This document discusses instrument maintenance practices at National Fertilizers Limited, a chemical process industry. It outlines the importance of instrumentation in process industries and describes various types of control loops used. It then discusses different types of maintenance practices including day-to-day, preventative, shutdown, and breakdown maintenance. Finally, it outlines upgrades made to instrumentation systems, including implementing a distributed control system and programmable logic controllers, to improve reliability, efficiency, and use of latest technologies.
In this session you will learn:
DCS Introduction
PLC
SCADA
General architecture of DCS
Process or application
Scan time
Input and Output requirement
Redundancy
RTU and LCU
PLC vs DCS
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
In this session you will learn:
History of Industrial Automation
Types of Industrial Automation
Process Industries
Overview of Continuous & Batch Process
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
This presentation is about the Distributed Control system in Power plants. DCS is a computerised control system for a process or plant usually with many control loops, in which autonomous controllers are distributed throughout the system, but there is no central operator supervisory control.
In this session you will learn:
Instruments
Transmitters
Control valves
Valve actuators
Valve positioner
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
In this session you will learn:
DCS Introduction
PLC
SCADA
General architecture of DCS
Process or application
Scan time
Input and Output requirement
Redundancy
RTU and LCU
PLC vs DCS
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
In this session you will learn:
History of Industrial Automation
Types of Industrial Automation
Process Industries
Overview of Continuous & Batch Process
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
This presentation is about the Distributed Control system in Power plants. DCS is a computerised control system for a process or plant usually with many control loops, in which autonomous controllers are distributed throughout the system, but there is no central operator supervisory control.
In this session you will learn:
Instruments
Transmitters
Control valves
Valve actuators
Valve positioner
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
In this session you will learn:
Instruments - Introduction
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
This code deals with the work satges required to commission automatic control systems in HVAC constuction industry. Represents standards for good practice in the form of recomantations and guidance. Is applicable for stand alone, BMS, DDC networked DDC and Integrated BMS systems.
Siemens ,
Catalog Thiết Bị Điện Siemens , Catalog Thiết Tự Động
Catalog Phụ Kiện Siemens , Catalog Phụ Kiện,
Catalog Siemens , Catalog,
https://www.dienhathe.com,
Chi tiết các sản phẩm khác của Siemens tại https://dienhathe.com
Xem thêm các Catalog khác của Siemens tại https://dienhathe.info
Để nhận báo giá sản phẩm Siemens vui lòng gọi: 0907.764.966
GridPoint\’s Energy Management System Intelligent ControllersMichele_Zambrano333
GridPoint offers a new breed of intelligent Energy Management System (EMS)controllers equipped with revenue-grade accurate metering devices to monitor electricity, natural gas, propane, or water consumption. Our patented system transcends traditional energy management systems while having the ability to submeter, interface with alarm security systems, provides information to assist in monitoring facility maintenance services, and much more. The EMS delivers rapid ROI for buildings of 1,500 square feet and above.
In this session you will learn:
Programmable Logic Controller(PLC)
Types of PLC’s
PLC architecture
Scan cycles
Scan patterns
PLC programming
Ladder diagram programming
Latch and Unlatch
DCS architecture
Vlt® hvac drives a complete range of advanced solutionsDanfoss India
Setting new standards, the modular VLT HVAC Drive integrates seamlessly with HVAC systems at the lowest cost of ownership in the market. Danfoss’ extensive experience in advanced variable frequency drive technology for HVAC applications has produced an unmatched product offering. The VLT HVAC Drive is suited for a range of needs, from simple follower operation to intelligent standalone control. From “drive only” to complete package solutions, the VLT HVAC Drive is so economical, flexible and user-friendly that it makes HVAC operation pure child’s play.Setting new standards, the modular VLT HVAC Drive integrates seamlessly with HVAC systems at the lowest cost of ownership in the market. Danfoss’ extensive experience in advanced variable frequency drive technology for HVAC applications has produced an unmatched product offering. The VLT HVAC Drive is suited for a range of needs, from simple follower operation to intelligent standalone control. From “drive only” to complete package solutions, the VLT HVAC Drive is so economical, flexible and user-friendly that it makes HVAC operation pure child’s play. For more info, visit http://www.danfoss.in/
In this session you will learn:
Basics of control systems
Open and Closed loop control systems
Elements of automatic control
Two position control system
Modes of automatic control
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
In this session you will learn:
Instruments - Introduction
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
This code deals with the work satges required to commission automatic control systems in HVAC constuction industry. Represents standards for good practice in the form of recomantations and guidance. Is applicable for stand alone, BMS, DDC networked DDC and Integrated BMS systems.
Siemens ,
Catalog Thiết Bị Điện Siemens , Catalog Thiết Tự Động
Catalog Phụ Kiện Siemens , Catalog Phụ Kiện,
Catalog Siemens , Catalog,
https://www.dienhathe.com,
Chi tiết các sản phẩm khác của Siemens tại https://dienhathe.com
Xem thêm các Catalog khác của Siemens tại https://dienhathe.info
Để nhận báo giá sản phẩm Siemens vui lòng gọi: 0907.764.966
GridPoint\’s Energy Management System Intelligent ControllersMichele_Zambrano333
GridPoint offers a new breed of intelligent Energy Management System (EMS)controllers equipped with revenue-grade accurate metering devices to monitor electricity, natural gas, propane, or water consumption. Our patented system transcends traditional energy management systems while having the ability to submeter, interface with alarm security systems, provides information to assist in monitoring facility maintenance services, and much more. The EMS delivers rapid ROI for buildings of 1,500 square feet and above.
In this session you will learn:
Programmable Logic Controller(PLC)
Types of PLC’s
PLC architecture
Scan cycles
Scan patterns
PLC programming
Ladder diagram programming
Latch and Unlatch
DCS architecture
Vlt® hvac drives a complete range of advanced solutionsDanfoss India
Setting new standards, the modular VLT HVAC Drive integrates seamlessly with HVAC systems at the lowest cost of ownership in the market. Danfoss’ extensive experience in advanced variable frequency drive technology for HVAC applications has produced an unmatched product offering. The VLT HVAC Drive is suited for a range of needs, from simple follower operation to intelligent standalone control. From “drive only” to complete package solutions, the VLT HVAC Drive is so economical, flexible and user-friendly that it makes HVAC operation pure child’s play.Setting new standards, the modular VLT HVAC Drive integrates seamlessly with HVAC systems at the lowest cost of ownership in the market. Danfoss’ extensive experience in advanced variable frequency drive technology for HVAC applications has produced an unmatched product offering. The VLT HVAC Drive is suited for a range of needs, from simple follower operation to intelligent standalone control. From “drive only” to complete package solutions, the VLT HVAC Drive is so economical, flexible and user-friendly that it makes HVAC operation pure child’s play. For more info, visit http://www.danfoss.in/
In this session you will learn:
Basics of control systems
Open and Closed loop control systems
Elements of automatic control
Two position control system
Modes of automatic control
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
ncreased automation can help the pharmaceutical industry make more efficient usage of energy and raw materials; improve safety in working conditions; enhance regulatory compliance, and improve both product quality and consistency.
Drilling Choke Control Panel - Worldwide Oilfield Machinewomgroup
WOM's Drilling Choke Control Panel is equipped with intelligence that allows mechanization of the well control manifolds. Its function in the system is to ensure pressure control during drilling operations.
Controls and Instrumentation, Control System Software - WOM Groupwomgroup
The WOM Control system software is equipped with intelligence that allows mechanization of the well control manifolds. WOM is providing custom configuration upon request.
Basics of Automation in Solid Dosage Form Production (Formulation & Developem...Vishal Shelke
Basics of Automation in Solid Dosage Form Production by Mr. Vishal Shelke(Formulation & Developement M.Pharm Sem II)
https://youtube.com/vishalshelke99
https://instagram.com/vishal_stagram
Sub :- Formulation & Developement
M.Pharm Sem II
Savitribai Phule Pune University
Session 03 - History of Automation and Process IntroductionVidyaIA
In this session you will learn:
History of Industrial Automation
Types of Industrial Automation
Process Industries
Overview of Continuous & Batch Process
In this session you will learn:
Self Introduction.
What does control system, industrial automation mean?
What is your expectation from this course?
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
The explosion hazard in urea process (1)Prem Baboo
In Urea plant passivation air is used in reactor, stripper and downstream of the all equipments. The reactor liner material used Titanium, Zirconium, SS 316L (urea grade), 2RE-69 and duplex material .except Titanium and Zirconium all stainless steel required more passivation air. In CO2 some quantity of Hydrogen is present about 0.14% to 0.2% . The passivation oxygen and Hydrogen makes explosive mixture. To avoid a fire or explosion in a process vessel is to introduce inert (noncombustible) gases in such a way that there is never a mixture with a combustible concentration in exit of MP vent. Mixtures of fuel, oxygen, and inert gases are not combustible over the entire range of composition. In CO2 stripping process the HP scrubber is the risky vessel and this vessel consisting blanketing sphere, Heat exchanger part and a scrubbing part. With help of triangular diagram that shows the shape of the combustible/noncombustible regions for a typical gaseous mixture of fuel, oxygen, and inert at specified temperature and pressure. Present article how to avoid that combustible rang and how to tackle that gases in CO2 & ammonia stripping process.
Over the past two decades, the ammonia and urea industry have witnessed spectacular metallurgical developments for process equipment. For example, stainless steels, modified with special materials, can improve high temperature creep rupture resistance. Using duplex stainless steels and modern corrosion abatement techniques are other methods that improve plant-operating performance.
Ever since the declaration of 100% neem coated urea by India Government, the number of neem trees is increasing continuously in India Neem coated urea requires neem oil, more urea more oil and trees also required more. When it comes to oil, neem plants are rather promising. Probably no other plant yields as many exploitable by-products and benefits. Earlier, 100% Neem Coated Urea was made mandatory in 2015.
Prills /granular urea are not only costly for the producer but may be harmful to humans and the environment. Furthermore, nano Urea may also be used for enhancing abiotic stress tolerance. Nano-Urea prevents environmental pollution and improves physiological traits of wheat grown under drought stress conditions. The nano urea consist of higher surface area because lesser in size of the nano particle and have high reactivity, solubility in water. Nano Urea are the important tools in agriculture to improve crop efficiency, yield and quality parameters with increase nutrient use efficiency, reduce wastage of fertilizers and cost of cultivation. Nano-urea is very effective for precise nutrient management in precision agriculture with matching the crop growth stage for nutrient and may provide nutrient throughout the crop growth period. Nano-Urea increase crop growth up to optimum concentrations further increase in concentration may inhibit the crop growth due to the toxicity of nutrient. Nano-Urea provide more surface area for different metabolic reactions in the plant which increase rate of photosynthesis and produce more dry matter and yield of the crop. It is also prevent plant from different biotic and abiotic stress.
Installation of S-50 ammonia synthesis converter along with waste heat boiler in downstream of existing S-200 ammonia synthesis converter is one of the major schemes of Energy Saving Project of Ammonia plant. The energy saving reported 0.18 G.Cal/T of Ammonia. Several ammonia plants have installed an additional ammonia synthesis converter in combination with a HP steam waste heat boiler, downstream of the existing ammonia converter. The result is increased conversion per pass, reduced compression requirements due to the smaller recycle gas stream, and improved waste heat recovery. Among the methodologies aimed at finding energy saving opportunities, pinch analysis linked to power and steam modeling has proved to be a powerful way for determining projects to improve the overall energy efficiency of industrial sites. This procedure has been applied successfully in many industrial facilities, allowing optimal energy recovery in the process and hence reduction of fuel consumption.
Super conversion in urea reactors with super cup high efficiency traysPrem Baboo
In Urea Conversion gas/liquid mixing in urea reactor with application of high efficiency trays homogeneous and heterogeneous phases’ iquilibria and kinetics is very important. The efficiency of Urea Reactors can be improved by the application of the latest generation of internals .Generally Fluid dynamics phenomenon are created by the concurrent gas liquid flow through the simple perforated trays which generates irregular bubbles now this problem has been solved by new generation high efficiency device super cup patented by M/S. Saipem. Present article intended how conversion increases by super cup with geometry of the shape of super cup etc. The increase in the efficiency has permitted direct benefits to the overall production and energy of the units, thus allowing lower energy consumption and a reduced environmental impact emission of greenhouse gases. The Super Cups can be applied to design a new generation of urea reactors as well as to improve the performance of existing equipment in a revamp design.
In the plant, ammonia is produced from synthesis gas containing hydrogen and nitrogen in the ratio of approximately 3:1. Besides these components, the synthesis gas contains inert gases such as argon and methane to a limited extent. The source of H2 is demineralized water and the hydrocarbons in the natural gas. The source of N2 is the atmospheric air. The source of CO2 is the hydrocarbons in the natural gas feed. Product ammonia and CO2 is sent to urea plant. The present article intended the description of ammonia plant for natural gas based plants and the possible material balance of some section.
Sweet and sour experience of commissioning 1Prem Baboo
The paper describes a successful of plant start-up despite the pandemic difficulties and introduces a set of first considerations about the possible future application of available digital technologies for remote and distributed control system from central control room commissioning of complex Dangote Fertilizer Plants. The numbers of problem were faced during commissioning stage ultimately the 17th march 2021 was the historical date for achieved plant production of line-1 plant .The major problem was pandemic due to which scarcity of staff availability. However numbers of problems faced in Ammonia and urea plants. About 4 time’s unsuccessful attempt were done and finally we got historical success. In this paper we described the failure attempt and types of problems faced in ammonia and urea plants and each time problems were differ from previous.
How to improve safety and reliability of the high pressure section of urea pl...Prem Baboo
This paper elaborates the most critical safety hazards: Ruptures and toxic ammonia leaks. The paper also provides the Top 10 prevention and mitigation measures. To minimize / avoid that incidents do repeat, we recommend to make use of the Center for Chemical Process Safety: Risk Based Process Safety Management approach. Pay proper attention to avoid ruptures, to handle leaks and to apply the right and state-of-the-art leak detection systems.
Experience of material in fertilizers industriesPrem Baboo
Materials plays very important role in any industry. Selection of material is vital at design stage itself ,Wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In the latest plants specialty 2 RE-69 materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study Material in urea plant in different vessels and equipment design. In Primary reformer numbers of materials are modified such as micro alloy are also used in tubes.
This book covers design of high Pressure equipment and developments, Process flow diagram of different section of Ammonia, Urea and others fertilizers .Fundamentals of ammonia urea plant trouble shooting risk assessment corrosion in different vessels and remedies. This book is useful for Engineers and Sr. Managers for plant commissioning and trouble shooting and Engineering Students. This book contains about 51 tables and 144 useful diagram and chart graphics etc. Detail description of ammonia/CO2 stripping process and new developments. Design Parameters of High pressure vessel and comparison. Study of corrosion for various equipments and control. How to control corrosion by changing of equipments material.
High pressure vessel_leakage_in_urea_plants (1)Prem Baboo
In urea plant ammonium carbamate solution is very corrosive; all metals have corrosion problems with ammonium carbamate and the corrosion problems increase with temperature, a ten degree Celsius rise in temperature doubles the corrosion rate to the point where the duplex steel is no longer acceptable. The material plays a very important role in Urea plants. The space between the reactor liner and the shell is most often empty and employs various methods of detecting a leak ranging from conductivity measurements. Vacuum leak detection system, pressure leak detection system etc. Titanium, SS316L (urea grade), 2 RE-69 etc.) Over the years that can resist ammonium carbamate corrosion. Materials plays very important role in any industry. Selection of material is vital at design stage itself ,Wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In the latest plants specialty duplex materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Reactor, Stripper, Carbamate condenser etc. How to detect leakage and troubleshooting during detection and attending the leakages.
High pressure vessel leakage in urea plantsPrem Baboo
In urea plant ammonium carbamate solution is very corrosive; all metals have corrosion problems with ammonium carbamate and the corrosion problems increase with temperature, a ten degree Celsius rise in temperature doubles the corrosion rate to the point where the duplex steel is no longer acceptable. The material plays a very important role in Urea plants. The space between the reactor liner and the shell is most often empty and employs various methods of detecting a leak ranging from conductivity measurements. Vacuum leak detection system, pressure leak detection system etc. Titanium, SS316L (urea grade), 2 RE-69 etc.) Over the years that can resist ammonium carbamate corrosion. Materials plays very important role in any industry. Selection of material is vital at design stage itself ,Wrong selection of material may lead to catastrophic failures and outage of plants & even loss of Human lives, Right selection of material leads to long life of plant. In the latest plants specialty duplex materials are used for liner. The actual reactor has been constructed using a variety of materials, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Zirconium, Vessel inside a protective liner. This paper intended study of number of leakage in the HP loop vessels, e.g. Reactor, Stripper, Carbamate condenser etc. How to detect leakage and troubleshooting during detection and attending the leakages.
If the material of liner changed with 2RE 69 or Duplex material instead of SS316(urea grade), then passivation air can be reduced, resulting the energy saving because the inerts vented from M.P section and loss of ammonia and problem of pollution. To enhance capacity and energy of the existing plant the internals like vortex mixture and HET may be changed the capacity may increase up to 10-15%.HET, you can changed with super cup.The CO2 and feed top of the vortex mixture nozzle and Ammonia plus carbamate feed from side of the vortex mixture. In the mixing area the initial dispersion of gas and formation of liquid – gas mixture are performed.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...Amil Baba Dawood bangali
Contact with Dawood Bhai Just call on +92322-6382012 and we'll help you. We'll solve all your problems within 12 to 24 hours and with 101% guarantee and with astrology systematic. If you want to take any personal or professional advice then also you can call us on +92322-6382012 , ONLINE LOVE PROBLEM & Other all types of Daily Life Problem's.Then CALL or WHATSAPP us on +92322-6382012 and Get all these problems solutions here by Amil Baba DAWOOD BANGALI
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Overview of the fundamental roles in Hydropower generation and the components involved in wider Electrical Engineering.
This paper presents the design and construction of hydroelectric dams from the hydrologist’s survey of the valley before construction, all aspects and involved disciplines, fluid dynamics, structural engineering, generation and mains frequency regulation to the very transmission of power through the network in the United Kingdom.
Author: Robbie Edward Sayers
Collaborators and co editors: Charlie Sims and Connor Healey.
(C) 2024 Robbie E. Sayers
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
3. Introduction
• National Fertilizers Limited is a chemical process
industry. Any process industry is a combination of
all Technical and Non-Technical disciplines. All
disciplines/ departments functions are interlinked
to each other.
• Instrumentation in process industry plays a very
important role. In the very beginning we need to
measure all inputs and outputs at a pre-determined
level. For measuring different process parameters,
we need particular type of instrumentation. The
combination of all type of measurements, its
transmission for monitoring, recording and
controlling at desired level comes under process
Instrumentation.
4. Following are the basic needs to know by every process
engineer/operator to start/run any chemical process, plant or
section-
1. Process parameters like Pressure, Level, Flow,
2. Temperature, Chemical composition, Vibration etc.
3. Transmission of these parameter to Controlling
device in Control Room
4. Control action at pre-determined level
5. Maintaining Safety of Process for the safety of Man,
Machine & Material
6. Operation of the all sections at optimized level to
achieve maximum capacity utilization within minimum
energy investment
Let us start with an outline and overview of basic concept of
Instrumentation in process industry.
5.
6. Control Loops
With the basic concept of process
control overview, we further derive
from it to following control loops-
Single variable Control Loop
Multi-variable Control Loop
These control loops are being given here
for your understanding only.
7. Single Variable Control Loops
- Pressure Control
- Temperature Control
- Level Control
- Flow Control
16. MAINTENANCE PRACTICES
• DAY TO DAY MAINTENANCE
• PREVENTIVE MAINTENANCE
• SHUTDOWN MAINTENANCE
• BREAKDOWN MAINTENANCE
• SPARES MANAGEMENT
• UP-GRADATION OF SYSTEMS
17. • During normal operation of the plant,
there may arise some doubts on the
performance of some instruments. The
same has to be checked, confirmed and
rectified.
• There are some routine checks which are
to be done and consumables are to be
provided.
DAY TO DAY MAINTENANCE
18. Procedures followed
• The normal practice is that the operation
group will be raising an MWO for any type of
maintenance job which has to be carried out.
• Prepare for the job, refer related documents
to ensure safe operation
• Clearance has to be taken and proper
isolation / bypassing is required
• Job to be carried out
• Clearance to be given
• Ensuring of results
19. PREVENTIVE MAINTENANCE
• Preventive maintenance is the one done
to prevent the instruments from
reaching a breakdown. Some of them are
– Daily Check Lists
– Weekly Schedules
– Monthly Schedules
– Quarterly Schedules
– Half yearly Schedules
– Yearly Schedules
20. SHUTDOWN MAINTENANCE
• We normally go for annual maintenance
shutdown of the plant every year. All the
preventive maintenance jobs which
cannot be taken up during running of the
plant is taken up during shutdown.
21. BREAKDOWN MAINTENANCE
• During running of the plant some times we
face serious troubles with the equipments
which may require a complete stopping of
the system. This is normally termed as
break down maintenance
22. SPARES MANAGEMENT
• Normally in new projects we keep provision for
sufficient spares for maintaining all equipments
and Control system for minimum 2-years
operation. After this we review the requirement of
spares and keep provision for procuring the spares
in Revenue budgets. The Revenue budget is being
approved in advance so that spares procurement
action can be taken to meet any emergency and for
repair & maintenance of defective instruments,
minimum spares shall be kept always in spares
inventory. Procurement action is being initiated as
per requirement in due time every year.
23. UP-GRADATION OF SYSTEMS
• In Instrumentation field, a lot of development is being done.
The old process instrumentation was pneumatic type and
control system was Single loop controller type.
• Interlock systems which is also known as Emergency
Shutdown system were based on Electro-mechanical relay
type system.
• But now a days there is total change in Instrumentation
philosophy. Total instrumentation is based on Electronic
systems i.e. right from Transducer/transmission system to
DCS, PLC based systems. So to make maximum use of latest
instrumentation we always go for Up-gradation.
• To take maximum benefits from these developments, we
always go for latest features and diagnostics in our
Instrumentation systems.
24. - Keeping in view of latest instrumentation we have
taken total Electronic control system for our Line-II
Expansion plants I.e.the field instrumentation is total
electronic smart transmitters, the control system is
Distributed type Control system (DCS) and Interlock
systems are PLC based failsafe, redundant and available
system.
- Similarly as best maintenance practices we have gone
for up-gradation of Instrumentation system of our Line-
I Plants. We have implemented many up-gradation
schemes of Instrumentation systems in last 2-years and
it is planned to upgrade other obsolete systems.
25. UPGRADATION SCHEMES
IMPLEMENTED
• ‘Yokogawa’ make Centum CS-3000 Distributed Control
System in Ammonia & Urea Line-I Plants along with
Compressors Instrumentation
• ‘Bently-Naveda’ make 3500-series with System-1
Diagnostic Vibration, Axial Thrust & Speed Monitoring
and protection system for Steam Turbine driven High
Speed Centrifugal Compressors
• ‘GE-Fanuc’ make 90-70 series Programmable Logic
Controllers of D.M.Plant-I, Condensate Polishing Unit &
Old Ammonia Storage Plant
In brief, it is described in next slide that how the
scheme of up-gradation is being implemented.
26. UPGRADED SYSTEMS
DISTRIBUTED CONTROL SYSTEM (DCS).
‘Foxboro’ make micro processor based
Single Loop Programmable Controllers
of Ammonia & Urea Plants Line-I with
Latest ‘Yokogawa’ make Centum CS-3000
Distributed Control System along with
split and pneumatic control systems of
High Speed Centrifugal Steam Turbine
Compressors to make it centralize.
28. Urea 11
Compresso
r
Urea main
plant11
Urea 21
compressor
Urea main
plant21
Urea 11 P1
& P2
Urea 21 P1
& P2
550 MR
450 MR
550 MR
450 MR
Separate Single loop
Based control
Separate pneumatic
control
Separate pneumatic
control
Old Control Philosophy
of Urea Plant
29. LIMITATIONS OF THE OLD
CONTROL SYSTEM
• The life expectancy is not ensured due to
continuous use for last 18 years.
• Un-predictive failure due to ageing
problem.
• Non-Working Data Acquisition System.
• Non Reliable Recording with high
maintenance cost.
• Optimization through cascaded loops not
possible.
30. • Plant disturbance in case of single point
failure- non redundant system.
• Non Centralized Controls of pilot plants
& Compressors.
• Compressor pneumatic controllers with
slow response time leads to inefficient
operation of compressors.
31. SUPERIORITY OF LATEST SYSTEMS
• All the limitations listed previously will be wiped
out
• In addition, the latest control system is
- certified and ensured for reliability
- Availability
- Redundancy
• Minimum Down time on account of Control
System failure
• user friendly
• on line modeling for process graphics
• The System being offered is certified spare and
service support for next 15-Years
32. • historical data.
• alarm management.
• self diagnosis.
• auto tuning.
• on line maintenance.
• These features are directly resulting to
Energy saving with optimum manpower.
• Latest control system is having open-end
connectivity and platform for other
system like advance control system,
Mass spectrometer, Management
information system etc.
33. NEW INTEGRATED CONTROL SYSTEM FOR
AMMONIA PLANT
Amm
Comp
Vibr
Amm
Comp
ESD
Amm
main
ESD ASSH
PLC
IAC-III
PLC
Comprssr
DCS
CPU
plant PLC
Ammonia
Storage
PLC
Amm
Main DCS
35. Compressor control room
Six operator stations Historian
Controller1
Remote Stns for S/Ic
& P/Ic
Engr station
Controller2
Controller3
600Mr
AMMONIA-I CONTROL SYSTEM
36. 11- Compressor
control room
Six operator stations Historian
Controller11 sec
Remote Stns for S/Ic
& P/Ic
Engr station
Controller21 sec
600Mr
UREA-I CONTROL SYSTEM
21- Compressor
control room
300Mr
37. UPGRADATION SCHEMES UNDER
IMPLEMETATION
• Up-gradation of Solid state & Electro-mechanical relay
based Emergency Shutdown Systems of Ammonia & Urea
Line-I Plants to Fail-safe PLC based ESD systems along
with Line-I Compressors ESD systems
• Up-gradation of Gas Turbine Generator-1/2 Control
Systems (GE Mark-IV to GE Mark-VI)
• Up-gradation of Control Systems of Heat Recovery Units
(HRU-1/2/3) in Captive Power Plant
• Up-gradation of Burner Management system of Heat
Recovery Units (HRU-1/2/3) in Captive Power Plant
• Up-gradation of FIRE ALARM SYSTEM of the Complex
38. PROPOSED UP-GRADATION
SCHEMES
• We are also planning to up-grade the
instrumentation of Material Handling and Urea
Bagging Plant
• Even the latest instrumentation of Line-II plants
i.e.DCS & ESD, Compressors Control system
shall be due for up-gradation between year 2010
to 2015
39. Major projects of other units
under implementation
• In our sister units at Bhatinda, Panipat &
Nangal we are having Fuel oil based
fertilizer plants which are still having old
instrumentation. These plants are being
switched over to NG/LNG based plant and
the all instrumentation shall be up-graded
to latest electronic, DCS, PLC based
instrumentation. There we shall be having
more advanced instrumentation.
40.
41.
42. Conclusion
• In brief I just conclude here that the NFL corporation as a
whole is becoming a Powerful and Giant Fertilizer
industry which is having Latest technology in every field
and Instrumentation in particular.
• We are having the richest culture of the best maintenance
practices.
• Our Management is also considered to be progressive and
liberal to adopt latest energy efficient schemes.
• We all shall be having very good opportunities to work in
latest technological environment & full utilization of your
latest technical skills.
• All of you are having very bright future and full
satisfaction to work with us.