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Role of c&i engineers in industry

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What Controls&Instrumentation engineers do in industry?

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Role of c&i engineers in industry

  1. 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. 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. 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. 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. 5. Dr.R.Jayapal C & I PRODUCTS  Local Instruments  Remote Instruments  Remote Panels  Instrument Cables  Electrical Equipments
  6. 6. Dr.R.Jayapal LOCAL INSTRUMENTS for  Pressure Measurements  Temperature Measurements  Flow Measurements  Level Measurements
  7. 7. Dr.R.Jayapal LOCAL INSTRUMENTS Pressure / DP Measurements  U Tube manometer  Draught gauge  Bourdon tube Pressure Gauge  Diaphragm type Pressure gauge  Pressure / DP Transmitters  Pressure / DP switch
  8. 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. 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. 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
  11. 11. Dr.R.Jayapal REMOTE INSTRUMENTS  INDICATORS  RECORDERS  ANNUNCIATOR
  12. 12. Dr.R.Jayapal ADVANCED TECHNOLOGIES  SMART SENSORS WIRELESS SENSORS MEMS BUS TOPOLOGIES -MODBUS,PROFIBUS, FOUNDATION FIELD BUS, ASI,CAN…..
  13. 13. Dr.R.Jayapal FIELD TO REMOTE PANEL SIGNAL TRANSMISSION  * 4 -20 mA CURRENT SIGNAL * HIGH WAY ADDRESSABLE REMOTE TRANSMISSION (HART) * DIGITAL BUS
  14. 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. 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. 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
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  19. 19. Dr.R.Jayapal ELECTRICAL EQUIPMENT  HT/ LT MOTORS  HT / LT MCC  POWER AND CONTROL CABLES  CABLE TRAYS AND ACCESSORIES  HT / LT CAPACITOR BANKS  VARIABLE FREQUENCY DRIVES  EDDY CURRENT DRIVES
  20. 20. Dr.R.Jayapal INSTRUMENT CABLES  SCREENED CABLE  COMPENSATING CABLE FOR T/C  TRIAD CABLE FOR RTD  CONTROL CABLE
  21. 21. Dr.R.Jayapal OPPORTUNITIES….. DESIGN/ CONSULTANCY MAINTENANCE MANUFACTURING R&D ERECTION & COMMISSIONING MATERIALS MANAGEMENT GENERAL MANAGEMENT SOFTWARE TEACHING
  22. 22. Dr.R.Jayapal Design/Consultancy Function P&ID preparation Open loop & Closed loop control Design M&C table preparation Instrument Specification Valve sizing & list,spec. of valves (Solenoid,Pneumatic,Motorised control, on/off) List & Spec of drives Flow element Design Installation Diagrams
  23. 23. Dr.R.Jayapal COMBUSTION CONTROL
  24. 24. Dr.R.Jayapal HMI FOR PUMPING STATION
  25. 25. Dr.R.Jayapal HMI FOR GASIFIER
  26. 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. 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. 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. 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. 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. 31. Dr.R.Jayapal VARIOUS INDUSTRIES…. • POWER PROCESS /CHEMICAL REFINERY CEMENT,PAPER INSTRUMENTATION SYSTEMS ELECTRONICS SYSTEMS
  32. 32. Dr.R.Jayapal POWER (THERMAL,HYDRO,NUCLEAR) NTPC,NHPC,NPC,POWER GRID NEYVEY LIGNITE CORPORATION ELECRICITY BOARDS PRIVATE UTILITIES LIKE: RELIANCE,ADANI,KSK,BGR, HINDALCO,BIRLA,TATA,STERLITE JINDAL,JAIPRAKASH,VASAVI …
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  37. 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. 38. Dr.R.Jayapal REFINERY MADRAS REFINERY INDIAN OIL CORP. MANGALORE REFINERY RELIANCE PETRO COCHIN REFINERY MANY AROUND MUMBAI…… 606666666
  39. 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. 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. 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. 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. 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
  44. 44. Dr.R.Jayapal Thank you

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