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ADVANCE INSTRUMENTINSTRUMENT
M.HAROONI
WELCOME TO ADVANCE INSTRUMENT TRAINING COURSETRAINING COURSE
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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 PARAMETERFLOW MEASURMENTFLOW MEASURMENT
PRESSURE MEASURMENT
LEVEL MEASURMENT
TEMPRATURE MEASURMENT
SPEED MEASUREMENT
DENCITYDENCITY
MOVEMENT , VELOCITY, ACCELERATION
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FLOW MEASURMENT
WHY MEASURE FLOW?CUSTODY TRANSFERCUSTODY TRANSFER
FISCAL MEASURMENT
LEAK DETECTION
CONTROL
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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
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VELOCITY FLOW METER
VOTEX FLOW METER
TURBINE FLOW METER
ULTRA SONIC FLOW METER
MAGNETIC FLOW METERMAGNETIC FLOW METER
MASS FLOW METER
CORIOLOIS FLOW METER
TERMAL FLOE METER
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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?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
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INDUSTRIAL FLOWMETER MARKET
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PRESSURE MEASURMENT
TYPE OF PRESSURE MEASURMENT
ABSOLOTE PRESSURE MEASUREMENT
GAUGE PRESSURE MEASURMENT
DIFFRENTIONAL PRESSURE MEASURMENT
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MEASURABLE PRESSURE TYPE
HAED PRESSURE(HYDROSTATIC)
STATIC PRESSURE (LINE)
VACCUM PRESSURE
LEVEL MEASURMENT
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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
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ELECTRO MECHANICAL
DISPLACER
MAGNETOSTRICIVE
RESISTANSE TAPE
SERVO
ELECTRONIC CONTACTING
CAPACITANCE
CONDUCTIVITY
OPTICAL
PRESSURE‐BASED LEVEL TECHNOLOGI
BUBBLER SYSTEM
THERMAL
VIBRATING LEVEL(TUNING FORK)
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ELECTRONIC NON CONTACTINGELECTRONIC NON CONTACTING
RADAR
ULTASONIC
NUCLEAR
INITIAL / MENTENANCE COST.
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TYPE OF TEMPRATURE MEASURMENT
RTD (RESISTANCE TEMPRATURE DETECTOR)
T/C (THERMOCUPLE)
WHY MEASURE TEMPRATURE ?PROUCT QUALITYPROUCT QUALITY
EFFICENCY
SAFETY
MONITORING
CUSTUDY TRANSFER
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COMPARISON OF T/C TYPE
COMPARISON OF RTD
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TYPE OF MEASURING SPEEDOPTICAL TYPE
MAGNETIC PICK UP
TACHOMETER
CONTROL VALVE
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FAIL OPEN
FAIL CLOSE
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TYPE OF ACTUATORS DIAPHRAGM PISTON ELECTRIC ELECTROHYDROLIC MANUAL MANUAL
SEVER SERVICE ITEMS NOISE NOISE DELTA P CAVITATION CHEMICAL ATTACK MATERIAL EROSION FLASHING FLASHING SELECTION HIGH PRESSURE VIBRATION HIGH / LOW TEMPRETURE
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TYPE OF CHARCTRISTIC LINEAR LINEAR
EQUAL PERCENTAGE
QUICK OPENING
VALVE CHARACTRISTIC
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TYPE OF BONNET
EXTENTION BONNET
BELLOWS SEAL BONNET
TYPE OF PACKING
TFE UP TO 450°F
GRAPHITE UP TO 1200°F
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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
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SPLIT RANGE CONTROL VALVE
CONTROL VALVE
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CONTROL VALVE WITH SOLENOIED
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INSTRUMENTATION DESIGHN CRITERIA
STANDARD AND RECOMMENDED PRACTICE
PROTECTION AND CERTIFICATE
CONTROL SYSTEM DESIGHN PHILOSOFY
PROVISION OF INSTRUMENTS ON PACKAGE O O O U O C GUNIT
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CONTROL SCHEMATIC
TYPES OF CONTROL
CONTINIUS CONTROL
BATCH CONTROL
SEQUENCE CONTROL
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CONTROL LOOPS
OPEN LOOP CONTROL
CLOSE LOOP CONTROL
OPEN LOOP
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CLOSE LOOP
ADVANTAGE OF CLOSE CONTROL LOOP
INCREASED PRODUCTIVITY
ON SPEC PRODUCTS
ENERGI AND MATERIAL CONVERSATION
SAFETY
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ACTING ELEMENTS
DIRECT ELEMENT
REVERSE ELEMENT
DIRECT ACTING ELEMENT(INCREASE/INCREASE)
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REVERSE ACTING ELEMENT(INCREASE/DECREASE)
INSTRUMENT SIGNALS
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CONVENTIONAL CONTROL LOOPr
Set Point
mI / P
TRC
b
Fs
Steam
TT
CProcess Fluid
F Ti
Steam Trap
Condensate
FEEDFORWARD CONTROL
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FEED FORWARD CONTROL LOOP
FEEDBACK CONTROL
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RATIO CONTROL
RATIO CONTROL
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VOUTING 2 OUT OF 3
P‐T COMPENSATION
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OVER RIDE
CASCADE CONTROL
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VOUTING 2 OUT OF 3
SPLIT‐ RANGE
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TYPE OF CONTROL SYSTEM MANUAL
SELF ACTUATED
PNUMATIC
ELECTRONIC
CENTRALIZE
DCS
FCS
MANUAL CONTROL
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SELF ACTUATED CONTROL
COMPARISON BETWEEN DCS&FCS
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COMPARISON BETWEEN DCS&FCS
COMPARISON BETWEEN DCS&FCS
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COMPARISON BETWEEN DCS&FCS
CONVENTIONAL CONTROL ROOM
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TODAY CONTROL ROOM
INDUSTRIAL SAFETY
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What a Safety Instrument System really does (prevention)
Trip level
Operatortakes action
Safety System
High Level Alarm
Wild process parameter
PlantShut Down
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Process parameter value
Normal behaviorDCS Control Level
Control Level
Wild process parameter
Risk-ReductionManagement Systems:
• Procedures
• Operating instructions
• Maintenance
instructionsControl Layer
Human Layer
instructions
Safety System SIS:
• HIPS
• ESD/PSD
Mitigation Systems:
• Fire & Gas Systems
Control Layer
Physical Layer
Mitigation Layer
Prevention Layer
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• Blow-down systems
Physical Systems:
• Dikes
• Concrete Fire walls
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DIN V 19250 AK ClassW1 W2 W3
1S1S: Extent of damage
S1-minor injury/damageS2 serio s inj r /death of one person
2
3
4
5
6
7
8
1
2
3
4
5
6
7
1
2
3
4
5
S2
S3
A1
A2A1
G1
G2
G2
G1S2-serious injury/death of one personS3-Death of several personsS4-Catastrophic consequences
A: Frequency of exposureA1-SeldomA2-Quite often to permanent
G: Avoiding of hazardG1-PossibleG2-Almost impossible
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S4 A2
W: Probability of eventW1-HighW2-LowW3-Very low
Primary cause (by phase) of control system failure (based on 34 incidents)
44.1%Specification
14.7%Design & implementation
5 9%
More than 60% of failures "built into safety-related system" beforetaken into service
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14.7%Operation & maintenance
20.6%Changes after commissioning
5.9%Installation &commissioning
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IEC 61508Safety Integrity Levels
Minor
Serious
Severe
Safety Integrity LevelSIL
PFDProbability ofFAILURE on DEMAND
1
2
3
<10-1 - >10-2
<10-2 - >10-3
<10-3 >10-4
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Severe
Catastrophic
3
4
<10-3 - >10-4
<10-4 - >10-5
SIL Levels of different Systems
Low Safety
PFD = 10-1 1 in 10 Y
Included are: Hardware, Systematic & Common Cause failuresAccording to the TR84 calculations
SIL 1
SIL 2
SIL 3
1 in 100 Y
1 in 1,000 Y
1 in 10 000 Y
10-2
10-3
average
2oo3
1oo2D
DSP PLS
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SIL 4
High Safety
10-5
1 in 10,000 Y
13 wks 26 wks 39 wks 52 wks
Logic Solver periodical Proof Test Interval Time
10-4
1 in 100,000 Y
DSP SLS
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TÜV versus IEC (SIL Levels)
Process pipe
Pipe to Pipe
Process pipe
Safe Fail-Safe
Protection logic
Logic solver
OAD
0 cm
0 cm
0 cm
0 cm
0 cm0 cm
Air
Vent.
Safetyvalve
44
Ü
85
Sensors Final elementsAK
(TÜV)SIL(IEC 61508)
* rough estimate only
TÜV versus IEC*88776655
4
44
33
22
11
System Redundancy1oo1 1oo2
Defected failure,safe and un-safe
1oo2 2oo3
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Safety False Trips
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1oo2D: the best of two worlds
2oo2
1oo2
Safe failures
Diagnostic
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Unsafe Failures
Diagnostic
Relative positionL RedundantInherent FailSafe
Fal
se T
rip
Rat
e
SpecialR l
InherentFailSafe
2oo3
FailSafe
1oo2D
2oo3
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SafetyL H
Relays
PneumaticsH
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PREVENTION AND MITIGATION LAYER
SAFETY INTEGRITY LEVEL
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SYSTEM ARTECHECTURE
HAZARDOUS AREASENVIRONMENTS:IIA PROPANE AND LIKEIIB ETHYLENE AND LIKEIIC HYDROGEN AND LIKE
ABILITY OF GAS IGNITION ON A HOT SURFACE:T1 450’CT2 300’CT3 200’CT4 135’C
PROTECTION TECHNIQUES:“Ex o” Oil Filled“Ex q” Powder Filling“Ex m” Encapsulation4 35
T5 100’CT6 85’C
ZONES:ZONE 0: CONTINUOUS PRESENCEZONE 1: NORMAL OPERATIONZONE 3: SHORT OCCURRENCE
Ex m Encapsulation“Ex p” Pressurization“Ex e” Increased Safety (Dust/Water)“Ex d” Flameproof“Ex I” Intrinsically safe
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ANY QUESTION
THANK YOU FOR YOURATTENTION