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1.
Dr.R.Jayapal
Dr.R.JAYAPAL
Former Additional GM,BHEL,TRICHY
Former Vice President, Cethar Vessels,Trichy
Independent Automation consultant &
Technical content creator
www.elecspot.com
drrj1950@rediffmail.com
ROLE OF
C&I ENGINEERS
IN INDUSTRY
2.
Dr.R.Jayapal
Why Controls &
Instrumentation?
To monitor/record/control various parameters
like
Pressure,Differential pressure
Temperature,Differential Temperature
Flow (Solid,Liquid,Gas)
Level ,Vibration,Speed
Electrical parameters like volt,Amp,power,PF
To generate Alarms / Trip in case of abnormal
conditions.
3.
Dr.R.Jayapal
Facilitate data analysis
Facilitate automatic control of various
parameters.
Remote monitoring & operation
Interface with ERP for MIR
Ensure equipment and operating
personnel safety.
4.
Dr.R.Jayapal
ELECTRICALS
To provide Drives for Mechanical
Equipment
To feed & control Power to various
equipments
To facilitate starting and stopping of
various equipments in sequential way
5.
Dr.R.Jayapal
C & I PRODUCTS
Local Instruments
Remote Instruments
Remote Panels
Instrument Cables
Electrical Equipments
6.
Dr.R.Jayapal
LOCAL INSTRUMENTS
for
Pressure Measurements
Temperature Measurements
Flow Measurements
Level Measurements
8.
Dr.R.Jayapal
Temperature Measurements
Glass Tube Thermometer
Mercury in Steel Dial Gauge
Resistance Temperature Detector
Thermocouple (Type K,N,T,B,S)
Temperature Transmitters
Temperature Switch
LOCAL INSTRUMENTS
9.
Dr.R.Jayapal
LOCAL INSTRUMENTS
FLOW MEASUREMENT
Pitot Tube - Gas Application
Aerofoil - Gas Application
Positive Displacement Meter
Coriolis mass flow meter
Ultrasonic flow meter
Turbine Flow Meter
Orifice Plate/venturi Assembly
Flow Nozzle
Variable area/Rotameter
10.
Dr.R.Jayapal
LOCAL INSTRUMENTS
LEVEL MEASUREMENTS
Direct Level Gauge
Electronic Water level Indicator
Dp Transmitters
RF type/Radar type/Nucleonic
FLAME SCANNERS
VIBRATION MONITORS
GAS ANALYSERS
Proximity sensors
12.
Dr.R.Jayapal
ADVANCED TECHNOLOGIES
SMART SENSORS
WIRELESS SENSORS
MEMS
BUS TOPOLOGIES
-MODBUS,PROFIBUS,
FOUNDATION FIELD BUS,
ASI,CAN…..
13.
Dr.R.Jayapal
FIELD TO REMOTE PANEL
SIGNAL TRANSMISSION
* 4 -20 mA CURRENT SIGNAL
* HIGH WAY ADDRESSABLE
REMOTE TRANSMISSION (HART)
* DIGITAL BUS
14.
Dr.R.Jayapal
REMOTE PANELS
PROGRAMMABLE LOGIC
CONTROLLERS
DISTRIBUTED CONTROL SYSTEM
(DCS) WITH OPERATOR CONSOLE
SUPERVISORY CONTROL & DATA
ACQUISITION (SCADA)
These Panels execute Analog and Digital
controls.
15.
Dr.R.Jayapal
Compiled by Sri Koppikar CE-Mktg
T O T A L C O N T R O L S O L U T I O N S
ELECTRONICS DIVISION, BANGALORE
JAN 2006
Distributed
Processing Unit
(DPU)
I/O Modules
8 pack rack
(DPU4F and I/O)
Eight-pack rack
I/O Bus
Connector
Field 24V
Field 48V
System 24V
I/O Bus
Connectors
Remote Processing
Unit (RPU)……..
System Cabinets
System introduction… Control level
D
P
U
I
O
I
O
I
O
I
O
I
O
I
O
I
O
I
O
I
O
I
O
D
P
U
D
P
U
I/Osignals
16.
Dr.R.Jayapal
REMOTE PROCESSING UNITS (RPUs)
TYPICAL CONFIGURATION DIAGRAM
Redundant 100 Mbps maxNET
REMOTE I/O
FIBRE OPTIC
LINK
REMOTE maxVUE
• Serverless Configuration • Scalable…as large as required
Plant information network
PLANT SUB-
SYSTEMS
maxLINK
maxSTATIONS
ENGINEER’S
STATION / maxSTORIAN
26.
Dr.R.Jayapal
Design/Consultancy Function
PLC/DCS Specification
I/O List preparation
MMI Design
Control panel/Room design
Earthing,Illumination,lightning arrestors,safety
items
MCC,Electrical Panel Design/specification
Cable engineering & cable spec.
Quality Assurance/Control Documents
Inspection
O&M Manual
Field engineering support
27.
Dr.R.Jayapal
Maintenance Function
Calibration of Instruments/sensors
Repair & Maintenance
Spares Management
Periodic replacement planning
Aim is to ensure zero downtime of plant
28.
Dr.R.Jayapal
Manufacturing Function
Managing PCB shop,Assembly & wiring shop
Loading of software & Functional testing
Environmental Testing
Periodic calibration of instruments
Coordination with MM for components
Labour Management
Coordination with statutory authorities
Safety Management
29.
Dr.R.Jayapal
R&D Function
R&D proposal & approval
Development of instruments & Systems
Patent/Copy Right
Embedded/PC,PLC based/Custom IC development
Field Testing/Proving
Type testing at reputed labs
Documentation & Knowledge Management
Transfer knowhow to manufacturing
Performance feed back & improvement
30.
Dr.R.Jayapal
E & C Function
Erect the instruments/sensors/panels
as per the documents
Earthing,illumination installation
Cable tray laying/supporting
Cable laying / terminations/connection
Field calibration
Checking of total system
Handing over documentation
31.
Dr.R.Jayapal
VARIOUS INDUSTRIES….
• POWER
PROCESS /CHEMICAL
REFINERY
CEMENT,PAPER
INSTRUMENTATION SYSTEMS
ELECTRONICS SYSTEMS
37.
Dr.R.Jayapal
PROCESS/CHEMICAL…..
PETROCHEMICAL INDUSTRIES (SPIC)
NATIONAL FERTILISER CORP.
CHEMPLAST SANMAR
TUTICORIN ALKALI & CHEMICALS
STERLITE INDUSTRIES
METTUR CHEMICALS
MANY IN MUMBAI,BARODA……
38.
Dr.R.Jayapal
REFINERY
MADRAS REFINERY
INDIAN OIL CORP.
MANGALORE REFINERY
RELIANCE PETRO
COCHIN REFINERY
MANY AROUND MUMBAI……
606666666
39.
Dr.R.Jayapal
CEMENT,PAPER …..
• MANY NEAR ARIYALUR
DALMIA CEMENTS
CHETTINAD CEMENTS
MADRAS,SHANKAR CEMENTS
BIRLA,SHREE,RAJSHREE,ACC….
TNPL,SESHASAYEE PAPER
ITC BHADRACHALAM ……
606666666
40.
Dr.R.Jayapal
m
m
INSTRUMENTATION SYSTEMS
ABB, HONEYWELL
BHEL,BANGALORE
EMERSON ,SIEMENS
ALLEN BRADELY
ROCKWEL AUTOMATION
ENDRESS+HAUSER
MASSIBUS
INSTRUMENTATION LTD
PLC/DCS SYSTEM HOUSES
41.
Dr.R.Jayapal
m
m
ELECTRONIC SYSTEMS
BEL,ITI,ECIL,HAL,ISRO
DLRL,DRDO,GTRE,NAL,NPL
BARC,IGCAR,NGRI
BHEL,BANGALORE
SIEMENS,ABB
MANY SMALL & MEDIUM SCALE
INDUSTRIES IN CHENNAI, BANGALORE,
MUMBAI,BARODA,DELHI
42.
Dr.R.Jayapal
m
m
DESIGN/CONSULTANCY
NTPC,EIL,BHEL,PDIL,MECON
DEVELOPMENT CONSULTANTS
BLACK &VEACH, FISCHTNER, DESEIGN
TATA CONSULTING ENGINEERS
CETHAR CONSULTANTS,LLOYDS,UHDE
HUMPHRY & GLASCO
SEVERAL FOREIGN CONSULTANTS
43.
Dr.R.Jayapal
m
m
RECOMMENDATIONS……
•LEARN & PRACTICE
• -AUTOCAD
• -HMI SOFTWARE LIKE INTELUSION
•READ INSTRUMENATAION HAND BOOK
BY LIPTAK
•EACH STUDENT TO OWN ONE MC KIT &
DEVELOP SKILLS IN EMBEDDED SYSTEM
•SPEND ONE HOUR IN INTERNET DAILY &
RECORD YOUR FINDINGS
•REGISTER IN PLANT WEB UNIVERSITY
IN EMERSON WEBSITE & GET
CERTIFICATE (FREE)
• EACH STUDENT TO GIVE LECTURE
ON ADVANCED TOPIC PERIODICALLY