
output = K1 * e + K2edt
Proportional + Integral + Derivative Action
output = K1 * e + K2edt + K3 de/dt
Where
e = error (difference between setpoint and
measured variable)
K1 = Gain
K2, K3 = constants
53
Instrumentation Controls
Application specific
Compressors – Anti-surge, performance,
speed control
Furnace/Boiler – Lead-Lag control
Boiler – 3-Term Control
On-off / PID controls
Complex loops / traditional advanced control
Ratio, feedforward, cascade, adaptive
54
Thank You
55