Instrumentation

Overview

D G Sangawar
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 What is Instrumentation
◼ Instrumentation is art and science of measurement
and control.
◼ It makes available the necessary process information
[ indication / trending / status ] at a predetermined
destination in a predetermined form.
◼ It also controls the parameter within a specified limits
/ at specified value.
◼ Instrumentation provides a means to the plant
operator to operate the plant safely, continuously,
and consistently with optimum productivity.
◼ It minimizes the human element in the plant
operation.
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 What is Instrumentation
Instrumentation provides handle for monitoring:
◼ Health of the process,

◼ Health and performance of Equipments

◼ Draws attention to the exceptional conditions

In fact instrumentation acts as eyes and ears for

engineers of all the disciplines in general and
chemical engineers in particular.

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 Parameters Measured
The parameters encountered in a process
industry are:
◼ Pressure
◼ Level
◼ Flow
◼ Temperature
◼ Quality of intermediate and finished products
- Physical
- Chemical
◼ Speed/vibration/displacements for rotary machines

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 Parameters Measured
◼ Every possible law of physics and chemistry
has been exploited to achieve accurate
measurement of the above parameters
◼ All the field instruments/devices adhere to
Ingress Protection (IPnn) & Area
Classification norms

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 Evolution of Instrument Engg Field
Mechanical Engg Industrial Engg
Production Engg
Chemical Engg
Electronics Engg Elect & Telecommunication
Communication
Computers/IT
Electrical Engg
Mechanical Engg
Instrumentation
Electronics Engg
Computer/IT Engg

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Evolution of Instrument Engg Field
“ Instrumentation and Automation” was
recognized as a separate branch of
engineering in between the two world
wars as the concept of mass production
came into vogue due to war efforts.

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 Changing Technologies
1. Indication local
2. Indication remote –
Pneumatic
Analog electronics
Digital electronics
Microprocessors (Configurable)
DCS & PLC (Programmable)
3. Recording
Paper-pen
Thermal charts
Trending
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 Changing Technologies
4. Exception reporting/Alarms
Local
Remote audiovisual – annuciators
Alarm logs

5. Control
Local instruments
Local panels
Plant wise control room
Centralized control room for number of plants

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 Changing Technologies
Transmission media
◼ Pneumatic air pressure 0.2 to 1.0 kg/cm2 through
tubes
◼ Electrical 4 to 20 ma through copper conductor
◼ Digigtal signals through twisted / shielded pairs
◼ Light signals through Fiber optic cables
◼ Air waves – wireless

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 Changing Technologies
Connectivity
One to one
Multiplexing
Multidrop – bus topology
Networks
Logics
Switches
Relay
PLC
ESD

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 Changing Technologies
◼ Hardware Base
◼ Configuration Base
◼ Software Base

CPUs have shifted approach from individual instruments

to systems.
Networking capabilities have shifted approach towards
large integrated systems.

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 Networks
CRITERIA STANDARD
RS 232 RS 422 RS 485 TCP/IP
TWISTED TWISTED TWISTED
MEDIA CO-AXIAL / F.O
PAIR PAIR PAIR
THEORITICALLY
MAX DIST. 50 FT 5000 FT 5000 FT
NO LIMIT
NO. OF TWO(POINT MUTI DROP MUTI DROP THEORITICALLY
DEVICES TO POINT) 256 NODES 256 NODES NO LIMIT
MAX SPEED 19.2 KBPS 906KBPS 10MBPS 10 TO 100 MBPS
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 System Components
◼ Power supply ®
◼ Central Processing Unit ®
◼ Memory
◼ Input Modules
◼ Output Modules
◼ Communication Modules ®
◼ Bus/network ®
◼ Programming terminal
◼ Human Machine Interface
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 System Features
Redundancy
Fall back – primary/main – secondary/standby
Sharing – 50/50 – 100/0
◼ Cold standby: If primary system fails, the

changeover to secondary is manual.

Interruption in operation.
Moderate cost. Almost obsolete.

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 System Features
Redundancy (contd.)
◼ Hot standby: Both primary and secondary are
running continuously & processing I/Os in
parallel. Only the primary has control on
outputs. If primary fails, secondary
immediately takes charge bump-lessly. Widely
used. Moderate cost.

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 System Features
◼ Easy troubleshooting
◼ Easy expandability
◼ High availability – redundancy
◼ High reliability – fail safe design
◼ Self-diagnostic capability
◼ Alarm handling & Sequence Of Events (SOE)
◼ System security from unauthorised changes.
◼ Hierarchical Presentation like Complex, Plant, Unit, Tag.
◼ Historisation & data logging for ease of maintenance.
Each system has the capability to communicate with another
system in general and DCS in particular

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 Objectives of Control Systems
◼ Operating personnel and Plant safety.
◼ Simplified and Efficient Plant operation.
◼ Automated stepwise start – loading – unloading – S/D
◼ High Plant availability.
◼ Easy and guided maintenance/diagnostics.
◼ User friendliness for Engineering, Operation and
Monitoring functions.
◼ Fast and accurate analysis.

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 Instrumentation Systems
◼ DCS
◼ PLC
◼ ESD
◼ F&G
◼ MCMS
◼ ATG
◼ CTM
◼ BMS
◼ AMS – lab / online analyzers
◼ CCTV & Security Automation

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 Distributed Control System
• The distribution can be
- Functional (most commonly used)
- Functional + Physical
• Operator window for interface with plant
• Integrated in to a single site wide system.
• Single window to operations makes plant more
manageable by reducing operator training by
supporting information from all the other control
systems.

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 Distributed Control System
▪ Used for monitoring & control of regulatory level,
advance control & Optimisation.
◼ Self documenting features like loop diagrams.
◼ Redundancy is provided in all control processors &
communications.
◼ Two to three operator console monitors are provided
per operator.
◼ Provides detail History of plant with Alarm summary,
Trend displays, detail displays etc.

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 PLC System
◼ PLCs are used for control & monitoring of packaged
equipment like compressors, fired heaters, water
treatment plants, back wash filters, etc.
◼ Stand alone control system & also having considerable
facilities for centralised configuration & data monitoring.
◼ Systems are redundant in processors, power supplies &
communications.

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 PLC System
◼ Each PLC system has serial interface with DCS for
centralised data & status monitoring by control room
operators.
◼ Both CPUs run the application programmes. Primary
CPU only controls the I/O & secondary CPU monitors
the I/O.
◼ Windows based HMI software packages can be used for
stand alone control of the PLC.

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 Logics
Voting at I/O level to improve safety/reliability
1oo1 – Low on safety/low on reliability
1oo2 - High on safety/low on reliability
2oo2 - High on Safety/high on reliability
2oo3 - Highest on Safety/highest on
reliability

2oo3 - - - 2oo2 - - - 1oo1

2oo3 - - - 1oo2

Fail safe design takes the process to safe condition on

failure of component/instrument/system

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 Emergency Shutdown System
◼ Monitors & controls startup & shutdown of entire plant.
◼ These systems are fault tolerant, Triple Modular
Redundant (TMR) with a high availability, self test & self
diagnostic facilities. Three CPUs solve logic parallely
and output is based on 2oo3 voting.
◼ Sequence of events recording facility.
◼ All ESD systems are connected to plant wide DCS.
◼ Fail safe philosophy is adopted.
◼ 2oo3 logic is utilised in critical areas.

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 Emergency Shutdown System

◼ ESD devices are separate from process instruments &

will be used only for the the purpose of shutdown.
◼ Start ups are automated as far as possible.
◼ Soft/Key lock bypass switches with status indication.
◼ All bypasses are serially interfaced with DCS for
monitoring.

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 Scan Time comparison for
DCS, ESD & PLC

◼ DCS 500 msecs

◼ PLC 20 TO 50 msecs
◼ ESD 1 msec

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 Hazards in Refinery
◼ Fire
◼ Leakage of Toxic Gases
◼ Leakage of Combustible Gases
◼ Rise in Temperature

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 Atmospheric Air (20.8 % Oxygen)

HC
Inside
the Flange
Plant
equip-
ment
and Electrical
piping Equipment

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 Release of HC Atmospheric Air (20.8 % Oxygen)

HC
Inside
the Flange
Plant
equip-
ment
and Electrical
piping Equipment

Release can cause release of fuel

OR
Expose personnel to Toxic Vapor / Gas
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 Release of HC Atmospheric Air (20.8 % Oxygen)

HC
Inside Spark from
the Flange Lightening
Plant Hot Surface
equip- Spark Electrical Spark
ment
and Electrical
piping Equipment
HC

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 Fire and Gas Monitoring System

◼ Detection of LEL , Toxic gas , Fire, Smoke,

Heat.
◼ Also displays wind speed & Direction.
◼ Universal viewing at all strategic points like Fire
stations, Security offices, Plant Control Rooms,
Site in-charge’s offices etc.

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 F&G Indicators
◼ Stand alone indicator
◼ Addressable LCD display
◼ Dedicated F&G Work Station
◼ Integrated DCS F&G Work Station

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 F&G Devices
Type Of Detector Service Location Alarm Setting

Flame Detector Detects flames Near Pumps, in the Gantries

Senses the continuous rise in
Linear Heat Detector Tank Top 70° C
temperature
Detects the rise in temperature at
Rate of Rise Heat Detector Battery Rooms
a predefined rate
Manual Call Point Can be used to attract attention Universal
In the buildings, ceiling and
Optical Smoke Detector Used to detect thick smoke
floor void
In the buildings, ceiling and
Ionization Smoke Detector Senses the invisible smoke
floor void
Plant process area, HVAC 20 / 30 % LEL(LOW)
Combustible Gas Detector Sense release of Hydro Carbon
Intake 40 / 60 % LEL (HI)
Battery Rooms, Compressor 20 / 25 % LEL (LOW)
Hydrogen Gas Detector Senses Hydrogen Gas leakage
Houses 40 % LEL (HI)
Sense release of Hydro Carbon Perimeter monitoring, Gantries, 1 / 1.5 % LELm (LOW)
Open path LEL Detector
over an open path LPG pumps 3 % LELm
H2s : 5 / 10 ppm (LOW)
10 / 20 ppm (HI)
Plant process area, HVAC SO2 : 5 ppm (LOW)
Toxic Gas Detector Senses the Toxic Gas leakages
Intake 10 ppm (HI)
Cl2 : 1 ppm (LOW)
3 ppm (HI)

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 Machine Condition Monitoring
System
The system is used for monitoring health and protection
of the rotary machines.
The following machine parameters are normally
measured:
◼ the vibration levels of the casing and / or the shaft

◼ the shaft RPM

◼ axial shift of the shaft

◼ temperature of the thrust bearing pads / bearing

housing
◼ Measure "Rider band" wear and tear (Rod drop
measurement) in case of Reciprocating Compressor.
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 Machine Monitoring System
Following sensors are used in general to take vibration
and temperature data of the rotary machines:
◼ Displacement probes

◼ Velomitors

◼ Accelerometers

◼ RTDs

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 ATG
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 )
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 ATG Objective
Raw parameter measurements in tank
• Level
• Temperature – multi spot / single spot
• Hydrostatic Pressure
• Static Pressure
• Water bottom

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 ATG Objective
Calculated Tank Inventory
• Gross volume @ amb.
• Net Volume @ amb.
• Net standard volume @ 15 deg C.
• Mass
• Ullage
The above values are either calculated in TIS/DCS

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 Types of Tank gauging

• Servo

• Hydrostatic

• Radar

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 Custody Transfer Metering System

◼ Used For Custody transfer of raw materials & finished

products
◼ N+1 meter run configuration for providing stand by &
master meter.
◼ Individual meter runs are corrected for pressure , temp.
& density in the flow computers.
◼ Provers are provided for calibration of flow meters.
◼ Accuracy of the system should be 0.25% or better and
repeatability should be 0.02% or better.
◼ Integrated with DCS. 41
 Burner Management System
▪ BMS is required for controlling the Fired Heaters light
up sequence and also to monitor the safe operation of
the furnaces.
▪ Relays/PLCs are used for the implementation of the
BMS logic.
▪ A local panel is provided near fuel skid for operator
interface during heater start up operation.
▪ For the detection of individual flames, ionisation rods
are provided for the pilot flame & IR scanners are
provided for the main flame.
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 Burner Management System
▪ Automatic shut off valves in double block & bleed
arrangement are provided for fuel lines in fuel skid.
▪ Start up sequence can be typically divided in to leak
test , purging , pilot firing & main fuel firing.
▪ Hard wired interface with ESD system for shutdown.
▪ Serial interface with DCS for monitoring by control room
operator.

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 Burner Management System
Heater trip logic is in general based on following
philosophy:

Event Pilot Fuel Trip Main Fuel trip

Loss of pilot pressure/flame Y Y
Loss of fuel pressure/flame N Y
Rise in furnace pressure N Y

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 Analyser Management System

Various types of Analysers include :

◼ Steam & water quality analyser – pH, Conductivity, silica,
oil in water
◼ Gas Analysers – CO, O2, H2S, SOX/NOX, SO2, H2
◼ Physical property analysers - Flash point, Pour Point,
Distillation, Moisture, density, Smoke/Opacity, Viscosity
◼ Gas Chromatograph – It can analyse multiple components
based on retention & evolution in/from an adsorption
media.

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 Analyser Management System
Sampling: It is the extraction of the process fluid and its
delivery to the analyser

Sample conditioning: It consists of assembly of

components which remove moisture, particulate and
regulates sample pressure, temperature & flow at
acceptable limits to the analyser

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 Analyser Management System
Sampling Delay: It is the time taken by the sample in
reaching the analyser from the process.

Fast Loop: Part of the sample is recycled to the process

to avoid dead volume in the sampling system.

Cycle Time: It is the total analysis time taken by the

analyser for analysing desired components in the
process stream.

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 Analyser Management System
◼ Analyser Houses are located at strategic locations to
collect various samples required for analysis & reduce
the length of sample lines.
◼ All analysers are connected to analyser management
system for collection of data.
◼ The system
- monitors the healthiness of sampling system
- monitors the healthiness of analyser electronics
- trends the parameters

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 CCTV & Security Automation
CCTV system
◼ is used for monitoring of flare stacks, General
surveillance ( loading /unloading , major equipment's
monitoring ), fire prone areas etc.
◼ Time lapse video recording is provided for reviewing
history.
Security system
◼ Used for access control
◼ Automatic movement of gates

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 Controllers
One of the basic functions executed by
instrumentation system in process industry is
‘controlling the process parameter’. There may
be two types of controls:
1. Open Control Loop
2. Close Control Loop

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 Open Control Loop

Liquid In

Liquid
Out
In Out
Process

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 CLOSED LOOP
AUTOMATIC FEEDBACK CONTROL

Error
signal
Comparator

Setpoint Final Controlled

variable
+/- Controller control Process
element

Feedback

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 PID/Regulatory Control
◼ Proportional Action
output = K1 * e
◼ Proportional + Integral Action
output = K1 * e + K2edt
◼ Proportional + Integral + Derivative Action
output = K1 * e + K2edt + K3 de/dt
Where
e = error (difference between setpoint and
measured variable)
K1 = Gain
K2, K3 = constants
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 Instrumentation Controls
◼ Application specific
Compressors – Anti-surge, performance,
speed control
Furnace/Boiler – Lead-Lag control
Boiler – 3-Term Control
◼ On-off / PID controls
◼ Complex loops / traditional advanced control
Ratio, feedforward, cascade, adaptive

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Thank You
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