Plant operation systems

PLANT OPERATION systems

Typical objectives of plant operation include: 1. protect peopleprotect people 2. protect environment 2. protect environment 3. protect equipment 3. protect equipment 4. maintain smooth operation 4. maintain smooth operation 5. achieve product rates & quality 5. achieve product rates & quality 6. Profit=optimizing first five 6. Profit=optimizing first five 7. monitoring & diagnosis 7. monitoring & diagnosisThese are achieved through These are achieved through process controlprocess control…..…..

Distributed control system(D.C.S):

D C S is a computerized control system used to control the production line in the industry.

D C S was introduced in 1975 by HONEYWELL and YOKOGAWA(CENTUM).

Other vendors :ABB,FOXBORO, EMERSON (ROSEMOUNT) AND ETC..,.

DCS ARCHITECTURE:System

Consoles Host

Computer Data

Storage Unit

PLC

Data Highway (Shared Communication Facilities)

Process Transmitters and Actuators

Local Console

Local Control

Unit

Local Control

Unit Local

Console

FIELD BUS TECHNOLOGY:

Introduced 1988but underwent many development Standard IEC61158 introduced in 1999 Based upon smart devices installed in the field. Uses data highway to replace wires for signal transfer. Can mix sensors, transmitters, and control valves from different vendor

PLC ARCHITECTURE:A plc is a micro processor based controller.Programmi

ng Interface

Power Supply

Input Devices

I/O Modules

Output Devices

Processor

PLC Cabinet

Data Highway

A plc uses programmableMemory to store information and carry out functions to control machines and process.

REDUNDENCY:

Digital control system

sensors sensors

SIS system

i/o

i/o

i/o

i/o

We desire independent protection layers, without common-cause failures - Separate systems

DCS handles controls and alarms functions

PLC handles SIS and Alarms associated with SIS

INPUTS: These are typically “switches” and “sensors”. The switches and sensors are connected to an input module that provides the interface between the switches (or) sensors to the PLC.

OUTPUTS: The plc output are connected directly or indirectly(eg: Through relay) to actuator controls. Eg: “solenoid valves” and warning lights.There are three main types of output modules:- 1. RELAY 2. TRANSISTOR 3. TRIAC

APPLICATIONS:

* Pneumatic machines. * Hydraulic machines. * Robots. * Production process. * Packaging lines. * Traffic lights & signalling

systems. * Refining processes.

Basic control system:

TC

TT

Actuator System

Sensor System

Controller

F1

T1

F2

T2

T

F

ACTUATOR SYSTEMS: ON/OFF: ON – OFF VALVES

PUMPS (MOTORS)

VARIABLE POSITION:

Control Valves Variable speed pump

•DC motor •3-phase motor •Turbine drive

CONTROL VALVE:

BUTTERFLY VALVE:

ACTUATOR:

VALVE WITH ACTUATOR & POSITIONER:

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15345A0428