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TRAINING IN THE FIELD OF PROCESS CONTROL,AUTOMATION AND INSTRUMENTATION

COMPANY OVERVIEW

Worlds largest petroleum refinery. Capable of refining sweet, sour and mixture crude. Manufactures fuel from motor fuel to ATF and various petrochemicals and fibers. Complex also houses worlds largest polypropylene plant DTA and JERP refineries both can refine 12,40,000 barrels of oil per day combined. Manufactured products are exported to 26 countries. DTA refinery has nelson complexity of 11.4 and JERP has 14 making it most complex refining complex in world

VARIOUS PROCESS TECHNOLOGIES


Hydrodesulphurisation Catalytic Reforming Unit Fluid Catalytic Cracking Unit Delayed Coker Unit : Foster Wheeler Inc. Sulphur Recovery : Black & Veatch Pritchard Hydrogen Generation Merox Treating SHP / TAME*

PROGRAMMABLE LOGIC CONTROLLER (PLC)

BASIC COMPONENTS OF PLC

Central Processing Unit. Communication Modules. Memory. Input Modules. Output Modules. I/O rack back plane. Power supply. Programming terminal. Human Machine Interface

Input / Output for PLC In earlier days PLC was able to handle only digital I/O. But nowadays such PLCs are available that can handle both type of I/O digital as well as analog. Digital I/O: It is two state (binary) I/O signal. Typical digital input devices are Proximity switches, Relay contacts, Pushbuttons. Typical digital output devices are Relay, Indication lamp, Solenoid, Hooter. Analog I/O It is continuous signal I/O (4-20 ma, 1-5 volts etc). Typical analog input devices are Transmitters for process parameters. Typical analog output devices are I/P converter of control valve, Variable frequency drive

Advantage of using PLC over relay logic


Less cabling. High reliability. Very fast response time. Easy troubleshooting. Highly flexible & Easy to change Logics. Easily expandable. Less installation space requirement. Self-diagnostic capability. High computing capabilities Communication & Integration facilities Variety of I/Os available Large scale digital I/O processing (2048 I/Os) I/O racks can be located far away from CPU (10000 ft.) Networking of PLCs Security: Password and Privileges can be configured

PLC IN REFINERY

Mainly of ALLEN BRADLEY made. PLC 5 and SLC family. PLC 5 having CPU level redundancy. PLC 5/40, 5/60 and SLC installation. Controls operation of the compressors, heaters, filters, f& g, analyzer safe guarding and other package unit. PLC are used in hot redundant configuration. In SLC family SLC 5/02,5/04 Signal strength of input- 4 to 20 mA. The baud rate for communication is 57.6k.

DISTRIBUTED CONTROL SYSTEM


InformationNetwork TCP/ IP
Computers, W orkstations, X-Terminals, PCs etc IEEE 802.3

I/ A Series LAN

IEEE 802.4

I/ A Series Nodebus

W orkstation Processor (W - 51) P

Control Processor (CP- 40)

Application Processor (AW- 51)

Communications Processor COM10 RS232 Peripherals; B/ W&Color Printers, Terminals; FoxW atch

Device Integrator ( DI,MG30 ) RS232 3rdParty Devices e.g. PLCs,ESDs RTUs Scanners Power Plant Scales Tank Farms Analyzers Spectrum

I/ A Series Fieldbus
Digital Field Link
Foxb oro Foxb oro oro Foxb Foxb oro Foxb oro Foxb oro oro Foxb Foxb o ro Foxb oro Foxb oro Foxb oro oro Foxb Foxb oro oro Foxb Foxb oro oro Foxb Foxb oro oro Foxb Foxb oro Foxb oro Foxb oro X X X L B U G X X X L B U G X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

Intelligent & Conventional FieldDevices

Fieldbus Module

Fieldbus Cards

Reliance Jamnagar DCS architecture

Function of equipment installed in plant control centres;


System administration and system management File server Human interface for plant operation. Alarm management Interface as engineering station. Information management. Interface for system maintenance

Function of equipments installed in PIBs :


Interface for process inputs and outputs. Process control Interface for third party system via serial links.

DCS systems in complex :


Refinery( 15 node system- refinery PCC, PIB:6,7,8,9,10,11,13,14,15,16,17,18) Tank farms(11 node system- marine PCC,PIB 19,20,21,23,27,28,29) Captive power plant(3 node system- CPP PCC,MRS 1,2) Aromatics(6 node system- Aro PCC,PIB:1,2,3,4,5 Poly propylene(5 node system- PP PCC,PIB:24,25,34) Port operations(Single node system- port pcc)

Basic building blocks:


Analog input/output block PID block/auto tune PID block Digital I/O block Calculation block Characterizer block Comparison block Switch block Data blocks/Memory blocks Sequence blocks Mathematical block Motor operated valve/pneumatic valve.

Communication

Star Ring Linear bus Star wired ring Tree


Communication standardard: 802.1: committee deals with high level interface and network management 802.2: standard committee define logical link control 802.3:new standard of LAN 802.4: a physical layer of LAN used for token passing 802.5: establish the standard for token ring acess method

Salient Features Of DCS network in Reliance Jamnagar:

Worlds largest ever process control network 242 kms of fibre optic network. Reaching out to physical boundaries of carrier band LAN catering to 19.96 kms of length. There are 26 nodes over the network. Scanning, Control & monitoring of 1.3 lacs parameters every second. Total 2309 regulator control loops 37 engineering stations. 87 operator stations 1118 station with a combination of 468 fault tracking center. 225 serial interfaces with various package vendors linking varieties of plcs. Allen Bradley , Siemens ,CCC, Bentley Nevada, Smith meters, ABB, P&B excell, SAAB ATG, MTL temperature multiplexers, Rotork MOV. 4700 emergency shutdown parameters 12393 logic networks Integrated 15 number of fully safe and secure triple redundant emergency shutdown system.

AUTOMATIC TANK GUAGING SYSTEM


TYPES OF TANKS

Cone Roof Tank (With or W/O N2 purging) Open Floating Roof Tank Internal Floating Roof Tank. (With N2 Purging) Dome Roof Tank Sphere Horizontal ( Bullet )

CONE ROOF

OPEN FLOATING ROOF

INTERNAL FLOATING ROOF

DO ME RO OF

HORIZONTAL

SPHERE ROOF

MEASUREMENT IN TANKS
The following are measured in a tank

Temperature Hydrostatic Pressure Static Pressure Level Water bottom

SAAB TANK GUAGE SYSTEM


The SAAB system has the following components., Radar level gauge Multi spot temperature probe Single spot temperature probe Bottom water level probe Vapour/N2 pressure transmitter Hydrostatic pressure transmitter Data acquisition unit Independent display unit Field communication unit Field bus modem OPI station

Types of tank guages


The Horn Antenna Gauge, RTG 2920 / 3920 The Parabolic Antenna Gauge, RTG 2930 / 3930 The Still Pipes Gauge, RTG 2940, for measuring in still pipes. The Still Pipes Gauge, RTG 2945, for measuring in still pipes in pressurizes tanks. The LPG/LNG Gauge, RTG 2960, for liquid gas, LPG and LNG.

Electronic unit cards of tank guage

Power supply card : Used for giving power supply to the electronic unit. Communication card : Used as a communication link. Signal Processing card : Used for data processing. Current loop card: It provides intrinsically safe 4-20 mA inputs and outputs to the Radar Tank Gauge. Barrier unit : It provides intrinsically safe power and communication between the Slave Data Acquisition Unit and the Radar Tank Gauge

TRANSMITTERS
There are four types of transmitters: PT (Pressure transmitter) In this we have to measure pressure directly. DPT (differential Pressure transmitter) In this we have to measure differential pressure, from that one is low pressure and one is high pressure. LT (Level transmitter) In this we have to convert pressure in terms of level. In this we have to take samples of level & measures pressure and then convert it into level. FT (Flow Transmitter) In this we have to convert pressure in terms of flow. In this we have to put DPT in between pipeline & measures differential pressure , then take square root of pressure & we can measure directly flow

Range of transmitters

IDP 10 300 mm H2O IGP 20 5080 mm H2O IGP 10 - 2.10 kg IDP 10 DF1 21 kg IDP10 DS 1 210 kg

Software used for transmitters


Hart Communicator: It will give output in terms of 4 to 20 mA. Foxcom or PC 20: They will convert output in terms of 4 to 20 mA like hart communicator as well as give digital communication but at that time mA will constant.

THANK YOU

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