ADVANCE M.HAROONI WELCOME TO ADVANCE INSTRUMENT

Transcription

1 ADVANCE INSTRUMENT M.HAROONI WELCOME TO ADVANCE INSTRUMENT TRAINING COURSE ۱

2 TITLE TRAINING COURSE MEASURING PARAMETER CONTROL VALVE CONTROL LOOPS FEEDBACK CONTROL FEEDFORWARD CONTROL CASCADE CONTROL RATIO CONTROL TYPE OF CONTROL SYSTEM LAYER CONTROL SAFETY IN CONTROL MEASURING PARAMETER FLOW MEASURMENT FLOW MEASURMENT PRESSURE MEASURMENT LEVEL MEASURMENT TEMPRATURE MEASURMENT SPEED MEASUREMENT DENCITY MOVEMENT, VELOCITY, ACCELERATION ۲

3 FLOW MEASURMENT WHY MEASURE FLOW? CUSTODY TRANSFER CUSTODY TRANSFER FISCAL MEASURMENT LEAK DETECTION CONTROL ۳

4 TYPE OF FLOW METERS DP FLOW METER VELOCITY FLOW METER MASS FLOW METER POSITIVE DISPLACEMENT FLOW METER DP FLOW METER ORIFICE PLATE VENTURI TUBE FLOW NOZZLE PITOT TUBE ANNUBAR ELBOW ۴

5 VELOCITY FLOW METER VOTEX FLOW METER TURBINE FLOW METER ULTRA SONIC FLOW METER MAGNETIC FLOW METER MASS FLOW METER CORIOLOIS FLOW METER TERMAL FLOE METER ۵

6 IMPORTANT PARAMETER FOR SELECING FLOW METER How much does the fluid cost? Is the fluid to be measured liquid or gas? Is there just one fluid, or are there many? In the case of liquid is it exceptionally viscous or exceptionally thin? Will there be extremes of temperature and pressure? What is the range of flow rate? How much pressure loss can the system tolerate? Is the fluid conductive? Do we have to meet any specific rules? Is there an on-site prover? What about maintenance? IMPORTANT PARAMETER FOR FLOW METER REPEATABILITY UNCERTAINTY(ACCURACY) RANGEABILITY(TURNDOWN RATIO) LINEARITY ۶

7 ۷ INDUSTRIAL FLOWMETER MARKET

8 PRESSURE MEASURMENT TYPE OF PRESSURE MEASURMENT ABSOLOTE PRESSURE MEASUREMENT GAUGE PRESSURE MEASURMENT DIFFRENTIONAL PRESSURE MEASURMENT ۸

9 MEASURABLE PRESSURE TYPE HAED PRESSURE(HYDROSTATIC) STATIC PRESSURE (LINE) VACCUM PRESSURE LEVEL MEASURMENT ۹

10 TYPE OF LEVEL MEASURMENT MANUAL/ MECHANICAL ELECTRO MECHANICAL ELECTRONIC CONTACTING ELECTRONIC NON CONTACTING MANUAL/ MECHANICAL FLOAT SYSTEM ROD GAUGING/ DIP PROB SIGHT /GAUGE GLASS TAPE SYSTEMS ۱۰

11 ELECTRO MECHANICAL DISPLACER MAGNETOSTRICIVE RESISTANSE TAPE SERVO ELECTRONIC CONTACTING CAPACITANCE CONDUCTIVITY OPTICAL PRESSURE BASED LEVEL TECHNOLOGI BUBBLER SYSTEM THERMAL VIBRATING LEVEL(TUNING FORK) ۱۱

12 ELECTRONIC NON CONTACTING RADAR ULTASONIC NUCLEAR INITIAL / MENTENANCE COST. ۱۲

13 TYPE OF TEMPRATURE MEASURMENT RTD (RESISTANCE TEMPRATURE DETECTOR) T/C (THERMOCUPLE) WHY MEASURE TEMPRATURE? PROUCT QUALITY PROUCT QUALITY EFFICENCY SAFETY MONITORING CUSTUDY TRANSFER ۱۳

14 COMPARISON OF T/C TYPE COMPARISON OF RTD ۱۴

15 TYPE OF MEASURING SPEED OPTICAL TYPE MAGNETIC PICK UP TACHOMETER CONTROL VALVE ۱۵

16 FAIL CLOSE FAIL OPEN ۱۶

17 TYPE OF ACTUATORS DIAPHRAGM PISTON ELECTRIC ELECTROHYDROLIC MANUAL SEVER SERVICE ITEMS NOISE DELTA P CAVITATION CHEMICAL ATTACK MATERIAL EROSION FLASHING SELECTION HIGH PRESSURE VIBRATION HIGH / LOW TEMPRETURE ۱۷

18 TYPE OF CHARCTRISTIC LINEAR EQUAL PERCENTAGE QUICK OPENING VALVE CHARACTRISTIC ۱۸

19 TYPE OF BONNET EXTENTION BONNET BELLOWS SEAL BONNET TYPE OF PACKING TFE UP TO 450 F GRAPHITE UP TO 1200 F ۱۹

20 DATA NEEDED FOR SELECTION OF CONTROL VALVE TYPE OF FLUID TEMP OF FLUID VISC OF FLUID S.G OF FLUID Q MAX / MIN P1 MAX / MIN DELTA P MAX / MIN NOISE LEVEL PIPE SIZE VALVE ACTION TYPE OF PACKING TYPE OF ACTUATOR ACCESORIES DOUBLE ACTING CONTROL VALVE ۲۰

21 SPLIT RANGE CONTROL VALVE CONTROL VALVE ۲۱

22 ۲۲ CONTROL VALVE WITH SOLENOIED

23 INSTRUMENTATION DESIGHN CRITERIA STANDARD AND RECOMMENDED PRACTICE PROTECTION AND CERTIFICATE CONTROL SYSTEM DESIGHN PHILOSOFY PROVISION O OF INSTRUMENTS ON PACKAGE UNIT ۲۳

24 CONTROL SCHEMATIC TYPES OF CONTROL CONTINIUS CONTROL BATCH CONTROL SEQUENCE CONTROL ۲۴

25 CONTROL LOOPS OPEN LOOP CONTROL CLOSE LOOP CONTROL OPEN LOOP ۲۵

26 CLOSE LOOP ADVANTAGE OF CLOSE CONTROL LOOP INCREASED PRODUCTIVITY ON SPEC PRODUCTS ENERGI AND MATERIAL CONVERSATION SAFETY ۲۶

27 ACTING ELEMENTS DIRECT ELEMENT REVERSE ELEMENT DIRECT ACTING ELEMENT(INCREASE/INCREASE) ۲۷

28 REVERSE ACTING ELEMENT(INCREASE/DECREASE) INSTRUMENT SIGNALS ۲۸

29 CONVENTIONAL CONTROL LOOP Set Point r I / P m TRC b Steam Fs Process Fluid F Ti TT C Steam Trap Condensate FEEDFORWARD CONTROL ۲۹

30 FEED FORWARD CONTROL LOOP FEEDBACK CONTROL ۳۰

31 RATIO CONTROL RATIO CONTROL ۳۱

32 VOUTING 2 OUT OF 3 P T COMPENSATION ۳۲

33 OVER RIDE CASCADE CONTROL ۳۳

34 VOUTING 2 OUT OF 3 SPLIT RANGE ۳۴

35 TYPE OF CONTROL SYSTEM MANUAL SELF ACTUATED PNUMATIC ELECTRONIC CENTRALIZE DCS FCS MANUAL CONTROL ۳۵

36 SELF ACTUATED CONTROL COMPARISON BETWEEN DCS&FCS ۳۶

37 COMPARISON BETWEEN DCS&FCS COMPARISON BETWEEN DCS&FCS ۳۷

38 COMPARISON BETWEEN DCS&FCS CONVENTIONAL CONTROL ROOM ۳۸

39 TODAY CONTROL ROOM INDUSTRIAL SAFETY ۳۹

40 What a Safety Instrument System really does (prevention) Safety System Wild process parameter Plant Shut Down Operator takes action Trip level High Level Alarm DCS Process parameter value Normal behavior Control Level Control Level 79 Risk-Reduction Human Layer Control Layer Prevention Layer Mitigation Layer Physical Layer Management Systems: Procedures Operating instructions Maintenance instructions Safety System SIS: HIPS ESD/PSD Mitigation Systems: Fire & Gas Systems Blow-down systems Physical Systems: Dikes Concrete Fire walls 80 ۴۰

41 DIN V AK Class S: Extent of damage S1-minor injury/damage S2-serious s injury/death of one person S3-Death of several persons S4-Catastrophic consequences A: Frequency of exposure A1-Seldom A2-Quite often to permanent G: Avoiding of hazard G1-Possible G2-Almost impossible W: Probability of event W1-High W2-Low W3-Very low S1 S2 S3 S4 A1 A2 A1 A2 G1 G2 G1 G2 W1 W2 W Primary cause (by phase) of control system failure (based on 34 incidents) 44.1% Specification More than 60% of failures "built into safety-related system" before taken into service 14.7% Design & implementation 5.9% Installation & commissioning 14.7% Operation & maintenance 20.6% Changes after commissioning 82 ۴۱

42 IEC Safety Integrity Levels Safety Integrity Level SIL PFD Probability of FAILURE on DEMAND <10-1 ->10-2 <10-2 ->10-3 < >10-4 <10-4 ->10-5 Minor Serious Severe Catastrophic 83 Low Safety PFD = SIL Levels of different Systems SIL 1 SIL 2 Included are: Hardware, Systematic & Common Cause failures According to the TR84 calculations 1 in 10 Y 2oo3 1oo2D average 1 in 100 Y 1 in 1,000 Y High Safety SIL 3 SIL 4 DSP PLS DSP SLS 13 wks 26 wks 39 wks 52 wks Logic Solver periodical Proof Test Interval Time 1 in 10, Y 1 in 100,000 Y 84 ۴۲

43 cm0 cm 0 0 cm 0 cm 0 cm 0 cm TÜV versus IEC (SIL Levels) Pipe to Pipe Process pipe Process pipe Logic solver Safe A D 4 Protection logic Fail-Safe O Vent. Air Safety valve Sensors AK (TÜV) TÜV versus IEC* SIL (IEC 61508) Final elements 4 1 * rough estimate only 85 System Redundancy Defected failure, safe and un-safe 1oo1 1oo2 1oo2 2oo3 Safety False Trips 86 ۴۳

44 1oo2D: the best of two worlds 2oo2 Safe failures Diagnostic 1oo2 Unsafe Failures Diagnostic 87 Relative L position False Trip Rate H L 2oo3 1oo2D 2oo3 Special Relays Pneumatics Safety Redundant Inherent FailSafe Inherent FailSafe H 88 ۴۴

45 PREVENTION AND MITIGATION LAYER SAFETY INTEGRITY LEVEL ۴۵

46 SYSTEM ARTECHECTURE HAZARDOUS AREAS ENVIRONMENTS: IIA PROPANE AND LIKE IIB ETHYLENE AND LIKE IIC HYDROGEN AND LIKE ABILITY OF GAS IGNITION ON A HOT SURFACE: T1 450 C T2 300 C T3 200 C T4 135 C T5 100 C T6 85 C ZONES: ZONE 0: CONTINUOUS PRESENCE ZONE 1: NORMAL OPERATION ZONE 3: SHORT OCCURRENCE PROTECTION TECHNIQUES: Ex o Oil Filled Ex q Powder Filling Ex m Encapsulation Ex p Pressurization Ex e Increased Safety (Dust/Water) Ex d Flameproof Ex I Intrinsically safe ۴۶

47 ANY QUESTION THANK YOU FOR YOUR ATTENTION ۴۷

48 E MAIL & TEL TEL: ۴۸