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Induction to Control System

The document provides an overview of plant safety and control systems, focusing on measurement and instrumentation, risk management, and the roles of basic process control systems (BPCS) and safety systems. It discusses the importance of smart transmitters, various control systems, and risk reduction measures, including instrumented protective functions. Additionally, it outlines relevant standards and design inputs necessary for effective process control and safety management.

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chhandak bera
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5 views

Induction to Control System

The document provides an overview of plant safety and control systems, focusing on measurement and instrumentation, risk management, and the roles of basic process control systems (BPCS) and safety systems. It discusses the importance of smart transmitters, various control systems, and risk reduction measures, including instrumented protective functions. Additionally, it outlines relevant standards and design inputs necessary for effective process control and safety management.

Uploaded by

chhandak bera
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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Overview of Plant Safety and

Control
Overview of Instrument System
& Control System

A brief presentation
By D.Guha (C&I)
Foster Wheeler India Pvt. Limited
Debasis
r
Guha
Foster Wheeler-KEC 1
Programme
Today’s Session
„ Introduction
„ Measurement & Instrumentation
„ Risk management
„ BPCS & Safety System
„ Control System Overview
„ Question & Answer session

2
Measurement & Instrumentation
“ Any thing (Process
!!) which can be
sensed (Sensor
( !!) ,
can be measured
and transmitted
(Transmitter) and
can be controlled
( Controller !!) and
Safeguarded
( Safety !!” )
3
Transmitter

„ What is a Smart Transmitter & why is


it required?

„ Transmitter is a part of control system,


required to transmit process signal to
control room. “smart” means it carries out
lots of self checks/ diagnostics and can
sense multi-variables (parameters).

„ What are diff type of signals to be


transmitted ? (Few examples)

„ 4-20 mA ( Non Smart-Conventional )


„ 4-20 mA HART signal (smart).
„ FF signal (smart).
„ Profibus signal (smart).

4
Flow Measurement-Challenges..

5
Flow Measurement

6
Final Control/Shutdown Element
Examples of
Valves
•ESD Valve
•PSD Valve
•Control Valve
•Special
Application
Valve
•Regulator
•Angle Valve
7
•Choke Valve
Design Input for Field Engineering
from other Disciplines

„ P&ID
„ PFD
„ Process Instrument Datasheet
„ BEDD (Basic Engineering Design Data)/Design
Basis
„ SLD (Single Line Diagram)
„ Piping Material Specification
„ Piping Plot Plan
„ Piping Layout
„ Static Equipment GA Diagram 8
Back Ground
The initial Risk associated with operating a process unit or a piece
of equipment may be reduced by applying a range of Risk
reduction measures, including IPF ( Instrumented Protective
Function).

Reduction can be achieved using a number of means, including


mechanical devices (relief valves, bursting discs, etc.) and
instrumented devices (IPF).

In most designs, both types of protection systems are applied, with


the mechanical system being the last line of defence wherever
possible.
9
Risk Risk Every where..

10
Risk Management

Tolerable Risk is defined by


corporate risk tolerability criteria).

11
What is Safety ?
Safety can be defined as “Freedom
from unacceptable Risk.”

12
How “good” is “good” ?

13
Risk Reduction

Layers of Protection

14
Basic Function of Control &
Safety Systems
Control System
„ The primary objective is to control the Plant within the permissible operating
envelope during start-up and changes in operating parameters, thereby avoiding
ESD System protective action
„ The second objective is to achieve long term stable operation at target

throughput, yields and product qualities.

Safety System

„ Preventing process conditions from reaching design values and causing


relief valves to lift.
„ Containing or disposing of significant liquid and vapour inventories so
as to minimise any potential for loss of containment and the creation of
a hazardous situation.

15
Explanation

16
Process Control & Shutdown
System

„ Distributed Control System (DCS) : Honeywell / Yogogawa / Invensys /Emerson


„ Emergency Shutdown and Equipment Protection (ESD/EPS) : Triconex/HIMA
„ Advanced Process Control System (APC) : Aspen Tech
„ Process Analysers ( GCs ) & Data Management System (AMDS) : ABB/Rosemount
„ Compressor Control System (CCS) :CCC/Troconex
„ Burner Management System (BMS) : Triconex
„ Vibration Monitoring Systems (VMS) : Bently Navada, B&K
„ Condition Monitoring System (CMS) for Critical machines : Bently Navada, B&K
„ Online Corrosion Monitoring System (CRMS) : Rohrback Cosasco
„ Instrument Asset Management System (IAMS) : Refer DCS Vendor
„ Fire & Gas Detection System (FDS) : SIEMENS/ General Monitor/Honeywell
„ Operator Training Simulator (OTS) : Omega/ Protomation
„ Maintenance Training Simulator ( MTS) : Refer DCS Vendor
„ Data Acquisition & Historian System : OSI-PI
„ Metering Skid : Panametric/ Danyel 17
Auxiliary System (Other than
Instrument )

„ Laboratory Information Management System ( LIMS)


„ Heating Ventilation and Air-condition System (HVAC)
„ Power Management System (HVAC)
„ Mechanical Packages and Skids ( Compressor/Turbines etc)
„ Smart Motor Control Center (MCC)
„ Plant Information Management System Network (PIN)
„ Plant Security & Surveillance System
„ Enterprise Recourse Management System ( Like SAP )
„ Wireless Radio / Satellite Communication System
„ SCADA/Wide Area Network (WAN)

18
Typical Architecture

Satellite media

router

Vnet/IP

Sub-sea Fiber Optic


F.O.
F.O. router

Vnet/IP
Vnet/IP
router

router

Vnet/IP Microwave Radio 19


Typical Conventional DCS

20
Typical Foundation Fieldbus DCS

21
Security

22
Fire-Wall

23
Why Fire-Wall
A popular solution for industrial security is to
install single firewall between business and the
control system.

24
Basic Interfaces
„ DCS is the main system where all the other systems are linked either
directly ( hardwire) or via redundant serial interfaces ( Modbus RTU/
Modbus TCP-IP).
„ All the trip signals are essentially hardwired to ESD system.
„ All the trip signals from auxiliary systems ( CCS/VMS etc) to ESD are
hardwired.
„ Field instruments are directly connected to the respective system either
directly ( one to one) or through network ( Foundation Fieldbus/
Profibus)

25
Interface Diagram

26
Design Input for PCS Engineering
from other Disciplines

1. Process Risk Area Segregation


2. P&ID
3. Cause and Effect Diagram
4. Automation & Control Philosophy
5. Emergency S/D Philosophy
6. Control Narrative
7. Logic Description
8. International/Client Specific Standard

27
Relevant Standards

„ IEC 61508/IEC 61511


„ ISA 84.01
„ Shell DEP 32.80.10.10-Gen
„ DIN V 19250

( Shell DEP based on IEC and DIN)

28
Thank you

29

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