AB Control Logix 5000
Hw 1756, 5556 Logix Control Net
New project
On left I O Configuration right click to add modules
Check firmware no. I.e. 2.5 on side of module, and model no. While adding v hav to enter it
On left Task->Main Task->Main Program-> Main Routine double click
e e e e beside Rungs means Error in rung will appear if Elements like PB coil not assigned addresses. To assign addr right click on element Alias Local1:Idata0 (its on main Shaashi Local PLC not Remote) I input, 0 first bit. After assigning it will apear in Controller Tags Folder on Left of main screen.
After No Error Save program
Open RS linx RS232 communication, ->Configure Driver-> choose in Available Drivers-> AB DF1 RS232 Devices-> Com Port, Baud Rate, Parity etc will b asked Just set right Port n press AUTO CONFIGURE. It will show successful. Close it then u will see in Configure driver window its in Running status. Click OK
Go to top menu Communication->WHO ACTIVE select Ab DF1 ->Download to PLC. Stop process before doing it
Open Main Prog, Run Battery, Ctrller OK, IO Ok indicator must b on now, right Click on FORCE->ENABLE
Force Only when 100%Sure it willnt cause any damage to Process or Equipment.
Force ur Start PB to check Coil gets ON
AGT Gas Detector Red Black White wires
VMS
Buffer outputs r used during Vibration balancing of rotor
Tdi(transient Data Interface) module makes communication with rest of the modules blinking tx/rx led on all module indicates there communication. Serial port on TDI is for programming, reset button on it is used for reseting alarm in modules or relay modules
One module for monitoring Differential Expansion & Casing Expansion
4 channel relay module has spdt(single pole double throw)contact, 16 ch relay module has (spst)
Red led on relay module shows alarm is active
All front modules r called Monitors, rear side modules r called IO Modules
Each module has at the bottom 4-20 outout for Re Trasmitting to DCS.
Communication Module has redundancy its connected to DCS
Keyphasor: key on rotor shaft causes voltage variation more significant than possible by vibration
If Multimeter shows 135mVAC how much is Vibration?
Multimeter measures rms value so 135 mv rms = 135× 2 sqrt 2 = 381.78 mv pk-pk
Eddy probe sensitivity 7.87 V/mm or 200mV/mils
200mv/25 micron so 381.78mv pk-pk =381.78x 25/200=47.72 micron Vibrations
Settings Radial VXT 0-250um pp H-125, HH-175
Axial Thurst -1 to 1 mm alarm H +- 0.3, HH- +-0.6 mm
VMS DCS Mapping Temp address 405187 bit 0- Temp Fault, Bit 1- Temp Alarm H, Bit 2- Temp Alarm HH, Bit 3- TI2157_MA Temp Bypass
TI2157 405050 U16B Temp Reading PV
Same for VXI
Foundation Fieldbus Hardware
DCS Host(H1Interface)->Power Hub(Barrier+4Segment)->Segment Protector(Field)
Cat Ion An Ion Exchangers(Water Softners)
Cation resin releases H+ ions by allowing Ca2+ present in impure or Hard Water to replace H+ from resin. Dil HCl/H2SO4 acid is used to regenerate cation Resin
RH2 +(Ca2+)--> RCa + 2(H+) Hardness of Water is due to Ca, Mg, Na ions these r trapped by this resin. Water from this exchanger is still Acidic so we need to make it react with Basic Solution
Anion resin releases OH- ions by allowing SO2- ions in water to replace OH- ions in Anion resin.
R(OH)2+ HCl-->RCl2+2(OH-)
R(OH)2+H2SO4--> RSO4+2(OH-)
2H+ + OH- --> H2O Soft Water
Dil NaOH alkali is used to regenerate Anion Resin
Water is finally freed from Dissolved Gases like CO2, O2 in Degasifier tower whose sides r heated and a Vacuum pump reduces pressure inside tank, this High Temp & Low Pressure causes Gases to leave Water.
Regeneration in Cation Exchanger RCa+HCl-->RH2+CaCl2
RMg+HCl-->RH2+MgCl2
These salts CaCl2, MgCl2 etc r drained out
Regeneration in Anion Exchanger
RCl2+2NaOH-->R(OH)2+2NaCl
Square Root Output for DP FT
0% at 4 mA
50% at 8 mA(25%)
70.7% at 12 mA(50%)
86.6% at 16mA(75%)
100% at 100%
Boiler
main fuel trip (MFT) there should be MFT kicker logic. An MFT occurs when the burner management system detects a dangerous condition and shuts down the boiler by securing the fuel per NFPA and boiler manufacturer requirements
Atomizing steam Low pressure steam which is introduced to the oil gun to help atomize the oil, to assist the burning process, and to keep the oil gun from plugging
Maximum continuous rating (MCR) is the capability of steam boiler to produce and provide the stated quantity of steam continually and easily with no all kinds of deficit or unwanted effects
Ratio of Fuel gas to oxygen is 1/13. Oxygen analyzer analyses O2 in flue gas exiting firebox or to stack it shud b around 2%
low A/C voltage is applied to the FLAME ROD, and when that flame rod is inserted into a proper flame, the voltage converts to a D/C voltage by traveling through the flame to ground.
You can measure flame signal by putting your meter (capable of measuring micro amps) in line between the flame sensor and the wire that was connected to it (see picture). If you are reading anything under 5 uA (micro amps), it is likely that your flame sensor is dirty.
Interface Level Measurement
Using DP tr
I. Level= (dp-LRV)L/span whr dp-d.press.
L full length, span =urv-lrv
SIL(Safety Integrity Level)
SIL no. R assigned based on Risk Analysis in conjunction with HAZOP as described in ISA S84.01 & IEC 61511
There are several methods used to assign a SIL. These are normally used in combination, and may include:
Risk matricesRisk graphsLayers of protection analysis (LOPA)
Of the methods presented above, LOPA is by far the most commonly used
standard IEC 61508 defines SIL using requirements grouped into two broad categories: hardware safety integrity and systematic safety integrity. A device or system must meet the requirements for both categories to achieve a given SIL.
61508 is used by mfg for circuit level diagnostic, software testing etc
61511 is used by process designers i.e. Redundancy requirement & proof testing
System Integrity Test
Communication between speed Governor & DCS is validated
Data coming from field via 2 optical fiber links, in DCS system both links shud b Healthy & there should be 0 errors in transmission packets reading shud b displayed.
On DCS turbine page parameters from field r fetched it shud remain intact if 1 link fails, if both fails parameter values will blackout Communication Failure alarm to b generated in both cases.
If NW switch which redirects signal from Optical Fiber to Ethernet switch nw, if power fails Communication fail alarm shud appear for all signals that LAN network has connection.
FGS function test
1ooN Smoke(fire) detectors in Sub Station or Heat detectors above Transformer & Battery room will result in Alarm horn + beacon after pressing silence from system horn will silence but Red beacon will contastantly glow till detector undetect.
2ooN will cause HVAC of SS to Circulation or shutdown. In Battery room if H2 gas detected Battery Charging to b stopped by logic
Woodward 505
Forcing from field login to Service mode
User id service password wg1112
To force relay select that relay from display then Force Output->Energize ask DCS side if Forced or not De energize to deactivate
TC PiD Reverse action(op decreases with increase in error) EqC
Range 0-650 setpt 400 CO 43.5% PV 400.2
Kp 2.5 Ti 9 minutes
Honeywell Control Builder
IsNaN -Is not a Number
X?y:z means if, then else
Genlin (general linearization )block: calculates output based on user defined input output table values
Process:
deaerator is a device that removes oxygen and other dissolved gases from liquids. Upper tank is deaerator below tank is storage tank from where BFW is pumped out by pump. Condensate is sprayed on steam to acheive it.
Refinery process animation https://youtu.be/DgPGo8lqfY0
Distillation: heating crude oil converts it into vapour, different light oils reach higher in column n gets collected on trays(kind of NRV system) from whr pumped out.
Cracking: breaking longer HC into smaller
Reforming: Naphtha has same no. Of Carbon as gasoline, its Reformed into Gasoline. Catalytic reforming used Temp Pressure n Catalyst inside reactors to reform Naphtha into gasoline. Before sending to CCR product is Hydrotreated or desulfurizationed in which sulfur, N2 etc r removed
Blending: Mixing in different ratio to achieve desired Octane no. Fuel grade 91 has 91 parts octane 9 parts heptane
Treating: removing Sulfur from oil. Oil is heated in presence of Catalyst. Sulfur leaves oil. Sulfur is used in Pharma & Fertilizer
Scanner IR gain of first floor burner 65
Of 2nd floor 70. Reading 900-1100 & 1800-2200
Ultrasonic GE panaview software file ext .af
RTD Red & (white+Black)
Remote I/O only one Controller
Distributed I/O 2 or more controllers i.e. Main Controller->IO Controller-> Remote I/O
Instrumentation software such as SPI, Instrucalc, Flowel , Flowel simplifies and expedites the process of accurately sizing Venturi meters, orifice plates, and flow nozzles
FDM Field device mgr->all Transmitters & valves->DD file
Validity refers to the degree to which an instrument accurately measures what it intends to measure
Inhibit =MOS in FGS SYSTEM
CO signal is sent to the final control element (e.g. valve, pump, heater, fan) causing it to change. change in the final control element (FCE) causes a change in a manipulated variable. change in the manipulated variable (e.g. flow rate of liquid or gas) causes a change in the PV
suppose the P-Only control algorithm shown above is used for cruise control in an automobile and CO is the throttle signal adjusting the flow of fuel to the engine.
Let’s also suppose that the speed SP is 70 and the measured PV is also 70 (units can be mph or kph depending on where you live in the world). Since PV = SP, then e(t) = 0 and the algorithm reduces to:
CO = CObias + Kc∙(0) = CObias
If CObias is zero, then when set point equals measurement, the above equation says that the throttle signal, CO, is also zero. This makes no sense. Clearly if the car is traveling 70 kph, then some baseline flow of fuel is going to the engine.
This baseline value of the CO is called the bias or null value.
PI controller
integrate or continually sum the controller error, e(t), over time, integral controller adds history of error over the time
integral of each shaded portion has the same sign as the error.
integral sum of all error is not zero. residual value enables integral action of the PI controller to eliminate offset.
e(t) can be zero, yet we can still have something to add or subtract from CObias to form the final controller output, CO.
integral term tends to increase the oscillatory or rolling behavior of the process response.
Some Vendors use proportional band rather than controller gain. Also, some use reset rate, Tr, instead of reset time. These are simply the inverse of each other:
Tr = 1/Ti
time derivative (rate of change) of a position is a velocity.
The proportional term considers how far PV is from SP at any instant in time.
The integral term addresses how long and how far PV has been away from SP. The integral term is continually summing e(t).
Derivative considers how fast, or the rate at which, error (or PV as we discuss next) is changing at the current moment.
derivative of e(t) is mathematically identical to the negative of the derivative of PV everywhere except when set point changes. And when set point changes, derivative on error results in an undesirable control action called derivative kick
de(t)/dt= d(sp-pv)/dt=d(sp)/dt-d(pv)/dt=0-d(pv)/dt
If setpt is constant d(sp)/dt will b 0 since derivative of const is Zero.
So in PID equation we remove d(sp)/dt. Instead of de(t)/dt we write -dpv(t)/dt coz Derivative on PV Does Not “Kick”. And Derivative term is based on PV only
Td is very small, the derivative term has little influence, regardless of the slope of the PV
Thus when dPV/dt is large and positive, the derivative term has a large influence and seeks to decrease CO.
Conversely, when dPV/dt is negative, the derivative term seeks to increase CO.
derivative term does not consider whether PV is heading toward or away from the set point (whether e(t) is positive or negative). The only consideration is whether PV is heading up or down and how quickly.
The result is that derivative action seeks to inhibit rapid movements in the PV. This could be an especially useful characteristic when seeking to dampen the oscillations in PV that integral action tends to magnify.
majority of DCS and PLC systems now use controller gain, Kc, for their dependent PID algorithms. There are notable exceptions, however, such as Foxboro who uses proportional band (PB = 100/Kc assuming PV and CO both range from 0 to 100%).
Honeywell Experion dcs Equation C: only integral term is applied on the error and both proportional and derivative terms act on the process value.
Integral Windup
valve cannot open more than all the way. A pump cannot go slower than stopped. Yet an improperly programmed control algorithm can issue such commands.
Integral controller sums error over time.
If an error is large enough and/or persists long enough, it is mathematically possible for the integral term to grow very large (either positive or negative): This large integral, when combined with the other terms in the equation, can produce a CO value that causes the final control element (FCE) to saturate. That is, the CO drives the FCE (e.g. valve, pump, compressor) to its physical limit of fully open/on/maximum or fully closed/off/minimum.
If the integral term grows unchecked, the equation above can command the valve, pump or compressor to move to 110%, then 120% and more. Clearly, however, when an an FCE reaches its full 100% value, these last commands have no physical meaning and consequently, no impact on the process.
Once we cross over to a “no physical meaning” computation, the controller has lost the ability to regulate the process. This is called integral windup
To prevent windup extra “jacketing logic” in the software is used to halt integration when the CO reaches a maximum or minimum value.
For eg in TC if new setpoint entered by operator cant b achieved even if Valve is acting 100%. Integral term will accumulate error. Later even if operator decreases set pt integral action wudnt return from saturation immediately it will keep forcing valve to go beyond its full capacity hence controller lost control coz of integral windup. As time passes, the integral term shrinks or “unwinds” as the running sum of errors balance out.
If CO > COmax, then CO = COdesired = COmax. if CO < COmin, then CO = COdesired = COmin. Back calculate the integral sum of error using our selected COdesired and save it for use in the next control loop calculation cycle.
BUMPLESS TRANSFER
In PI controller during switch over from Manual to Auto mode
Integral term shud b made 0
Set point of PI controller shud be PV just before switch over
Output Bias shud b output bias before switchover.
With the integral sum of error set to zero, there is nothing to add or subtract from CObias that would cause a sudden change in the current controller output. With the set point equal to the measured process variable, there is no error to drive a change in our CO.
PROPORTIONAL BAND
With 100% PB, 20% change in cause(level change in case of LC) will result in 20% movement in Control Valve stem to maintain setpoint
Sqrt output = 100* sqrt 25% * spanHONEYWELL DCS
Function block
Devctla: Device Control block ip DI op DO
Regctl : regulatory control for eg pid
CM Control Module
IOM I/O MODULE IOP I/O PROCESSOR
SCM sequential ctrl module
TP Trip Point
PVChar : pv characterization Linear/sqrt
PVHHALM.TP = PV high high alarm
Bad PV --> badpvalm.pr
Pvhisigchg.tp( high significant change) pvlosigchg.tp
Even to display Transmitter Indication on dcs chart wud contain Transmitter block- daca(data aquisition block) so it is for displaying values. Auxcalca block is for simple maths for eg in Expression u can write DP as P1-P2 then send this value to daca block to show dp value
Experion pks r500 honeywell dcs
Safety manager IPS
Fault Tolerant Ethernet (FTE)
Safenet for ips fgs bms
RCI Remote Communication Interface
MATERIAL
SA 106 CS
SA 210 Carbon steel
SA 316, 335 SS
SA 516 CS
Boiler Plant(Steam Generation Plant) Process flow
Polished water-Deaerator-BFW pump-Bfw- economizer(external)-economizer(internal)steam drum
Steam from steam drum -3 sets of (superheater & desuperheaters)- Superheated steam for distribution
MCR = maximum combustion rating
Emergency shutdown Isolates unit, Depressurize, stop supply of fuel, Equipment Isolation
Interface level
At 4 mA low density fluid is full, at 20 mA high density fluid is full
Interface level I = (DP-LRV) * L/span DP=differe tial pressure
Unilube process
Feed preheatingAbsorber(column)
Secondary raffinate recovery
Extract preheating(using heat exchangers)
Condensate/extract recovery
Extract stripping
Raffinate Recovery
Dry solvent condensation/raffinate recovery
Solvent handling & tankage
Soda ash tank
Solvent drying column
Stripping steam condensation (from Vessel bottom Light oil sent to storage)
Displacer level tr for 0 hang displacer or equi. Wt of displacer on torque tube adjust output to be 3 psi
For span => Reduced wt of displacer when immersed in fluid = actual wt - Volume x density
Magnetrol make displacer level transmitter displacer goes up and down causing change in LVDT(linear variable differential transformer) as the core position changes voltage is induced on secondary windings. Configuration needs only temp and specific gravity
The ProTech-GII is an overspeed safety device designed to safely shut down
steam, gas, and hydro turbines of all sizes upon sensing an overspeed or over-
acceleration event. This device accurately monitors turbine rotor speed and
acceleration via active or passive MPUs (magnetic pickups) and issues a
shutdown command to the turbine’s trip valve(s) or corresponding trip system.
2oo3 Voting modules n transducers.
failures in overspeed system components (switches, transducers, modules) are detected,
annunciated, and allowed to be repaired or replaced while the monitored system
continues to operate on-line
Woodward Peak 150 Turbine control
Peak 150 is designed to operate those
Steam Turbines with a single-valve or a single-valve rack
Steam Valve is controlled to ctrl spd of turbine based on Mag PUs
Turbine start-up is accomplished by controlling the inlet steam with the turbine’s
Trip & Throttle valve and/or the Actuator/Valve.
The MANUAL START MODE is when a turbine operator manually controls the
inlet steam by opening the TRIP & THROTTLE VALVE. The operator has control
of the turbine speed from zero RPM to the MIN GOVERNOR SPEED. While the
operator is starting the turbine, the Peak 150 ramps the speed set point to the
MIN GOVERNOR SPEED. It waits for the turbine speed to reach this point and
then it automatically takes control of the inlet steam
AUTO START
MODE, the VALVE RAMP controls the speed from zero to either IDLE SPEED or
to the MIN GOVERNOR SPEED depending on how the control is configured.
(see Figure 7-3).
If IDLE SPEED is configured, the speed will control at IDLE until the IDLE / MIN
GOV input is closed. When closed, the speed will RAMP up to the MIN
GOVERNOR SPEED.
This mode of operation starts with the ACTUATOR/ VALVE RAMP closed and
the Trip and Throttle fully opened.
Discrete Input #1 = LOWER SPEED
Input #2 = RAISE SPEED
Input #3 = EXTERNAL TRIP
Input #4 = START
Input #5 = RESET
Input #6 = IDLE / MIN GOV
Input #7 = REMOTE SPEED ENABLE
Input #8 = HI DYN SELECT or (OVERSPEED TEST)
Analog output #1 = Speed Readout
Analog output #2 = User Configurable
Actuator output = Signal to Actuator
SPEED READOUT output is included in the control to drive a tachometer
either near the turbine or in a control room. The maximum load for the readout
circuits is 600 Ω.
Speed sensor ip(mag pickup) minimum
detectable frequency is 200 Hz @ 1 Vrms. The maximum detectable frequency is
15 kHz 15000 rpm
Magnetic Pickups (MPUs) generate a speed signal that is used to provide
speed feedback to the Peak 150. The MPUs do this by generating voltage pulses
as the gear teeth pass through the MPU’s magnetic field.
Speed Governor Peak 150 counts
the number of pulses per second from the MPUs (frequency in HZ) and converts
this frequency to turbine RPM.
RPM = (Hz x 60) / Teeth
When the MPU signal is below 1.0 VRMS the Peak 150 activates an ALARM of
FAILED MPU.
CRITICAL SPEED BAND is used to prevent turbine operation at speeds
where there is excessive turbine vibration. The CRITICAL SPEED BAND function
does this by switching to a faster RAMP while the ACTUAL SPEED SETPT is in
the CRITICAL SPEED BAND. This function also prevents the ACTUAL SPEED
SETPT from being stopped while in the CRITICAL SPEED BAND (default 1500-1800 rpm)
DROOP feedback.
Droop is defined as a decrease in speed set point proportional to an increase in
load. The DROOP Signal is a function of the VALVE POSITION (ACTUATOR)
signal. When DROOP is configured, the SPEED CONTROL compares the
ACTUAL SPEED SET POINT to the combination of the SPEED signal+DROOP signal
use a “dual” T/C probe, or convert one T/C output to a 4-20 mA signal by using a transmitter or signal conditioner; then the new signal can be sent to more than one instrument
2. drawbacks of derivative action.
Derivative control itself is a crude prediction of the error in future, based on the current slope of the error and the time of error is measured with the Td. Some of its drawbacks are: (i) The output of controller is zero at constant error condition.
(ii) It will amplify the noise present in the error signal.
3. Concentric Orifice plate: are used for ideal liquid as well as gases and steam service.
Segmental : For colloidal and sherry flow measurement.
Eccentric : used in viscous and sherry flow measurement
4. Enraf level gauge is based on the servo powered null balance technique. A displacer serves as continuous level sensing element. A two phase servo motor controlled by a capacitive balance system winds unwinds the the measuring wire until the tension in the weight springs is in balance with the weight of the displaced part immersed in the liquid.
level measuring principle is based on the detection of variations in the weight of a displacer suspended in the process fluid. The displacer is connected to a wire wound on a precision measuring drum. A level change causes a change in the weight of the displacer that will be detected by the force transducer.
5. What are de-saturators?
When, in some processes, e.g. batch processes, long transient responses are expected during which a sustained deviation is present the controller integral action continuously drives the output to a minimum or maximum value.
This phenomenon is called ‘integral saturation of the control unit’. When this condition is met, then this unit is de-saturated.
3.8 under range, 20.8 mA over range
OOR alarm out of range for Over or Under range of IPS (HIPS high pressure integrity system ESD tags)
MOS doesnot work if alarm present
Burnout value shud b High for LL alarm, shud b low for HH alarm so in case of sensor failure it will show opposite value of alarm like high if LL alarm is there, MOS can b enabled only if No alarm is present.
Flare header
Steam is very often injected into the flame to reduce the formation of black smoke. When too much steam is added, a condition known as "over steaming" can occur resulting in reduced combustion efficiency and higher emissions. To keep the flare system functional, a small amount of gas is continuously burned, like a pilot light, so that the system is always ready for its primary purpose as an over-pressure safety system
flare stack system:[1][2][3]
A knockout drum to remove any oil or water from the relieved gases.
A water seal drum to prevent any flashback of the flame from the top of the flare stack.
An alternative gas recovery system for use during partial plant startups and shutdowns as well as other times when required. The recovered gas is routed into the fuel gas system of the overall industrial plant.A steam injection system to provide an external momentum force used for efficient mixing of air with the relieved gas, which promotes smokeless burning.A pilot flame (with its ignition system) that burns all the time so that it is available to ignite relieved gases when needed.[8]The flare stack, including a flashback prevention section at the upper part of the stack.
How would you do Glycol filling or fill seal liquids in seal pots 7 Draw and explain.
The procedure for glycol filling is : 1) Close the primary isolation valves(valve near flanges).
2) Open the vent on the seal pots. 3) Drain the use glycol if present. 4) Connect a hand pump on L.P. side while filling the H.P. side with glycol. 5) Keep the equalizer valve open. 6) Keep the L.P. side valve closed. 7) Start pumping and fill glycol. 8) Same reeat for L.P. side by connecting pump to H.P. side, keeping equalizer open and H.P. side isolation valve closed. 9) Close the seal pot vent valves. 10) Close equalizer valve. 11) Open both the primary isolation valves.
How will you vent air in the D.P. cell ? What if seal pots are used?
1) Air is vented by opening the vent plugs on a liquid service transmitter. 2) On services where seal pots are used isolate the primary isolation valves and open the vent valves. Fill the line from the transmitter drain pluge with a pump
PULSATING FLOW
According to ISO 5167-1:20031
, a flow is considered as not being pulsating when
rms 0.10 p
p
∆ ′ ≤
∆ ,
where ∆p is the time-mean value of the differential pressure
∆p′ is the fluctuating component of the differential pressure
and rms ∆p′ is the root mean square value of∆p′ .
With a pulsating flow the requirement may be to measure either the time-dependent flow or a
time-average.
filling tube with glycerin reason someone might do this is for freeze protection, since glycerin freezes at a lower temperature than water
MSA Ultima
1. Open Path Sensient : Gases detected: hydrogen sulfide (H2S), sour gas (H2S/CH4), methane (CH4), ethylene (C2H4), ammonia (NH3), carbon dioxide (CO2), hydrogen chloride, (HCl), hydrogen fluoride (HF)
Gas-specific Harmonic Fingerprint detection eliminates false alarms and prevents plant shutdowns
Tuneable LASERs SCAN more narrow portion of spectrum where water interference from weather conditions are minimized
2. ULTIMA® X5000 Electrochemical (CO+H2O->CO2+(H+)+
gas detection for oxygen, toxic and combustible gases
3. Observer-i UGLD Ultrasonic Gas Level Dr range 28m
Compressor 301
omni-direction acoustic detector utilizing ultrasonic
detects leaks from pressurized gas systems by sensing the airborne ultrasound
produced by gas escaping from the leak.
4. Ultima XIR gas detectors microprocessor-based, infrared Ultima XIR gas detector for combustible gases and vapors(combustible gas, toxic gas or oxygen)
5. Ultima XE series gas detector two-wire connection is possible for certain:
• Toxic Gas models
• Oxygen models
• A three-wire connection is required for all:
• Combustible Gas models
• Toxic and Oxygen models with internal relays.
For CO, H2S, SO2, NO, NO2, NH3, Cl2, O2, Methane etc Just need Sensor replacement
Sensors : 1. Electrochemical type can detect
carbon monoxide, H2S, hydrogen, hydrogen chloride, ammonia, chlorine, chlorine dioxide, nitric oxide, nitrogen dioxide, ozone O3, SO2, and oxygen deficiency
2. Catalytic Bead:
Calibration of Control Valve
Example calculation:
A: Max travel from stem = 70mm B: Scale plate =
50mm
New open adjustment should be (50/70) × 100 =
71.48%
Equipments required
Data sheet, Hart communicator.
Procedure of Control Valve
Calibration:
Ask panel man to put the controller in manual
mode for control loop. Isolate the Valve from the process.
WARNING: The Isolation of control valve from the
process shall be done by field operator. Careful step shall be done
to ensure no upset to the operation.
Hook up HART Communicator and verify some
parameters by refer to data sheet such as Tag Number, OP and
etc.
Change from normal mode to setup mode.
Select auto find stop (wait some minute).
If full open is more than 100% select open
adjustment and put new number as per calculation.
Make an auto calibration (wait some minute).
Verify the linearity by increasing and decreasing
the travel (0%, 25%, 50%, 75%, 100%, 75%, 50%, 25% and 0% of
range).
After completion of the job ask panel operator to
put loops back in normal mode.
Fill the calibration form and file it for future
reference.
Eg Zero adjustments are done at the nozzleSpan adjustment is done by moving flapper assembly (follower assembly) along the summing beamAir supply to the positioner is 20 psi.To calibrate move the flapper assembly to midrange of direct side or about no.6Increase the input signal to 3 psiAdjust the nozzle in or out slowly to make the output gauge output 0 psiIncrease the input pressure to 15 psiIf the output saturates too soon (at the output gauge) before giving 15psi move the flapper assembly to smaller number in the summing beamIf the output saturates too late or above 15 psi move flapper assembly to larger number at the summing beamEvery time when you move the flapper assembly reset the nozzle to zero also.
Modbus Mapping
Pkg plc has AI/AO/DI/DO which we want to read or write from DCS. ADDRESS of the Data stored in PLC register is required, ADDRESS of DCS register whr we want to copy data to b displayed, Modbus Station no. Of PLC & Modbus Function Code for eg 03(DI/AI),05(DO),04 are req for communcation.
Like if two different language person staying at different places will have need Address, then common laguage to talk and exchange information
In Sismic vibration probe gap voltage is set to -10V, if we increase the gap voltage will increase if we decrease the gap voltage will decrease
Free Vib, Forced Vib, Damp Vibration Undamp vibration
Pump damages due to dry run & cavitation will overpressuring of drum to which pump is feeding
SOE SER(seq of event recorder)
Steam Turbine Manual Start: Operator Run Command ->controller-> 1.Governor valve 100% open 2. Spd setpt min control spd ->field operator to open Trip & Throttle valve gradually till reach min ctrl speed & PID ctrl starts controlling turbine, once spd stablized open Trip Throttle valve 100%
For Hazop study chairman should b from process
For SIL instrumentation eng who is safety certified
Ssls system sequencing safety logic system I001, I004
Seq logic startup logic
Maintain SIF lifecycle of ESD system every 2 yrs
Project commissioning cycle helps to reduce it
BMS plc shud b Hard wired with ESD, & serial link with DCS
Calibration
K‘ type thermocouple:
mV = °C × 0.0416; °C = mV ÷ 0.0416
Temperature mV O/P Current
0°C 0 mV 4ma
50°C 2.08 mV 8ma
100°C 4.16 mV 12ma
150°C 6.24 mV 16ma
200°C 8.32 mV 20ma
pH level
Rinse electrode with distil water wipe with tissue paper.
place electrode into the first buffer of pH 7.
Calibrate the meter to read the temperature
corrected value of the first buffer.
Rinse the electrode as before and place in the
second buffer. Wait for a stable reading. Calibrate the meter to
read the temperature corrected value of the second buffer.
Rinse the electrode as before. Place the
electrode in the sample and wait for a stable reading. Record the
pH and temperature of your sample.
Avoid rubbing or wiping electrode bulb
Calibration of Bubbler type DP LT.
LRV = (Off set × Product S.G) – LP.
= (100mm x 0.89) – 0 = 89 – 0
URV =(Full length × Product S.G) – pressure at low side = (2100mm x
0.89) – 0 = 1869 – 0 = 1869 mmH2O
Calibration of Displacer type LT. Fill water
Compensate specific gravity difference of
water & process liquid.
Process liquid specific gravity is 0.7
Water specific gravity is 1.0
To calibrate level transmitter 100% level. Water
level to be fill up in chamber = 0.7/1.0 x 100 % = 70 %.
Calibration of
flow Example Calculation:
Instrument calibrated range: 0 – 2500 mmH2O Process
calibrated range: 0 – 130 m3 /h.
Q = K×P
0% (0 mmH2O) = (0/2500) × 130 = 0 ×
130 = 0 m3/h. 50% (1250 mmH2O) = (1250/2500) × 130 = 0.5
× 130 = 65 m3/h 100% (2500 mmH2O) = (2500/2500) × 130
=1× 130 = 130 m3/h
Alignment: dial indicators and feeler gauges nowadays Lazer alignment kits
IEEE802 open protocal for all systems
WiMax network for RTU n MCTU
WiMAX (Worldwide Interoperability for Microwave Access) is a family of wireless broadband communication standards based on the IEEE 802.16 set of standards, which provide multiple physical layer (PHY) and Media Access Control (MAC) options
Orifice plate straight run 28D upstream 7D downstream
Pressure loops: If the load change is minimum, then a proportional controller is suitable. If a frequent load change is expected then a Proportional + Integral controller is preferred. Level : Normally a proportional controller is preferred. Flow: Proportional + Integral controller is preferred Temperature: Proportional + Integral + Derivative controller is preferred
How much is the radial vibration, if the signal measured on a DVM is 135.00mv AC? The DVM measures the AC voltage in RMS (root mean square value). AC peak to peak =135.00*2 root 2 =381.837mv
Eddy probe sensitivity=200mv/mill or 200mv/25.4 Microns Hence, the vibration in Micron =(381.837*25.4)/200 =48.49 Micron
Thermocouple range
Copper- Constantan 0-300 Deg C
J Iron – Constantan 0-600 Deg C
K Chromel-Alumel 0-1200 Deg C
Platinum-Rhodium-Platinum 0-2000 Deg C
Use
On Pump's bearings: Iron constantan ON Gas Turbine's combustion chambers: Chromel Alumel
Zero suppression: when a static head transmitter is installed below the zero liquid level, the transmitter gets a +ve error in the level measurement.
14.How to calibrate a leveltrol for an interface level measurement? Fill the leveltrol chamber 100% with the lower density liquid and adjust its zero for 4.00mA output. Drain the liquid and fill the leveltrol chamber 100% with the higher density liquid and adjust its span for 20.00 mA output. The transmitter on line measures the percentage of higher density liquid in the lower density liquid at a known height.
SIL requires proof test(function test of instrument) 61511
Before proof test
stock of spare components is kept on hand in the event proof-testing reveals a failed component.
For a process transmitter, this sort of test usually takes the form of a full-range calibration check.
For a controller alarm check
For Control Valve full stroking of the element, coupled with physical leakage tests
choose a time when operations personnel plan on shutting the process down anyway, then use that time as an opportunity to proof-test one or more critical component(s) necessary for the system to run
Partial Stroke Testing
proof-testing a redundant system harbors no danger if all components of the system are good, but risks process disruption if there happens to be an undetected fault
Ask panel man to put the controller in manual mode for control loop and to put it on MOS for ESD loop.
In Gas Liquification
Gases can be converted to liquids by compressing the gas at a suitable temperature.
critical temperature of a substance is the temperature at and above which vapor of the substance cannot be liquefied, no matter how much pressure is applied.
critical pressure of a substance is the pressure required to liquefy a gas at its critical temperature
Methods of Proof Testing
The most direct method of testing a critical system is to stimulate it to its range limits and observe its reaction. For a process transmitter, this sort of test usually takes the form of a full-range calibration check.
For a controller, proof testing would consist of driving all input signals through their respective ranges in all combinations to check for the appropriate output response(s).
For a final control element (such as a control valve), this requires full stroking of the element, coupled with physical leakage tests (or other assessments) to ensure the element is having the intended effect on the process.
An obvious challenge to proof testing is how to perform such comprehensive tests without disrupting the process in which it functions.
Proof-testing an out-of-service instrument is a simple matter, but proof-testing an instrument installed in a working system is something else entirely.
How can transmitters, controllers, and final control elements be manipulated through their entire operating ranges without actually disturbing (best case) or halting (worst case) the process?
Even if all tests may be performed at the required intervals during shut-down periods, the tests are not as realistic as they could be with the process operating at typical pressures and temperatures.
Proof-testing components during actual “run” conditions is the most realistic way to assess their readiness.
One way to proof-test critical instruments with minimal impact to the continued operation of a process is to perform the tests on only some components, not all.
For instance, it is a relatively simple matter to take a transmitter out of service in an operating process to check its response to stimuli: simply place the controller in manual mode and let a human operator control the process manually while an instrument technician tests the transmitter.
While this strategy admittedly is not comprehensive, at least proof-testing some of the instruments is better than proof-testing none of them.
Another method of proof-testing is to“test to shutdown:” choose a time when operations personnel plan on shutting the process down anyway, then use that time as an opportunity to proof-test one or more critical component(s) necessary for the system to run. This method enjoys the greatest degree of realism, while avoiding the inconvenience and expense of an unnecessary process interruption.
Yet another method to perform proof tests on critical instrumentation is to accelerate the speed of the testing stimuli so that the final control elements will not react fully enough to actually disrupt the process, but yet will adequately assess the responsiveness of all (or most) of the components in question.
The nuclear power industry sometimes uses this proof-test technique, by applying high speed pulse signals to safety shutdown sensors in order to test the proper operation of shutdown logic, without actually shutting the reactor down.
The test consists of injecting short-duration pulse signals at the sensor level, then monitoring the output of the shutdown logic to ensure consequent pulse signals are sent to the shutdown device(s).
Pressure Transmitter has Strain gauge which changes resistance when applied pressure
Unstable atoms are said to be radioactive. In order to reach stability, these atoms give off, or emit, the excess energy or mass. These emissions are called radiation. The kinds of radiation are electromagnetic (like light) and particulate (i.e., mass given off with the energy of motion). Gamma radiation and x rays are examples of electromagnetic radiation.
Gamma radiation originates in the nucleus while x rays come from the electronic part of the atom. Beta and alpha radiation are examples of particulate radiation.
Gamma radiation is easily detected by survey meters with a sodium iodide detector probe
Examples of some gamma emitters: iodine-131, cesium-137, cobalt-60, radium-226, and technetium-99m
Unit measurement and uses the "gray" (Gy) and "sievert" (Sv) for absorbed dose and equivalent dose, respectively. In the United States, radiation absorbed dose, dose equivalent, and exposure traditional units called rad, rem, or roentgen (R), respectively
Cv by definition is the number of gallons per minute (GPM) a valve will flow with a 1 psi pressure drop across the valve. For example a valve with aCv of 10 will flow 10 GPM with a 1 psi pressure drop. The formula used to select the valve Cv with the specified differential pressure is: Cv=GPM/((SQ RT(∆P)).
Factory available Cv's are limited and sometimes the valve Cv will be selected to deliver full flow with a ∆P that is less than specified and the valve could be considered oversized. Other times the valve Cv may be selected to deliver full flow with a ∆P that is great than specified and the valve could be considered undersized.
An oversized valve will cause hunting, poor control and premature actuator wear due to excessive cycling. An undersized valve may not be able to provide enough flow to meet design specification if the actual available ∆P is inadequate.
ISA 75.01.01
IEC 60534-2.1
Kv/Cv= 0.865
Questions
orifice plates are: 1. Concentric 2. Segmental 3. Eccentric
.P. transmitter can be calibrated using following steps:
1. Adjust zero of Transmitter.
2. Perform static pressure test: Give equal pressure on both sides of transmitter. Zero should not shift either side. If the zero shifts then carry out static alignment.
3. Perform vacuum test: Apply equal vacuum to both the sides. Zero should not shift.
4. Calibration procedure: Give 20 psi air supply to the transmitter and vent L.P. side to atmosphere. Connect output of the instrument to the standard test gauge. Adjust zero. Apply required pressure to the high pressure side and adjust the span. Adjust zero gain if necessary.
Mag Flowmeter: is limited to electrically conducting liquids. The magnetic meter is particularly suited to measurement of slurries and dirty fluids.
Pressure sensors Bourdon Tube
b. Diaphragm
c. Capsule
d. Bellows
e. Pressure springs
Types of bourdon tubes:
1. C type
2. Spiral
3. Helix
What is furnace draft control?
Balanced draft boilers are generally used negative furnace pressure. When both forced draft and induced draft are used together, at some point in the system the pressure will be same as that of atmosphere.
Therefore the furnace pressure must be negative to prevent hot gas leakage. Excessive vacuum in the furnace however produces heat losses through air infiltration.
The most desirable condition is that the one have a very slight negative pressure of the top of furnace.
What is zener diode? What is voltage regulator?
The breakdown region of a p-n diode can be made very sharp and almost vertical, diodes with almost vertical breakdown region are known a s zener diodes.
A zener diode operating in the breakdown region is equivalent to a battery. Because of this current through zener diode can change but the voltage remains constant. It is this constant voltage that has made the zener diode an important device in voltage regulation.
Voltage regulator: The output remains constant despite changes in the input voltage due to zener effect.
Cavitation can occur in liquid systems when high velocity reduces the static pressure inside the valve to below the pressure level at which the liquid stats to boil and produce vapor bubbles. These vapor bubbles collapse whenever the downstream pressure is higher than the vapor pressure causing high pressure waves. These implosions result in very high noise levels and can cause considerable damage to the valve body or trim parts under prolonged service.
ISA-75.01.01-2007 – Flow Equations for Sizing Control Valves
When sizing control valves, a general rule of thumb noted in many engineering publications is to size thevalve such that it operates between 20 to 80% open at maximum required flow rate. It is also recommended to have the minimum opening no less than 20% to provide a safety margin at the minimum flow rate required.
A valve Cv can be described as the number of gallons per minute (GPM) at 60oF (15.5oC) that will pass through a valve with an associated pressure drop of 1 psi.
If the Cv is too small for the process, the valve itself or the trim inside the valve will be undersized resulting in the system being “starved” of the process fluid. Undersized valves exhibit a higher pressure drop across the valve to maintain adequate flow and exhibit limited flow capacity. Furthermore, since the restriction in the valve can cause a build-up of upstream pressure, higher back pressures created before the valve can lead to damage in upstream pumps or other upstream equipment.
If the Cv calculated is too high for the system requirements, the result is a larger oversized control valve is usually selected. In addition to the more obvious issues with an oversized valve such as a larger cost, weight and size, when in throttling service, significant control instability can occur. Usually the closure element, such as the valve plug or disk, is positioned just off the valve seat which leads to higher pressure drops across the valve and higher fluid velocities which can cause cavitation, flashing or erosion of the valve trim elements.
Vms s04c02A02 slot04 channel2 Alarm level2
Alarm level 1 alert 2 danger
Modbus
LRC(Longitudinal redundancy check) field is one byte, containing an 8–bit binary value. The LRC value is
calculated by the transmitting device, which appends the LRC to the message.
The receiving device calculates an LRC during receipt of the message, and
compares the calculated value to the actual value it received in the LRC field.
If the two values are not equal, an error results.
BN3500 -ve voltage coz of NPN transistor -7.5V/mm
-10V adjust in TK3 start motor .
Set voltage to AC for Vibration checking
If error is more than 2.5% error cant use on thurst
If more than 5% error cant b used in Velometer
Redundancy
power through the diode redundancy module:
Here, level transmitter 23a is a guided-wave radar (GWR), level transmitter 23b is a tape-and float, and level transmitter 23c is a differential pressure sensor.
For instance, if the process liquid density happened to suddenly change, it would affect the measurement accuracy of the differential pressure transmitter (LT-23c), but not the radar transmitter nor the tape-and-float transmitter.
If the process vapor density were to suddenly change, it might affect the radar transmitter (since vapor density generally affects dielectric constant, and dielectric constant affects the propagation velocity of electromagnetic waves, which in turn will affect the time taken for the radar pulse to strike the liquid surface and return), but this will not affect the float transmitter’s accuracy nor will it affect the differential pressure transmitter’s accuracy.
Surface turbulence of the liquid inside the vessel may severely affect the float transmitter’s ability to accurately sense liquid level, but it will have little effect on the differential pressure transmitter’sreading nor the radar transmitter’s measurement (assuming the radar transmitter is shrouded in a stilling well.
Anti Surge Controller Working Principle
Anti Surge Controller
The surge phenomenon in the centrifugal compressor can be understood as a complete breakdown and reversal of the flow through the compressor.
Every centrifugal compressor has its own operating characteristic map. This map will show us the surge line limit and the operating limit.
See below example of the compressor operating map. The surge will happen if the compressor operates on the left side of the surge line.
The surge can’t be eliminated but it can be avoided or prevented. This surge phenomenon can be prevented by recycling or blow off a portion of the discharge flow to keep the compressor away from its surge limit. This prevention in particular is done by the anti surge controller.
The anti surge controller must be able to accurately determine how close the compressor is surging so it can maintain an adequate but not excessive recycle flow rate.
A compressor’s surge limit is not a fix value. It is a very complex function that depends on gas composition, suction temperature and pressure, rotational speed and guide vane angle.
Surge protection is more complicated by the speed at which the surge develops. It can take only a fraction of a second for a compressor to move from a relatively healthy operating point to one in which the surge is inevitable.
Therefore it is a logic reason to have a very fast final control element which we called an anti surge control valves.
In general application, the anti surge controller received a signal from flow transmitter, pressure transmitter, and temperature transmitter from downstream and upstream of the compressor. The anti surge controller is then analyzes the entire received signal.
The surge margin (control line) usually determine as a 10% margin from the known compressor surge line (the surge line can be obtained from actual test or empirical data).
Typically the PI (Proportional Integral)control algorithm will active and start to modulate the anti surge control valve if the compressor operates between the control line and the surge line.
The set point of the PI controller is a flow rate that lies on the control line. Normally, a polynomial equation is used to approach the control line and determine the PI controller set point with the discharge and inlet pressure of the compressor as the variable.
Then, the anti surge controller (using PI controller algorithm) will open and close the anti surge control valve as necessary to bring the compressor operates on the control line.
The Anti Surge Control Valves
As briefly explained above, to avoid the surge phenomenon, there are an anti surge control system that analyze the compressor operating point and modulate the anti surge control valve as necessary.
Before designing the anti surge control valve, the compressor manufacturer usually has some anti surge system study with some set of process data required to design the anti surge control valve.
The process data it self has several cases for several surge possibility. The study also conclude the required anti surge control valve opening time during normal operation and during shutdown sequence operation.
In practice, there is no difference between anti surge control valve and ‘general’ control valves. The main difference is that the anti surge control valve has a certain required fast opening time to avoid the surge.
This time constraint will make the anti surge control valve need some additional accessories such as volume booster and three way pilot operated valve.
The valve accessories that will be used may differ from each anti surge control valve manufacturer; this is not a problem as long as the required opening time is achieved. But in general speaking, the anti surge control valve will has a general arrangement as below.
Operating Principle
The anti surge controller is started up, the solenoid valve is energized and all pilot operated valve is actuated. valve will fast open and fast close as necessary with the help of volume booster.
valve will fast open and fast close as necessary with the help of volume booster. The volume booster is used to increase the stroking speed by bypassing the instrument air supply or in other words, it amplify the pneumatic signal output of the I/P Positioner.
While there are an emergency cases (need to shutdown etc..), the anti surge controller will simply de-energized the solenoid valve and all pilot operated valve will un-actuated. The pressure of top side piston actuator is vented by the 3-way pilot operated valve no. 7 and 2-way pilot operated valve no. 6.
The low side of piston actuator is pressurized by the regulated instrument air supply (or from volume bottle if emergency). This top side vented and low side pressurized will make the valve in the open position in fast manner. The anti surge control valve will open very fast in less than one second in this case.
Motor signals to/from MCC ML- local start local moto status stop, motor status run, ctrl in auto, VSD ready to start
Alarms MA common alarm, motor tripped, earth fault, VSD in remote
Motor spd SI
VSD SY
Motor current MI
Motor trip MZS
Cascade ctrl Loop : 2 or more Transmitter with 2 controller i.e. LC OR PC OR FC first primary ctrller. Output of primary ctrller becomes the Setpoint of second controller
AGT if sensor validity expired(2 yrs over), to b replaced and recalibrate
Nuclear tr Cesium 137 0.66MeV gamma radiation emitter 30.2 yr half life, Cobalt 60 for 1.2-1.3 MeV 5.3 yrs half life
Absolute pressure transmitters have the low side sealed with a full vacuum. Gauge and absolute pressure transmitters (PT) have a single impulse line
In GWR for Boiler steam application, steam affects actual level, mfg uses reference probe to check shift in reference probe so calculating actual level
Zeroing Tr Isolate LP side then Open Equalize. Pressure on both side is equal now. Zero trim then Close Equalize then Open LP side
GE ultrasonic
Locate the transducers so that there are at least 20 pipe diameters of straight, undisturbed flow upstream and
10 pipe diameters of straight, undisturbed flow downstream from the measurement point To ensure undisturbed
flow, avoid sources of turbulence in the fluid such as valves, flanges, expansions, elbows and dips or low spots in
which condensed liquid may collect.
Because condensate or sediment at the bottom of the pipe may cause attenuation of the ultrasonic signal, locate the
transducers on the side of a horizontal pipe, when possible. If limited pipe access necessitates top-mounted
transducers and the sound beam path includes a reflection, shift the transducers to at least 10° off top dead center.
This will minimize the influence of any sediment on the reflected ultrasonic signals
Gas detector calib
Zero gas : perform a zero calibration of an oxygen-, or carbon dioxide analyser with pure nitrogen. Because nitrogen does not hold either oxygen or carbon dioxide, a zero point can be confirmed this way.
Saab TankRadar Pro transmitter sends a microwave signal with a con-
tinuously varying frequency towards the liquid surface. When the reflected
signal returns to the antenna, it is mixed with the outgoing signal.
Saab TankRadar Pro uses Fast Fourier Transformation (FFT), to obtain a frequency spec-
trum of all echoes in the tank. From this frequency spectrum the surface
level is extracted
Fourier Transform is a tool that breaks a waveform (a function or signal i.e. square wave) into an alternate representation, characterized by sine and cosines
Fourier transform (FT) decomposes a function of time (a signal) into its constituent frequencies
Controller
Proportional only
m=Kp(Pv-Sp)+b direct acting, =Kp(Sp-Pv)+b
Kp=prop. Gain, m=output b bias
Proportional band= %of error(Pv-Sp) change necessary to make output change m=100%
P.B.=1/Kp
Gain=20, PB=5%, PB=20% Gain =5
Iso 17025 instrument calibration
Tristation 1131 LT Less than, GT greater than, EQ Equal
GE Greater than or equal same LE
PT pulsed time, ET elapsed Time
RXM Remote Extender Module
Mother board id 136C11-S3-BP-2-1
Seg no. 3, BP no. 2-1, Slot no. A
So FBM id C1132A
Emerson Electro Magnetic Flow Transmeter
3 wire for magnet coil, 3 wires for sensors on the flowtube
220V supply on transmitter 2 wire
Setup-totalizer- totalizer A,B,C start all to see total flow on display
Velometer check by tk3
Process
Atmospheric Residue De-sulfurization (ARDS) unit for upgrading high-sulfur heavy fuel oil into low-sulfur fuel oil
Isomerization is the process by which one isomer is transformed into another one.
Isomerization unit converts linear molecules to higher-octane branched molecules for blending into gasoline or feed to alkylation units
COKER UNIT: converts the residual oil from the vacuum distillation column into low molecular weight hydrocarbon gases, naphtha, light and heavy gas oils, and petroleum coke.
Delayed coker Unit: is a type of coker whose process consists of heating a residual oil feed to its thermal cracking temperature in a furnace with multiple parallel passes. This cracks the heavy, long chain hydrocarbon molecules of the residual oil into coker gas oil and petroleum coke
Laminar flow turbulant flow transitional flow
PSSR
General Safety
Have ALL appropriate personnel (Operations, Maintenance, Technical, and Supervision) received adequate and appropriate training on the equipment and operating procedures?
Yes No N/A
Has adequate and appropriate PPE (Personal Protective Equipment) been specified in the Work Procedures and/or Standard Operating Procedures.
Yes No N/A
Has the PPE been provided?
Yes No N/A
Have the PPE users been trained in the use of the PPE?
Yes No N/A
Is the training documented?
Yes No N/A
Have measures been taken to adequately guard all dangerous parts of this equipment?
Yes No N/A
Has sufficient provision been made for the electrical and/or mechanical isolation of the equipment?
Yes No N/A
Are points of isolation clearly marked/labeled and readily accessible?
Yes No N/A
Have bump/trip hazards been properly identified and adequately marked?
Yes No N/A
Have all sharp edges been removed?
Yes No N/A
Has proper guarding, handrails/barriers, been provided to prevent falls?
Yes No N/A
Have all hot/cold surfaces been adequately guarded to prevent burns?
Yes No N/A
Are all cold surfaces adequately insulated to prevent condensation drips (slip hazards)?
Yes No N/A
Are Safety Showers and Eye Wash facilities provided and adequately marked?
Yes No N/A
Are the Safety Showers and Eye Wash facilities routinely inspected?
Yes No N/A
Do the Safety Showers and Eye Wash facilities locations comply with Corporate guidelines?
Yes No N/A
Are the Safety Showers and Eye Wash facilities readily visible and accessible?
Yes No N/A
Has sufficient lighting been provided so that operation, servicing, maintenance, and repair of the facilities can be carried out safely?
Yes No N/A
Are notices, dials, screens, etc. for providing operational instructions, safety warnings, and emergency information provided, if required, and positioned so that they are clearly visible and easily read?
Yes No N/A
Have all overhead fixtures, for example, pipe-hangers, pipe sleeves, pipe sleeve covers, valve handles, floor opening covers, etc., which could fall or be dislodged, been properly secured?
Yes No N/A
Are all of the applicable Work Permit Procedures (Confined Space Entry, Lock Out/Tag Out, Hot Work, High Work, etc.) in place?
Yes No N/A
Have the Operating, Maintenance, and Supervisory personnel been properly trained on the Work Permit Procedures?
Yes No N/A
Has the fire protection systems been inspected by the insurance company?
YesNoN/A
Has acceptance testing been completed and documented?
YesNoN/A
Is there an agreed on test and inspection program for the fire protection systems (including alarm systems)?
YesNoN/A
PSSR
Machinery/Equipment Safety
Has the machinery/equipment been installed so that it will be stable and secure during operation?
YesNoN/A
Has all access to dangerous moving parts, or danger zones created by the equipment, been prevented by the provision of the correct guards, interlocks (both safety & non-safety) and/or barriers?
YesNoN/A
Have the correct safety measures been taken to prevent any risk from hot/cold surfaces, ejection of material, failure of parts and their ejection, overheating/fire?
YesNoN/A
Has safe access been provided to the equipment that requires operator and calibration and maintenance personnel access for normal operations, adjustments, service, calibration, maintenance, or repair?
YesNoN/A
Have slip, trip, trap, crush, entanglement, fall, bump, and cut hazards been minimized?
YesNoN/A
Is the equipment provided with the properly identified START/STOP and EMERGENCY controls that are positioned for safe operation without hesitation, or loss of time, and without ambiguity?
YesNoN/A
Is the equipment provided with a clearly identified means to securely isolate it from ALL energy sources?
YesNoN/A
D1/2 K1/2 flow cal density calc. For coriolis mass flow meter
Tubes inside coriolis r precision spring element and H2 chambers, so its imp to know their spring char. And precise dimension of tubes
f=1/2Lsqrt(Ft/u) f is resonant freq of string hz
L=string length meter, Ft spring tension N, u= unit mass of string(kg/meter)
Vortex v=df/0.17 v velocity f signal freq d width of bluff body
Mcwd mechanical completion walk down
CfP vlean fuel project
RmP Refinery mordernization project
Fup further upgrading project
In tristation search valve tag, click on valve tag valve block output side, set 0,1 to fully open or close valve forcefully. Pst 85%
Search positioner tag i.e. XY2749_F to check segment details
Test instrument used should be four
times more accurate than the instrument being checked.
Maintenance actual Level was suspected drained both valve checked zero
Ph Level showing less calibrated it
Ohms = ºC×0.385+100
Dp transmitter has DP cell consiting of diaphragm and works on principle of capacitance. To calibrate dp tr keep hp and lp side open and check 0 pressure. If shifted do 0 trim. Load LRV and URV values if used as level tr. Apply pressure on hp side leave lp side open. Check corresponding mA and pressure in calibrator and master gauge.
Ultrasonic flowmeter ; GE GF868 with panel
Turndown Ratio=ratio of the maximum capacity to minimum capacity
Yokogawa centum vp
ST16 sequence table programming
LC64 Logic Chart prog
Analog prog
Pio block for analog ip i.e %%FT....
PVI Block for process variable indication on dcs
IEC 61508 mainly focuses on electrical/electronic/programmable safety-related systems. However it also provides a framework for safety-related systems based on other technologies including mechanical systems. The IEC 61511 is added by the IEC specifically for designers, integrators and users of safety instrumented systems and covers the other parts of the safety loop (sensors and final elements) in more detail
Field inst-> field termination assembly -> IO assembly-> Controller->Firewall-> NW Switch-
HIST host interoperability System test for FF devices
To change description of instrument in FGS/Safety Builder Open Application Editor change name then click file-> Publish
In Popup window tick Force then click publish
Kg/hr to Nm3/hr
PV=nRT in which n=m/M
n= mole number
m= mass or mass flow (kg/h)
V= volume or volumetric flow (m3/hr)
M= molecular weight of the gas for example Molecular weight of nitrogen (N2) =28 kg/kgmole
In Normal conditions according to the latest SI definition P=100 kpa and T=0 C or 273.15 K
R = gas constant =8.314 pa.m3/mol.K
So, PV=(m/M)*R*T or m(kg/h) = (P*V*M)/(R*T)
at Normal conditions then we have:
m(kg/h) = M* 100* V (Nm3/h) / (8.314*273.15) or
m(kg/h) = 0.044 M* V (Nm3/h)
example: 20 Nm3/h of Nitrogen is equal to:
m = 0.044* 28 (molecular weight) * 20 (Nm3/h)
m = 7 kg/h.r
Honeywell uses Fanout Block which gives 2 or more output
Gain and Bias is set in Fanout block it calculates ratio automatically eq y=mx+c m gain C bias
To calc gain for eg 0-6.5% & 6.5-100%
100/6.5 = 15.385 gain for first valve bias 0
For sec valve
Remaining 100-6.5=93.5
100/93.5=1.0695 gain for second output
Bias for second valve 100-1.0695×100 =-6.95 for second valve
To download DD files open Configuration Studio ->Control Strategy->Control Builder-> Monitor->Import DD files-(files shud b uploaded)? Will b shown Unassigned Device
If already latest updated DD files r installed system will detect the device automatically.
Devices can b assigned addresses at one time. Once device is healthy it will show in green color like others
FIM Field Bus Module 2 FIM -> Each FIM has 4 Segment-> Field Instrument
To access FF device connect Hart Communicator 475 in FF mode to Segment Protector all connected Devices will b shown access required device Change Tagname, Address range etc
Check FIM module on monitoring device->Segment(i.e. FIM04S03)-> 4 devices
? Mark will b show if device is connected Double click, click match with existing
Modify details of Unassigned device in top table as shown in Project device in Below Table
Tab Unassigned Devices-
Change address of new device if req
Right click on device in Project->Replace device-> Validate
Later device will b displayed in Project tree check in same FIM module double click on Device AI set Range and Unit, Tune-indirect for DP FT
After that select the Inst Tag Click on Down Arrow(Load) to download to control Builder
If at close condition close limit sw wire removed Uncommand Inbetween alarm will appear, after connecting wire alarm will go but u have to disable it.
HP valve demand 50-100%
Dpi 880 multifunxtion calibrator for simulating Hz
500 Hz will yield 1000 rpm on woodward
Login service, wg1112
Another Woodward 505 Turbine ctrl pass word 1111
P temp sound spd actual velocity
24ºC 3 barg 442 421 1.29
Calculated in pc aga10 software by entering Gas composition report by lab
SRU: Sulfur Recovery Unit 3H2S+O2-> 2H2S+SO2
In Reactor H2S reacts with compressed air
Adsorption: the atoms, ions, or molecules from a substance adhere to a surface of the adsorbent.Unlike absorption its exothermic
Chemical adsorption or chemisorption is when the gas molecules are bound to the surface by a chemical bond.
Physical adsorption also known as physisorption occurs when the gas molecules are bound by the sum of attractive or repulsive forces between molecules and electrostatic forces.
Flushing of Impulse lines
Calibration of PT TT LT FT Control Valve
TT shud b same as TG
PT shud b same as PG
FT shud b same as Mechanical FT
Corrective maintenance Breakdown handling
Calibration of AGT with 0 & Span Gas
Vanguard CCC PLC
Check quaterly free movement of fans, check if any wear, clean them
Replace Fan Tray assembly every 5 years
J White Red Iron Constantan
K Yellow Red Chromium Alumel
Cleaning redundancy check,
Checking panel light fan cables Power
Train view for hmi
Modbus RTU
2 tank master PC for redundancy. One primary active PC, and the other silent in backup mode (hot standby)
GWR, TT, PT, Local Indicator (Via Tank Bus) -> Hub 2140-> Field Communication Unit-> DCS
Tank Hub is Intrinsic safe and provides power to all 3 transmitters.
Parabolic Antena GwR microwave transmitter/receiver and a parabolic antenna
level measuring system is based on Frequency
Modulated Continuous Wave radar. Signal transmission and reception
is achieved by means of a waveguide projecting into the tank and a
parabolic reflector type antenna.
The radar gauge transmits microwaves towards the
surface of the liquid. The microwave signal has a continuously
varying frequency, around 10 GHz for the model 5900S. When the
signal has travelled down to the liquid surface and back to the
antenna, it is mixed with the signal that is being transmitted at
that moment. The transmitted radar signal has a linear frequency
variation.
The reflection from the liquid surface has a
slightly different frequency compared with the signal transmitted
from the antenna when the reflection is received. The difference in
frequency is measured, and it is directly proportional to the
distance to the liquid surface which corresponds to the tank liquid
level
FMS Fieldbus Message Specification
FMS allows users to send receive data using standard set of msg formats
Microcontroller: camera washing machine oven
Microprocessor has external RAM ROM(Hard disk)etc
Microcontroller has internal RAM ROM
32/64 bit OS means it can handle 32/64 bits data simultaneously.
Chip in Mobile is combination of Microprocessor & microcontroller called System On Chip (SOC)
Compiler converts text program language into machine langugage 0^,1
Browsers r programmed using C, C++
Ku is ultimate gain or value of Kp at which uniform oscillations appear, Tu Time between 2 oscillation
VXT, VYT
Alarm 4mils(101.6 um), Trip 5 mils(127 um) 0-250 um range
Axial Vibration VZT
Alarm 10 mils(254um) Trip 15 mils(381um)
-1 to 1 mm range
Bearing Temp Alarm 127ºC Trip 137ºC
Bearing Oil Pressure Alarm <7.3 psig(0.5barg)
Trip<4.4 psig(0.3 barg)
Trip Throttle Valve Control Oil Pressure
Alarm <19.3 barg
trip< 4.9barg
Tell Operator to put instrument into Manual for DCS & MOS for IPS system
Confirm if it is in Manual
Connect Hart Communicator-> Online->list of all FF device will apear choose ur instrument->Connect->Advanced Config-> for simulation and entering LRV URV values.-> Click on Ff logo Change Mode from Auto to Out Of Service(OOS)-> Send Config values to Instrument like new LRV URV, ->Ask Operator if reading is correct now if not Zero Check & Flush-> Change the mode to Auto from OOS-> Confirm with operator current reading-> Close the work Permit-> get it signed by issuer
C[2]=0?0:(C[1]) means if C[2] is 0, output C[1] else 0
If any of the output of Fanblock is in Manual input to FC will b set automatically to last value for Bumpless Transfer
In Power plant when we burn coal it may contain upto 4% Sulfur and forms SO2 gas which if exhausted to atmosphere may react with Water in clouds and form H2SO4 Acidic Rain which is dangerous for env.
Before Chimney we use Nitrogen Oxide Reducer equipment & ESP(Electro static Presipitator) & then FGD unit.
SO2 is nutralized using Lime or Lime Stone which r basic in nature. In Wet FGD Lime Solution is sprayed over SO2 gas(Pump suck lime solution from bottom then spray from middle portion) coming into FGD, it forms CaSO3 Compressed Air is inserted into solution to form CaSO4(Gypsum). Agitator(fans) r used at bottom for proper mixing then Gypsum slurry is taken out and sold.
AE Analyzer element
AC Soft controller
AFA Horn Fire Alarm
AFE Smoke detector optical
AFHS SW Manual Call pt
AFL Beacon
AFT detector Flame/IR/Heat
0 DI R
1 DO W
5 DO/AO W(Start stop from DCS) Force Single, Coil Pulse time 5sec
3 AI/DI Read Holding Register
Substation to DCS 10.65.54.197/198 Slave address 1, 5 digit modbus register no.
Pump/FD Fan - Read Only(DI- Motor Runing, Stopped,Common trouble alarm,Motor Tripped,Motor Earth Fault,Motor RCU in Auto Position, AI-Motor Current L1,L2,L3, DO Write Only-DCS Start,Dcs Stop
S
K
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