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1.3 Plant Operation System

This document discusses plant operation systems and process control. It describes typical objectives like protecting people, equipment, and the environment while maintaining smooth operations. This is achieved through distributed control systems (DCS) that use computerized control and fieldbus technology to connect sensors, valves, and transmitters. Key parts of a control system are described like PLC architecture, redundancy systems, control loops, and safety features. Sensor systems, actuators, and controller types are also outlined. The document discusses instrument reliability, safety integrity levels (SIL), and examples of typical product SIL ratings.

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317 views32 pages

1.3 Plant Operation System

This document discusses plant operation systems and process control. It describes typical objectives like protecting people, equipment, and the environment while maintaining smooth operations. This is achieved through distributed control systems (DCS) that use computerized control and fieldbus technology to connect sensors, valves, and transmitters. Key parts of a control system are described like PLC architecture, redundancy systems, control loops, and safety features. Sensor systems, actuators, and controller types are also outlined. The document discusses instrument reliability, safety integrity levels (SIL), and examples of typical product SIL ratings.

Uploaded by

arunkumar23101
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Plant Operation

Systems
DR. AA

Typical Objectives of Plant Operation

1.
2.
3.
4.
5.
6.
7.

Protect people
Protect Environment
Protect Equipment
Maintain Smooth operation
Achieve Product rates and quality
Profit = optimising first five
Monitoring & diagnosis

These are Achieved Through Process Control


2

Distributed Control System (DCS)


DCS (Distributed Control System) is a computerized control system
used to control the production line in the industry
DCS was introduced in 1975 by Honeywell (TDC2000) and Yokogawa
(CENTUM)
Other vendors: ABB (Bailey etc), Foxboro, Emerson (Fischer,
Rosemount etc)

DCS Architecture
System
Consoles

Host
Computer

Data
Storage Unit

PLC

Data Highway
(Shared Communication Facilities)

Local
Console

Local
Control
Unit

......

4-20 mA

Local
Control
Unit

Local
Console

4-20 mA

Process Transmitters and Actuators


4

Fieldbus Technology
P5001 0
... 150 bar

CEAG
I/O

Foundation Fieldbus (FF)


Profibus (Process Field Bus)

Others: ControlNet, P-Net, SwiftNet ,


WorldFIP, Interbus, EtherCAT, SERCODS etc

Introduced 1988 but underwent many


development
Standard IEC61158 introduced in
1999
Based upon smart devices installed
in the field.
Uses data highway to replace wires
for signal transfer.
Can mix sensors, transmitters, and
control valves from different vendors

Fieldbus Architecture
Data Storage

Plant Optimization

High Speed Ethernet


PLCs
Local
Area
Network

.................

H1 Fieldbus
Smart
Sensors

Local
Area
Network

H1 Fieldbus
Smart Control
Valves and
Controllers

H1 Fieldbus Network

Smart
Sensors

Smart Control
Valves and
Controllers

H1 Fieldbus Network

PLC Architecture

Programming
Interface
PLC Cabinet
Power
Supply

Processor
Data Highway
I/O Modules

Input
Devices

Output
Devices

Redundancy
We desire independent protection layers, without commoncause failures - Separate systems

Digital control system


i/o

.
sensors

DCS handles controls


and alarms functions.

i/o

SIS system
i/o

i/o

sensors
PLC handles SIS and
Alarms associated with SIS
8

Control Diagram of a Typical Control Loop


Actuator
System

F1

F2

T1

T2
Sensor
System

Controller

T
F

TC
TT

Sensor System
Sensors
Temperature, Flow, Liquid Level, Pressure, pH,

Transmitter

10

Temperature Measurement
Expansion Thermometer
Liquid in Glass
Mercury in Steel
Bimetallic Elements

Thermoelectric Thermometers (Thermocouple)


Type J, K, T, R, S, ...

Resistance Thermometers
Thermister
Resistance Thermal Detector (RTD), e.g. Pt100

Radiation Thermometers (Optical Pyrometers)

11

Pressure Measurement
Direct pressure Measurement
manometer

Indirect Pressure Measurement


Bourdon Tubes, Bellows, Diaphragms

Electrical Pressure Transducers


Capacitive, Resistive, Inductive

Other Pressure Transducers


Force Balance, DP Cell, Piezoelectric Transducer

12

Flow Measurement
Point Velocity Measurement
Pitot Tube, Hot Wire Anemometer, Transit Time
Velocimeters

Gross Volume Flow Measurement


Venturi Tube, Orifice Plate, Nozzle, Dall Tube,
Rotameter, Turbine Meter, Positive Displacement
Meters (piston, gear etc)

Gross Mass Flow measurement


Direct Method - Momentum Type, Thermal Type
Indirect Method - calculate density & pressure etc.

13

Liquid Level
Dipstick, Sight glass, Float
Diaphragm
Load Cell
Manometer, Direct Pressure, Differential
Pressure
Capacitive Probe
Ultrasonic

14

Chemical Composition
Refractive Index
Spectroscopy
IR/UV/Visible Spectrophotometer, Mass
Spectrophotometer, Atomic Absorption
Spectrophotometer

Chromatography
Gas Chromatography, Liquid Chromatography

15

Actuators System
On/Off
On-Off Valves
Pumps (motor)

Variable position
Control Valves
Variable speed pump
DC motor
3-phase motor
Turbine drive

16

Control valve

17

Butterfly valve

18

Actuator

19

Valve with actuator


& positioner

20

Why are some valves Fail-Opened, While


Others Fail-Closed

21

Typical response of Control Valves

A
Percentage of
Maximum flow

A. Quick-Opening
B. Linear
C. Square-root
D. Equal Percentage

Percentage of Stem Travel

Why do we need different shapes of plugs in the


control valves ?
22

Motor Speed Control


DC Motor Speed Control
Adjust the power of motor by varying current or
voltage

AC Motor Speed Control (3 Phase Motor)


Adjust the power of motor by varying the frequency of
the AC cycles

Steam Driven Turbine


Adjust the turbine speed to adjust the pumping rates

23

Safety Features
Alarms & Enunciators
Interlocks
To isolate the impact of process failures from one
section from another

Rupture Disks, Pressure Relieve Valves, etc

24

Controller System
Stand Alone Controller
Supervisory Control
DCS

25

How Reliable are Those Instruments?


Reliability can be estimated using the
following equation
t

Re

Here R is reliability, is the annual failure


frequency (failure/year) and t is time (year)
The failure probability can then be estimated:

p 1 R 1 e

Here p is the annual probability of failure


26

Safety Integrity Level (SIL)


A SIL is a measure of safety system performance, in
terms of probability of failure on demand (PFD). The
higher the SIL is, the more reliable or effective the
system is.
Every Safety Instrumented Function (SIF) has a SIL
classification guided by the IEC 61508 standard
ANSI/ISA S84.01 and IEC 61508 require that companies
assign a target SIL for any new or retrofitted SIS.
Three sector specific standards have been released
using the IEC 61508 framework, IEC 61511 (process),
IEC 61513 (nuclear) and IEC 62061 (manufacturing).

27

SIL and PFD


PFD - Probability of Failure on Demand per year
Safety Integrity
Level (SIL)

PFD
(Low Demand Mode)

PFD
(High Demand Mode)

> 10-2 to < 10-1

> 10-6 to < 10-5

> 10-3 to < 10-2

> 10-7 to < 10-6

> 10-4 to < 10-3

> 10-8 to < 10-7

> 10-5 to < 10-4

> 10-9 to < 10-8

Low Demand Mode intermittent operation (less than once a


year)
High Demand Mode Continuous operation or systems that
operates more than once a year
28

Examples
Component

Failure Rate

(faults/year)

Reliability
R=e(-t)

Failure
Probability
P=1-R

DP Cell

1.41

0.24

0.76

Control Valve

0.6

0.55

0.45

Standalone
Controller

0.29

0.75

0.25

29

How to Assign SIL Level?


PFD requirement typically determine by the
PHA Team. Based on this, required SIL is
identified.
There are various methodology available e.g.
HSE Research report no 216 as well as others

30

Typical Product SIL (General Motors)


Product

SIL Suitability
Level

FL4000 Flame Detector (MultiSpectral IR)

FL3111 Flame Detector (UV)

S100C Combustible gas detector

Field Mounted Display

TA102A Controller

31

End of Topic 1.3

32

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