Overview of Plant Safety and
Control
Overview of Instrument System
& Control System
A brief presentation
By D.Guha (C&I)
Foster Wheeler India Pvt. Limited
Debasis
r
Guha
Foster Wheeler-KEC 1
Programme
Today’s Session
Introduction
Measurement & Instrumentation
Risk management
BPCS & Safety System
Control System Overview
Question & Answer session
2
Measurement & Instrumentation
“ Any thing (Process
!!) which can be
sensed (Sensor
( !!) ,
can be measured
and transmitted
(Transmitter) and
can be controlled
( Controller !!) and
Safeguarded
( Safety !!” )
3
Transmitter
What is a Smart Transmitter & why is
it required?
Transmitter is a part of control system,
required to transmit process signal to
control room. “smart” means it carries out
lots of self checks/ diagnostics and can
sense multi-variables (parameters).
What are diff type of signals to be
transmitted ? (Few examples)
4-20 mA ( Non Smart-Conventional )
4-20 mA HART signal (smart).
FF signal (smart).
Profibus signal (smart).
4
Flow Measurement-Challenges..
5
Flow Measurement
6
Final Control/Shutdown Element
Examples of
Valves
•ESD Valve
•PSD Valve
•Control Valve
•Special
Application
Valve
•Regulator
•Angle Valve
7
•Choke Valve
Design Input for Field Engineering
from other Disciplines
P&ID
PFD
Process Instrument Datasheet
BEDD (Basic Engineering Design Data)/Design
Basis
SLD (Single Line Diagram)
Piping Material Specification
Piping Plot Plan
Piping Layout
Static Equipment GA Diagram 8
Back Ground
The initial Risk associated with operating a process unit or a piece
of equipment may be reduced by applying a range of Risk
reduction measures, including IPF ( Instrumented Protective
Function).
Reduction can be achieved using a number of means, including
mechanical devices (relief valves, bursting discs, etc.) and
instrumented devices (IPF).
In most designs, both types of protection systems are applied, with
the mechanical system being the last line of defence wherever
possible.
9
Risk Risk Every where..
10
Risk Management
Tolerable Risk is defined by
corporate risk tolerability criteria).
11
What is Safety ?
Safety can be defined as “Freedom
from unacceptable Risk.”
12
How “good” is “good” ?
13
Risk Reduction
Layers of Protection
14
Basic Function of Control &
Safety Systems
Control System
The primary objective is to control the Plant within the permissible operating
envelope during start-up and changes in operating parameters, thereby avoiding
ESD System protective action
The second objective is to achieve long term stable operation at target
throughput, yields and product qualities.
Safety System
Preventing process conditions from reaching design values and causing
relief valves to lift.
Containing or disposing of significant liquid and vapour inventories so
as to minimise any potential for loss of containment and the creation of
a hazardous situation.
15
Explanation
16
Process Control & Shutdown
System
Distributed Control System (DCS) : Honeywell / Yogogawa / Invensys /Emerson
Emergency Shutdown and Equipment Protection (ESD/EPS) : Triconex/HIMA
Advanced Process Control System (APC) : Aspen Tech
Process Analysers ( GCs ) & Data Management System (AMDS) : ABB/Rosemount
Compressor Control System (CCS) :CCC/Troconex
Burner Management System (BMS) : Triconex
Vibration Monitoring Systems (VMS) : Bently Navada, B&K
Condition Monitoring System (CMS) for Critical machines : Bently Navada, B&K
Online Corrosion Monitoring System (CRMS) : Rohrback Cosasco
Instrument Asset Management System (IAMS) : Refer DCS Vendor
Fire & Gas Detection System (FDS) : SIEMENS/ General Monitor/Honeywell
Operator Training Simulator (OTS) : Omega/ Protomation
Maintenance Training Simulator ( MTS) : Refer DCS Vendor
Data Acquisition & Historian System : OSI-PI
Metering Skid : Panametric/ Danyel 17
Auxiliary System (Other than
Instrument )
Laboratory Information Management System ( LIMS)
Heating Ventilation and Air-condition System (HVAC)
Power Management System (HVAC)
Mechanical Packages and Skids ( Compressor/Turbines etc)
Smart Motor Control Center (MCC)
Plant Information Management System Network (PIN)
Plant Security & Surveillance System
Enterprise Recourse Management System ( Like SAP )
Wireless Radio / Satellite Communication System
SCADA/Wide Area Network (WAN)
18
Typical Architecture
Satellite media
router
Vnet/IP
Sub-sea Fiber Optic
F.O.
F.O. router
Vnet/IP
Vnet/IP
router
router
Vnet/IP Microwave Radio 19
Typical Conventional DCS
20
Typical Foundation Fieldbus DCS
21
Security
22
Fire-Wall
23
Why Fire-Wall
A popular solution for industrial security is to
install single firewall between business and the
control system.
24
Basic Interfaces
DCS is the main system where all the other systems are linked either
directly ( hardwire) or via redundant serial interfaces ( Modbus RTU/
Modbus TCP-IP).
All the trip signals are essentially hardwired to ESD system.
All the trip signals from auxiliary systems ( CCS/VMS etc) to ESD are
hardwired.
Field instruments are directly connected to the respective system either
directly ( one to one) or through network ( Foundation Fieldbus/
Profibus)
25
Interface Diagram
26
Design Input for PCS Engineering
from other Disciplines
1. Process Risk Area Segregation
2. P&ID
3. Cause and Effect Diagram
4. Automation & Control Philosophy
5. Emergency S/D Philosophy
6. Control Narrative
7. Logic Description
8. International/Client Specific Standard
27
Relevant Standards
IEC 61508/IEC 61511
ISA 84.01
Shell DEP 32.80.10.10-Gen
DIN V 19250
( Shell DEP based on IEC and DIN)
28
Thank you
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