Control systems

DECEMBER 4/2019
 

MRC – KARBALA REFINERY PROJECT

JALAL KHALEEL AL NAJAR
Control system area :

1- Field
2 – Process interface building (PIB)
3 – Main control Building(MCB)
FIELD:
Include
1 – Transmitters :level ,pressure ,temperature , flow ,analyzers

2 – Valves : actuator ,solenoid

Process Interface Building (PIB )
1 – DCS cabinet
2 – marshaling cabinet
3 – SIS cabinet
4 – FGS cabinet
5 – BMS cabinet
6 – MMS cabinet
7 – Network cabinet
8 – Server cabinet
9 -AMS CLIENT/RCI MONITOR
Drawing for PIB
Main Control Building (MCB)

Consist of :
1 – operator work station (OWS)
2 – Engineer work station (EWS)
3 – server room
4 – Telecom room
5- operator training Simulation (OTS)
6 – supervisor room
Main control Building layout
Main Control Building
Operation work station (OWS)
Operation work station (OWS)

The Operator Work Stations (OWS) foreseen for the process monitoring and control (HMI)
Human-machine interface installed in the Control Rooms shall be the following:
EXPERION Process knowledge system(EXPERION PKS)
It is the latest base for Distributed Control Systems
(DCS) distributed by Honeywell and provides a
complete solution for all problems in the control
process and control management for any part of the
production processes through a unified and highly
integrated environment

This system consists of :

 Distributed Control System (DCS )
 Safety management (SM)
 Assist management system(AMS)
EXPERION Process knowledge system(EXPERION PKS):
Distributed Control System (DCS):

It is the system responsible for all control and control

of the production process and archiving all variables
over time in the form of stored data and for long
periods can be retrieved later as well as the system
gives powers from within the control room to the
operators in the production unit to enable them to
operate a certain equipment such as pump or press or
allow him Maintenance work on one of the parts of the
control system of transmitters and others.
Karbala refinery has 62 cabins DCS and each cabins contain the
following components:
 Firewall CF9 :
The CF9 provides eight ports for FTE connections to C300s and Series C
FIMs
within a Series C cabinet as well as FTE Bridge modules (FTEB) in a
Series A
Chassis I/O chassis. It has a ninth port for an uplink connection to the
supervisory FTE network and level 2 control area. It provides network
security
by
• Rejecting all Ethernet messages not needed for control,
• Giving priority to traffic on downlink ports over ingress traffic on the
uplink port, if the fabric becomes saturated, and allowing only valid
C300-compliant messages to pass on to the C300 domain
 C300 Controller :
The Experion C300 controller forms the heart of the Experion
control system . and deterministically executes control
strategies .
The C300 controller runs the field proven, deterministic
Control Execution Environment (CEE) which is the core C300
software.
The control strategies are
configured and loaded to the C300 controller through the
Control Builder, an easy and intuitive engineering tool
Controller C300
 series C modual :
1 - Series c digital input module
2- Series c digital output module
3- Series c analog input module
4- Series c analog output module

 Field bus interface module (FIM) :

It is a two-way digital communication network used to connect field
devices such as sensor, actuator and controller between them, a
network used instead of analog signals 4 - 20 mA
It is serialized, meaning that the data is transmitted sequentially
according to RS 232 or RS 485
The main components of this unit are:
1 - H1 Card
It transmits the signal from field to FIM8 via bidirectional
unidirectional cable and can connect 8H1 per FIM8
2 - Trunk cable
We can connect 16 devices (transmitter, engine, valve, ....)
3 - power supply unit
4 - actuator
5 - junction Box
6 - Terminator
Typical of FIM medual
Profibus gatway modual (PGM) :
It is a protocol for connecting fieldbus and controllers
with decentralized devices such as MCC, sensor, actuator
The Profibus network transmits signals via a single cable
where it connects these devices to the controlling C300 .
: 3rd party
It connects the signals coming from packages with DCS
system and the following are the most important Packges
:that will be connected with the DCS system
machine monitoring system (MMS) - 1
compressor control system (CCS) - 2
Anti surge control system - 3
Analyzers - 4
packge plcs - 5
metering system - 6
tank gauging system - 7
1- Machine Monitoring System (MMS ) :
It is a machine monitoring system and includes monitoring the following:
- Vibration
- Temperature (temperature)
- displacement
- Monitoring system

The main purpose of using MMS is to:

1- Continuity of collecting, storing, displaying and printing data of rotary machines
2 - Availability of data analysis tools
3- Providing information to operators and maintenance personnel on the condition
of the machine
4 - Implementing automatic safe extinguishing of critical machines before
widespread damage
5 - provides historical and current information regarding the status of the
machine .
The main operator interface of the MMS will be through the DCS operator within
the control room for that purpose
2- Compressor Control System (CCS):
This system will provide the operator with the following
information:
1- Compressor anti - surge
2 - Performance control
3 - Turbine speed
The engineer in the work station must perform the following tasks:
1 - On - line monitoring
2 - Diagnostics dignostics
3 - Configuration
3- Tank gauging system (TGS) :
The perpus of the system is :
1 - Data transfer
2 - Monitor measurements
3 depot Account Registration (Print)
Its main purpose is to:
1 - Provide accurate measurements of fluid level, temperature
and density
2 - Provide inventory management functions by volume and total
accounts (TOTALIZER)
3 - Provide data analysis tools that are not provided by
conventional control systems
The TGS system must be connected to the main control MCR as
well as to the DCR depot control building
4 - Anti – surge control system :

It is a controlling and a valve placed on the compressor . the purpose of

protection . where a set of sensors of pressure, flow and temperature
are compared between the input and output of the compressor
In the event of a problem, the controller gives an indication of anti-surge
valve and the valve opens and part of the outside goes to the input of
the compressor for the purpose of continuity of rotation without any
damage to the compressor.
Asset Management System (AMS)

The purpose of this system is to control the configuration and maintenance of

the fundation field devices linked to EXPERION.
It performs the following functions:
1 - Display the configuration of the equipment
2 - Change in configuration data
3 - Run advanced diagnostics
There are three main components of AMS:
1 - AMS (FDM) server   :  Provided with configuration and management functions
2 - AMS (FDM) clint
              Connects remotely with AMS (FDM) server and can access device data.
3 - AMS (FDM) RCI
             Allows the remote or on-site device to communicate with server and
connects AMS CLINTS RCI to AMS server through FTE
 SAFETY MANAGER
It is a highly reliable and high security safety system for
safety control applications thus providing protection for
people, plant equipment and the environment for optimum
operation continuously.
It is a microprocessor programmable system that enables it
to carry out a wide range of control functions with high
operations and safety.
The Safety Manager consists of the following components:
Safety station (Engineering work station)
Controller chassis
Control processor
Battery & key switch module
Safety manager IO and FTA s
Safety Instrumentation System (sis) :
It is one of the safety systems of Honeywell, which is the self-
protection system for workers, equipment and machinery.
The safe operation of the SIS system consists of sensors,
programmers and final elements designed to enforce a stop if
the alarm limits are exceeded too high.
Examples of typical safety systems include:
1 - Emergency shutdown system
2 - safety shutdown
3 - safety interlock system
4 - fire and gas system
Boiler Management System(BMS) :
It is a system dedicated to the operation of Berners and its continuity
and extinguishing to ensure the safe operation of Berners under the
following conditions:
1 - interlock system BMS
2 - igniting the Berners by fuel oil / gas
3 - Alarm system (alarm system)
4. Monitoring
This process is monitored by DCS
The system is designed to implement the following functions:
1 - prevent ignition unless the process of disinfection of the oven
safely
2 - Attend the startup unless you are sure the work of the system
Interlock
3 - Control and control the correct sequence at startup and extinguish
4 - Allow conditional continuous operation of the equipment only
while ensuring safety
Fire and gas detector system (FGS):
It is a fire and gas detection system that provides protection
function, provides warning to employees and allows immediate
response to minimize damage from an emergency.
There is an FGS system in each PIB building to cover all the refinery
In case of any emergency, the signal will come from F&G Detector or
from manual call point (MCP) and the output will be Alarm through
the alarm light system,
audible alarm (horns) and be distributed in the factory and inside
buildings.
The system does not automatically shutdown, but manually
extinguishes by operators,
The main interface of the FGS operators must be through the DCS
work station
Located in the MCR main control room and the DCR warehouse
control chamber showing the location of ALARM as areas in each
The following are the most important reagents that have been placed in
the refinery:
1 - Flammable gas detectors
2 - H2S gas detectors
3 - Gas line reagents
Heat sensors
5 - Flame detectors
6 - Smoke detectors
7 - Manual call point
The FGS should then initiate operational safety measures to mitigate the
consequences of these risks, including the operation of water pumps, the
activation of flood valves and the activation of fire extinguishing systems