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Saf Plant Control

The document discusses a proposed plant monitoring and control system for an industrial facility. It involves automating manual signal switching using a programmable logic controller (PLC) and supervisory control and data acquisition (SCADA) system to reduce human error. The system would optimally monitor and control critical processes. Field instruments discussed include flow meters, level measurement instruments (radar, ultrasonic), and temperature sensors (RTDs). Details are provided on models of instruments used, including specifications of a Fatek PLC, E+H and China brand flow meters, radar and ultrasonic level transmitters, and RTD temperature sensors.

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Engineer Atif Rasul Choudhry
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50 views13 pages

Saf Plant Control

The document discusses a proposed plant monitoring and control system for an industrial facility. It involves automating manual signal switching using a programmable logic controller (PLC) and supervisory control and data acquisition (SCADA) system to reduce human error. The system would optimally monitor and control critical processes. Field instruments discussed include flow meters, level measurement instruments (radar, ultrasonic), and temperature sensors (RTDs). Details are provided on models of instruments used, including specifications of a Fatek PLC, E+H and China brand flow meters, radar and ultrasonic level transmitters, and RTD temperature sensors.

Uploaded by

Engineer Atif Rasul Choudhry
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
You are on page 1/ 13

SAF PLANT CONTROL & INSTRUMENT

1- Plant Monitoring & Control System


1. Generaleral
2. Executive Summary
1.1: SCADA
1.1.2 SCADA Overview with Specification
1.2: PLC
1.2.1: Over View
1.2.2: Models with IO’s Capacity
1.3: Plant IO’s Tag Map
1.3.1: Loop Drawing
2- Field Instruments
2.1: Over View
2.2: Flow meter:
SNo. Description Brand Quantity Installed
1 Mass Flow meter E&H 03

2.3: Level Measuring Instrument

SNo. Description Type Quantity Installed


1 Radar Level Transmitter Non-guided 19
2 UL Transmitter 06

2.4: Temperature Measuring Instrument:


SNo. Description Type Quantity Installed
1 RTD PT-100 3-Wire 04

Field Instrument Data Sheet:


3.1: Flow meter Data Sheet
3.2: Level Instrument Data Sheet
3.3: Temperature Instrument Data Sheet
3.4: Pressure Instrument Data Sheet
Cable Schedules
4.1: VGA Cable
4.2: Multi-core Cable
4.3: Signal Cable
4.4: Modbus Signal Cable

5-Local Instruments:
5.1 Level Gauges
5.2 Local Pressure Gauges
5.3 Local Temperature Gauges
7-PC with LCD’s
8-Internet

9-AC

1-Plant Monitoring & Control System

The study proposes a possible solution for manual switching of multiple signals

in an industrial scenario where these signals are in use. In most developing

countries with irregular safety regulations, many industries perform manual

switching during power breakdowns or tripping due to weather issues. These

procedures involve many risks due to human error. The fundamental goal of the

designed model is to reduce human resources and increase the system's

efficiency. In this research, automated switching and monitoring of signals are

developed using SCADA and PLC programmed through ladder logic. A

scenario is evaluated where multiple signals are at use as a source of instrument

supply. The objective is to automate the manual switching through a


programmable logic controller, where it switches the signals to keep the

selected critical load activated. The concluded model design will feature

optimal monitoring and control through SCADA that would be beneficial in

reducing human error and increasing system efficiency.

1.2: PLC
1.2.1: Over View
Programmable logic controller (PLC) or programmable controller is an

industrial computer that has been ruggedized and adapted for the control of

manufacturing processes, such as assembly lines, machines, robotic devices, or

any activity that requires high reliability, ease of programming, and process

fault diagnosis.

PLC originated in the late 1960s in the automotive industry in the US and were

designed to replace relay logic systems.

1.2.2: Models with IO’s Capacity


Fatek PLC FBs-32MAR2-AC:

FATEK Automation Corp. was established in 1992 in Taiwan by a group of

engineers engaged in PLC design and development for many years. Since its

establishment, FATEK has strive for R&D in order to provide high-quality,

high-function and user-friendly automatic control products. The product line

focuses on PLC, HMI, IoT solutions, SCADA application software, OPC Server

and power supply, etc. With our endeavors for decades, we are now well-

recognized in the industry for high quality and reliability with the brand name
of "FATEK." While maintaining stability and dependability, FATEK also

continuously engages in R&D and innovation to expand a broader application

field, striving to become a professional, reliable and holistic solution provider.

Fatek PLC operate as show Voltage 20-30VDC.

IO’s Lists:

Fatek PLC provide many different IO’s like Analog Inputs (AI),
Analog Outputs (AO), Digital Inputs (DI), Digital Outputs (DO).

1.3: Plant IO’s Tag Map


2-Field Instruments
Field instrumentation to measure and monitor flow, level, pressure, temperature
and analyse liquids; depending on the application a field instrument is required
to measure and control different automation processes. This is why our field
instruments use different measuring principles to operate reliably and accurately
in any situation. See our wide range of process instrumentation to measure and
control, system components and data managers for data visualization, and
recording and software tools to support \the seamless integration of field
instruments into many different automation systems.
For this purposes many industries using following instruments.
2.2: Flow meter
2.3: Level Measuring Instrument (RDL, UL)
2.4: Temperature Measuring Instrument (RTD)

2.2: Flow meter


Flow meter is use to find the accurate flow of process line.
For Flow measurements there are different types of flow meter which are used
in different industries but in Bio-Tech Energy Pvt Ltd. Following types of FM’S
used
2.2.1-China
1.1-Turbine (China)
1.2-Vortex (China)
1.3-Elecmagnetic Type (China)
2.2.2-E&H
2.1-Coriolis Type
2.2-Vortex Type
3.3-Electromagnetic Type

2.2.1 China Type


Turbine flow meters use the mechanical energy of the liquid to rotate a rotor
within the flow stream. The rotational speed is directly proportional to the
velocity of the fluid traveling through the meter. These meters are used in
multiple industries to reliably measure liquids. These FM’s are not suitable at
high viscosity fluid.
Vortex flow meters are ideal for accurately measuring liquids and saturated
steam. Vortex meters have no moving parts and are virtually maintenance-free
once installed. Meters are available in wafer, insertion and flange designs .
These FM’s are used at high temperature and pressure lines.
Electromagnetic Flow Meters, simply known as mag flow meter is a volumetric
flow meter that is ideally used for wastewater applications and other
applications that experience low-pressure drop and with appropriate liquid
conductivity required.

2.2.2-E&H
E&H flow meters have been used throughout industries for more than 60
years. These meters are applicable for all conductive liquids, such as
oil,water,acids,alkali and many others. Typical applications are monitoring
of liquids, filling, dosing and precise measurement in custody transfer.
2.1-Coriolis Type
Coriolis Type FM’s has a long-standing reputation as a highly accurate sensor.
Immune to fluctuating and harsh environments, it is suited for the broadest range
of applications. With its compact transmitter Promass F 300 offers high flexibility
in terms of operation and system integration: access from one side, remote display
and improved connectivity options. Heartbeat Technology ensures measurement

reliability and enables extension of recalibration cycles. There are signal

opportunities in these FM’s like miliampere (mA), Profibus, and


Modbus (RS-485). These FM’s are operate at the supply of 20-
30VDC.
2.2-Vortex Type
Vortex flow meters are used in numerous branches of industry to
measure the volume flow of liquids, gases and steam. There are many
types Vortex FM’s which F300, F200 etc. These FM’s are used at low
viscosity fluid like Methanol. These FM’s operate on Analog input
signals (AI).
3.3-Electromagnetic Type
Electromagnetic flow meters are a type of velocity or volumetric flow meter
that operate pursuant to Faraday's law of electromagnetic induction which states
that a voltage will be induced when a conductor moves through a magnetic
field. Mag meters can detect the flow rate of conductive fluids only. There are
different types of Electromagnetic like P10, W10. W10 use for cool water line
while P10 use for hot water line.
2.3: Level Measuring Instrument

2.3.1: Radar Level Transmitter(China 26GHz)

High Frequency Radar Level Meter 906 adopted 26G high frequency radar
sensor, the maximum measurement range can reach up to 15 meters. Antenna is
optimized further processing, the new fast microprocessors have higher speed
and efficiency can be done signal analysis, the instrumentation can be used for
reactor, solid silo and very complex measurement environment.
Radar level transmitter antenna microwave pulse is narrow, the downward
transmission antenna. Microwave exposure to the medium surface is reflected
back again by the antenna system receives, sends the signal to the electronic
circuit automatically converted into level signals
2.3.2: Radar Level Transmitter (E&H FMR52)
The Micropilot is a "downward-looking" measuring system, operating based on
the frequency modulated continuous wave method (FMCW). The antenna emits
an electromagnetic wave at a continuously varying frequency. This wave is
reflected by the product and received again by the antenna.
2.3.3: Ultrasonic Level Transmitter
The Siemens SITRANS Probe LU ultrasonic level transmitter is a 2-wire,
loop-powered ultrasonic level transmitter. It is suitable for monitoring of level,
flow and volume in storage vessels and simple process vessels, as well as in
open channels. The range on the Probe LU is 6 or 12 meters (20 or 40 feet).

2.4: Temperature Measuring Instrument


2.4.1: RTD
Resistance temperature detectors, or RTDs, are perhaps the simplest type of
temperature sensor. These devices work on the principle that the electrical
resistance of a metal changes with temperature. Pure metals typically have a
positive temperature coefficient of resistance, meaning that their resistance
increases with temperature. RTDs can operate over a large temperature range
from -200 °C to +850 °C, as well as offer high accuracy, excellent long-term
stability, and repeatability.
3- Field Instrument Data Sheet
3.1: Flow meter Data Sheet
Total Flowmeter installed at Bio Tech Energy Pvt Ltd.
SNo. Description Brand Quantity Installed
1 Mass Flowmeter E&H 19
2 Vortex Flowmeter E&H 6
3 Mag Flowmeter E&H 1
4 Turbine Flowmeter China 14
Total Installed
40
3.2: Level Instrument Data Sheet
Total Level instruments installed at Bio Tech Energy Pvt Ltd.
SNo. Description Type Quantity Installed
1 Radar Level Transmitter Non-guided 28
2 DP Level Transmitter DP 11
3 Ultrasonic Level 1
Transmitter

3.3: Temperature Instrument Data Sheet


Total Temperature instruments installed at Bio Tech Energy Pvt Ltd.
SNo. Description Type Quantity Installed
1 Resistance Temperature PT-100 45
Detection 3-Wire
2 Thermocouple K 3
3 Temperature Switch Dry Contact 0

3.4: Pressure Instrument Data Sheet


Total Pressure instruments installed at Bio Tech Energy Pvt Ltd.
SNo. Description Type Quantity Installed
1 Pressure transmitter 2-Wire 06
4-20 mA
2 Pressure switch Dry Contact 03

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