Control System

Philosophy
~ An Overview
REAL - a member of Reliance Group

What are Control Systems ?

Distributed Control System. ( DCS ) Emergency Shutdown System. ( ESD ). Fire & Gas Control System. Machine Monitoring System. Automatic Tank Gauging System. Burner Management System.

What are Control Systems ?

Fiscal Metering System. Analysers Management Systems.

Programmable Logic Controller System. ( PLC )

Compressor Control System.

MOV system.
CCTV system.

Objectives of Control Systems

Operating personnel and Plant safety. High Plant availability. Simplified and Efficient Plant operation. Easy and guided maintenance. User friendliness for Engineering, Operation and Monitoring functions. Fast and accurate analysis. Systematic and planned scheduling and management of products and resources with a look ahead approach for future needs. System security from unauthorised changes.

Central Control Room

Management Information Centre

Monitor, supervise and record critical parameters of all process and utility plants. Detect emergency conditions in process plant and flash messages on video-screens of other effected plants. Custom graphic displays for monitoring usage of raw materials, utilities, fuels, electric energy etc. Utilisation of terminal and tank farm.

Central Control Room

Management Information Centre

Production Trend Specific Consumption Trend Energy Loses Trend

Inventory Report of Raw Material and Finished Product.

Periodic Report of Production of Finished Product. Periodic Report of Raw Material and Utility Consumption.

Central Control Room

Management Information Centre

Period Report of Specific Raw Material and Utility Consumption per ton of Product.
Trends of

Production of finished Product and Utilities.

Raw Material and Utility Consumption. Specific Raw Material and Utility Consumption per ton of Product.

Central Control Room

Management Information Centre

Specific Equipment Operation Status.

Constraints / Untapped Potential in Utilities Supply. Centralised Information Processing Facility to develop and run econometric models for decision making and report generation (hourly / shiftly / daily / weekly / monthly).

Plant Control Centre

Area of Operation

Monitor and Control Process Variables.

Monitor Plant Measured Variables. Monitor Process and Equipment Alarms. Monitor and Control product Quality. Adjust Manual Set Points and Automatic Control.

Initiate Plant Trips, Shutdown, Maintenance Over-rides etc.

Start-up

by-passes,

Plant Control Centre

Area of Operation

Monitor Plant Safety System.

Start and Stop of Required Equipment's. Check Healthiness of DCS. Check Healthiness of Equipment. Engineering Functioning.

Distributed Control System

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. Used for monitoring & control of regulatory level, advance control & Optimisation.

Distributed Control System

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 summery , Trends displays , detail displays etc.. Self diagnostic features included.

Emergency Shutdown System

These systems are fault tolerant , Triple Modular Redundant ( TMR ). With a high availability , self test & self diagnostic facilities.
Sequence of events recording facility . All ESD systems are connected to plant wide DCS. Fail safe philosophy is adopted.

2 out of 3 , logic is utilised in critical areas.

Emergency Shutdown System

ESD devices shall be separate from process instruments & will be used only for the the purpose of shutdown.
Start ups shall be automated as far as possible.

Key lock bypass switches with status lamps shall be provided in each area.
All bypasses shall be serially interfaced with DCS for monitoring.

Emergency Shutdown System

Detection of LEL , Toxic gas , Fire, Smoke, Heat. Also displays wind speed & Direction. Dual redundant Integrated Fire & Gas System.

Universal viewing at all strategic points like Fire stations, Security offices, Plant Control centres, Site in-charges offices etc.. Hierarchical Presentation like Complex wide , Plant wide , Unit / Building , Zones , Tag.

Fire & Gas Control System

Provides alarms within & outside of plant control centres & field areas using bells , Beacons. Interfaces with PA system for Voice message. Interfaces with Deluge & Extinguishing, foam systems. Separate MMI for Fire ( Red ) , LEL ( Amber ) & Toxic gas ( Blue ).

Large screen displays for immediate attention of operators in Control rooms.

Machine Monitoring System

Used for Machine Protection by measurement of following parameters :

Vibration Rod drop Thrust position Velocity & acceleration Bearing Temperature.

Machine Monitoring System

Each system is connected to respective DCS in the plant. & networked to Central Engg. Services for analysis of collected data by use of advance software. Fan monitors are exchangers. also used in plants for air cooled

Local indications are available using serial devices near the machine under protection.

Automatic Tank Gauging Sys.

Used for measurement of Level , Multi spot or single spot temp. , bottom water level , static pressure , & density .
Used for white oils as well as black oils & LPG.

Used in varieties of tanks like Internal floating roof , open floating roof , cone roof, spheres , bullets , cryogenic tanks etc.. Integrated via serial interfaces to DCS. & TIS.

Burner Management System

BMS is required for controlling the Fired Heaters light up sequence and also to monitor the safe operation of the furnaces. Dual redundant PLCs are used for the implementation of the BMS logic. A local panel is provided near fuel skid for operator interface during heater start up operation.

Burner Management System

For the detection of individual flames , ionisation rods are provided for the pilot flame & IR scanners are provided for the main flame.
Automatic shut off valves in double block & bleed arrangement are provided for fuel lines in fuel skid.. Start up sequence can be typically divided in to leak test , purging , pilot firing & main fuel firing.

Burner Management System

Hard wired interface with ESD system for shutdown requirements is provided.
Serial interface with DCS for monitoring by control room operator is provided.

Fiscal Metering System

Used For Custody transfer of raw materials & products

finished

N+1 meter run configuration for providing stand by & master meter .

Individual meter runs are corrected for pressure , temp. , & density in the flow computers.
Provers are provided for calibration of turbine meters. Integrated with DCS & OMIS .

Analyser Management System

Analysers are used for measurement & control of following parameters : pH & Conductivity CO / O2 analysis Dissolved oxygen Distillation

Flash point
Pour Point

Analyser Management System

Moisture
H2S NOX/SOX , CO Oil in Water Gas density

Silica
Smoke / Opacity

Analyser Management System

SO2
Sulphur in liquid HC Thermal Conductivity Total organic carbon Viscosity

Water in oil

Analyser Management System

Analyser Houses are located at strategic locations to collect various analysis required & reduce the length of sample lines.
All analysers are connected to analyser management system for collection of data. The AMS is connected to plant wide DCS.

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.

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 MMI software packages can be used for stand alone control of the PLC.

Comp. Control System

Used for Machine protection & control of Compressors.

Main controllers are :

Anti Surge Controller Performance Controller Speed Controller.

Load Sharing controllers.

MOV. Control System

Used to multi drop Intelligent actuators for Motor Operated Valves.

Two wire design saves cable costs as well as wiring termination . Serially linked to plant wide DCS. Local & Remote operation facility is available. &

CCTV Control System

CCTV systems in plants is used for monitoring of all flare stacks ,General surveillance ( loading /unloading , major equipment's monitoring ), fire prone areas etc..
Integrated with each control centre & fire & Gas control System. Time lapse video recording is provided to review history.

Instrument Datasheets

What is a Datasheet ?

Contains sizing information for instrument in a plant. Contains all process information, viz. flow data, Process Pressure , Temperature , Density ,Viscosity ,line size, operating and design conditions and hydro testing pressure. Contains all piping information, viz line no., end connections , rating , piping spec etc. Contains selected instrument data like make / model no. etc.

Contents of Datasheet

Tag Information [Tag Numbering]

Each and Every Instrument is designated by unique Tag No. Complete Process Information for the concerned Tag. MR and PO Details for the concerned Tag.

Tag No. = Unit+Instrument Type+Seq No. + Prefix ( if applicable )

Contents of Datasheet

Operating Conditions
Sources of Information

Process Flow Diagrams Process Instrument Diagrams Process Stream Data Sheets Project Design Data Project Utility Balances Vendor Data
Mass Flow and Volume Flow Rate Weight Percent Vapour Pressure Temperature Viscosity and Density at operating conditions Velocity Pressure Drop

Based on the Above

Use of Datasheets

Procurement of tagged instruments

With material requisition instrument datasheets are floated to enable vendors to quote right model and type.
Suitability of a particular make and model no. is selected based on instrument datasheet After selection vendor datas are reviewed based on instrument datasheet and released for manufacturing

Bid Analysis and Vendor Print Review

Interface Engineering

Instrument datasheets are used to check correct piping and instrument interface for overall integrity.

Use of Datasheets

Inspection at Vendor Shop and Site

Before shipment instrument is checked with respect to datasheet.

Final As Built datasheets are issued at the end of the project incorporating complete vendor details for future maintenance requirement and records.

Maintenance and Records

Sample Datasheets
Primary

Flow Elements

Sample Datasheets

CASE

Pressure Gauge
PURCH. SCALE
MECHANICAL STAINLESS STEEL SURFACE WHITE SAFETY RING. SCREWED NA YES 2" PIPE BLACK TYPE MOVEMENT MOVEMENT MATERIAL CONNECTION SIZE SIZE & TYPE CONN. LOC. GUARANT'D ACCUR. VACUUM PROTECTION OV'RANGE PROTECT'N ZERO ADJUST. TYPE VENT CONNECTION DIAPHRAGM VENDER TO ADVISE SS 1/2" NPT 1/2" NPT (F) TOP/BOTTOM 1% OF SPAN USE ACCESS. CODE F USE ACCESS. CODE G EXTERNAL YES ACCESSORY ACCESS CDE MATL CODE MATERIAL PULSE DAMPER R1 A1 C STL OTHER R2 A2 ST STL SIPHON COIL TYPE S1 A3 BRASS U-FORM S2 A4 MONEL DIAPH'M SEAL INTERNAL D1 B DESCRIBE IN NOTES FLG'D & CAPILL'Y D2 SANDWICH & CAPILL'Y D3 EXTENDED D4 NOMINAL DIAL SIZE 6 INCH M.R. / P.O.No. VERTICAL "0" YES MANUFACTURER RESTRICTOR GENERAL EL' MAT'L ACCESS'S & NOTES MODEL NO P& ID Number UNITS 221FE009 221FE010 221FE023 221FE024 221FE084 221FE112 221FE201 221FE220 5000 MM OF WC 2500 MMOF WC 2500 MMOF WC 5000 MMOF WC 2500 MMOF WC 2500 MMOF WC 1250 MMOF WC 1250 MMOF WC UNITS 0-300 M3/HR 0-16 M3/HR 0-4000 NM3/HR 0-160 M3/HR 0-350 NM3/HR 0-350 NM3/HR 0-175 NM3/HR 0-175 NM3/HR BLOCK MAT'L MAT'L CODES 316SS 316SS 316SS 316SS 316SS 316SS 316SS 316SS 316SS 316SS 316SS 316SS 316SS 316SS 316SS 316SS D1 A2 D1 A2 D1 A2 D1 A2 D1 A2 D1 A2 D1 A2 D1 A2 G42-AY221-113 G42-AY221-113 G42-AY221-112 G42-AY221-112 G41-AY221-017 G41-AY221-017 G41-AY221-012 G41-AY221-011

TYPE OF CONSTRUCTION MAT'L OF CONSTRUCT'N MOUNT. SURFACE/FLUSH DIAL COLOUR TYPE OF GLASS RING.SCREWED OR SNAP BLOWOUT DEVICE LIQUID FILL MOUNTING BRACKETS DIAL MARKINGS COLOUR

ELEMENTS

REV

PROCESS DATA INSTRUMENT TAG No. SERVICE FLUID Dens.Kg/M3 RECYCLE GAS ST/UP BYPASS WASH WATER TO A01 CNDN RECYCLE GAS TO OFF GAS CAUSTIC PMP PO5 DISCHARGE FG PURGE TO LP FLARE HDR NITROGEN PURGE TO LARE HEADER FUEL GAS PURGE TO FLARE HDR NITROGEN PURGE TO FLARE HDR HC/LIQ 709 Wash Water 992 OFF GAS 6.18 CAUSTIC 1046 FUEL GAS 1.72 NITROGEN 2.69 FUEL GAS 1.72 NITROGEN 2.69 Max Kg/cm2 Max.Deg.C Conn.From. Calib.Range SCALE RANGE Op.Kg/m2 105 70.2 75.2 58.2 70.2 52.7 15.4 7.94 6.5 1.5 10.5 1.5 6.5 1.5 10.5 1.5 Op.Deg.C 231 71 95 41 163 52 163 38 150 38 65 38 150 38 65 38

0 0 0 0 0 0 0 0

221FI009 221FI010 221FI023 221FI024 221FI084 221FI112 221FI201 221FI220

NOTES

PROJECT: RELIANCE JAMNAGAR REFINERY

0 1

ISSUED FOR P URCHA SE RE-ISSUED FOR P URCHA SE

ACCESSORIES

RF KJB

SC APK

SS RM

Jo b No 22960 DA TA SHEET No REV

DIFFERENTIAL PRESSURE GAUGE

JE0066D-A Y221 -01 0 Rev DA TE REVISION BY CHK LEA D P ROJ CLT SHEET 3 1

Bulk MTO & Material Requisition

What is Bulk MTO ?

Contains quantities of instrument bulk items needed to construct a plant. Items are identified by unique Stock Code in the material management system. Contains all piping information, viz line no. , end connections , rating , piping spec etc. Contains selected instrument data like make / model no.etc.

How Bulk MTO is generated?

In instrument database system ( CAIES ) one field is dedicated to Hook-up details for the concerned tag. Hookup details are entered in this field. Query is generated through CAIES MTO module and unit wise material take off is obtained for all instrument bulk items. For electrical bulks like cables , glands and junction box similar query is generated through Setroute ( Electrical Database Management System )

Use of Bulk MTO

Procurement of bulk material required to construct the plant. Unit wise allocation of material helps to capitalise cost associated with a particular unit.

How MR is generated

MTO is downloaded into procurement system electronically in form of a flat file Stockcode wise Material Requisition is generated from procurement system and PO is generated.

Instrumentation Deliverables

What are Deliverables ?

Deliverables are the output of detail engineering and broadly classified into following groups Documents required for procuring instrumentation items, like General Instrument Specification, Datasheets etc. Documents required for construction , like Instrument Location Plan, JB wiring Diagram, Hook-up Drawings etc. Documents required for DCS/ESD and other system engineering, like Control Schematics , Cause & Effect Diagram , Advanced Control Strategies etc.

List of standard instrument Deliverables

Instrument Index

Lists all tagged instruments along with details like Type of instrument , Service , P & ID no., Datasheet no. , Process / Pneumatic Hook-up details etc. Gives complete wiring details from Instrument to Control System. Gives the building blocks guideline for DCS / ESD loop configuration.

Instrument Loop Wiring

Instrument Loop Schematics

List of standard instrument Deliverables

Junction Box Schedule

Gives complete details of all JBs in a plant along with Type , No. of terminals , Certifications etc. Gives complete details all multicore field and inter panel cables. Gives complete details of all tagged instrument and junction box location in a plant along with elevation. This document also shows the instrument air header layout and tentative tapping points

Cable Block Diagram

Instrument Location Plan

List of standard instrument Deliverables

PIB and Control Room Equipment Layout

Gives location of various panels and control equipment within PIB & PCC. Gives intermediate steps and calculated design data for various instruments. Gives complete information to procure correct instrument Narrates effects of various process trip initiators.

Various Instrument Sizing Calculations

Datasheets

Cause & Effect Diagram

List of standard instrument Deliverables

Instrument Installation Details

Guideline for installing various instruments.

Gives complete details along with MTO for hooking any instrument with process. Gives stockcode wise quantities of all instrumentation bulk items of a project. Gives all basic inputs for various process interlocks in a plant.

Instrument Hook-ups

Instrument Bulk MTO

Instrument Logic Diagram

Thats All About

Control Systems & Instrumentation