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

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. 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

11. Dr.R.Jayapal
REMOTE INSTRUMENTS
 INDICATORS
 RECORDERS
 ANNUNCIATOR

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

17. Dr.R.Jayapal

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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. Dr.R.Jayapal
INSTRUMENT CABLES
 SCREENED CABLE
 COMPENSATING CABLE FOR T/C
 TRIAD CABLE FOR RTD
 CONTROL CABLE

21. Dr.R.Jayapal
OPPORTUNITIES…..
DESIGN/ CONSULTANCY
MAINTENANCE
MANUFACTURING
R&D
ERECTION & COMMISSIONING
MATERIALS MANAGEMENT
GENERAL MANAGEMENT
SOFTWARE
TEACHING

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. Dr.R.Jayapal
COMBUSTION CONTROL

24. Dr.R.Jayapal
HMI FOR PUMPING STATION

25. Dr.R.Jayapal
HMI FOR GASIFIER

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

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 …

33. Dr.R.Jayapal

34. Dr.R.Jayapal

35. Dr.R.Jayapal

36. Dr.R.Jayapal

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

44. Dr.R.Jayapal
Thank you