internship report ffc
DESCRIPTION
Report on Instrumentation and ControlTRANSCRIPT
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
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TECHNOLOGY
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
Internship
Report MUHAMMAD HASSAN Seat No: D_10_ES_1050
Final Year ( Electronics Engineering)
Dawood University of Engineering & Technology
Internship Duration ( 14 February 2013 to 27 March 2013)
Submitted toSubmitted toSubmitted toSubmitted to: Technical Training Center : Technical Training Center : Technical Training Center : Technical Training Center
(TTC)(TTC)(TTC)(TTC) Mirpur MathailoMirpur MathailoMirpur MathailoMirpur Mathailo
DAWOOD UNIVERSITY OF ENGINEERING
ECHNOLOGY KARACHI
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Engineering & Technology
Internship
Dawood University of Engineering & Technology
Internship Duration ( 14 February 2013 to 27 March 2013)
: Technical Training Center : Technical Training Center : Technical Training Center : Technical Training Center
NGINEERING &
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
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AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
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Acknowledgement
Ultimately, I have completed my report with all the hard work which I have been doing for the last
six weeks. First and foremost, thank you Almighty Allah for
report. Without Your Willingness I would not have been able to complete any work.
I would never forget to mention the names, which played a great role in the successful completion
of this project, and helped me, whe
books for assistance and gave me ideas on different thoughts.
I would like to take this opportunity to express my deepest gratitude to
Mr.Anjum Beig who have given me their constant
patience in monitoring my progress.
I am also grateful to my coordinators
who were a great help for me by monitoring my learning and helping me understand the pro
Finally, I would like to extend my sincere gratitude to
Mr. Aftab Ahmed Mazari for his helpful nature and valuable guidance provided time and again.
Without your willingness, suggestions and insights, this project would not h
I am very much thankful to FFC which provided
with industrial practical knowledge in a 6 weeks internship program.
about all the kind panel boardmen and opera
Control Room and on the plant site, respectively.
At last, I can say that my work was just an effort but wouldn’t have been an effort discernibly
without the support of all acknowledged people.
PREFACE
The purpose of this report is to explain what I did and learned during my internship period with the Fauji
Fertilizer Company Mirpur Mathelo. The report is also a requirement for the partial fulfillment of FFC
MM internship program. The report focuses pri
environment, successes and shortcomings that the intern did encounter when handling various tasks
assigned to him by the coordinator .Because the various parts of the report reflect the intern’s
shortcomings, successes ,observations and comments, it would be imperative that the
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
Acknowledgement
Ultimately, I have completed my report with all the hard work which I have been doing for the last
six weeks. First and foremost, thank you Almighty Allah for giving me the strength to finish up this
report. Without Your Willingness I would not have been able to complete any work.
I would never forget to mention the names, which played a great role in the successful completion
of this project, and helped me, whenever I required any guidance from them, provided me with
books for assistance and gave me ideas on different thoughts.
I would like to take this opportunity to express my deepest gratitude to Mr.Arif JAMAL
have given me their constant encouragement constructive advises and their
patience in monitoring my progress.
I am also grateful to my coordinators Mr. Muhammad Fahad Sayeed & Mr. Umair Akbar Khan
who were a great help for me by monitoring my learning and helping me understand the pro
numerous interactions.
Finally, I would like to extend my sincere gratitude to
for his helpful nature and valuable guidance provided time and again.
Without your willingness, suggestions and insights, this project would not have been completed.
I am very much thankful to FFC which provided me a chance to integrate my classroom knowledge
with industrial practical knowledge in a 6 weeks internship program. I would not forget to mention
about all the kind panel boardmen and operators who had been a very useful guide in the Central
Control Room and on the plant site, respectively.
At last, I can say that my work was just an effort but wouldn’t have been an effort discernibly
without the support of all acknowledged people.
The purpose of this report is to explain what I did and learned during my internship period with the Fauji
Fertilizer Company Mirpur Mathelo. The report is also a requirement for the partial fulfillment of FFC
MM internship program. The report focuses primarily on the assignments handled, working
environment, successes and shortcomings that the intern did encounter when handling various tasks
assigned to him by the coordinator .Because the various parts of the report reflect the intern’s
esses ,observations and comments, it would be imperative that the
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
Ultimately, I have completed my report with all the hard work which I have been doing for the last
giving me the strength to finish up this
report. Without Your Willingness I would not have been able to complete any work.
I would never forget to mention the names, which played a great role in the successful completion
never I required any guidance from them, provided me with
Mr.Arif JAMAL &
constructive advises and their
Umair Akbar Khan
who were a great help for me by monitoring my learning and helping me understand the process in
for his helpful nature and valuable guidance provided time and again.
ave been completed.
to integrate my classroom knowledge
I would not forget to mention
tors who had been a very useful guide in the Central
At last, I can say that my work was just an effort but wouldn’t have been an effort discernibly
The purpose of this report is to explain what I did and learned during my internship period with the Fauji
Fertilizer Company Mirpur Mathelo. The report is also a requirement for the partial fulfillment of FFC
marily on the assignments handled, working
environment, successes and shortcomings that the intern did encounter when handling various tasks
assigned to him by the coordinator .Because the various parts of the report reflect the intern’s
esses ,observations and comments, it would be imperative that the
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
P a g e | 3
recommendations are also given. Therefore the report gives a number of comments and
recommendations on the internship program. It is hoped that this report would serve as a cardinal
vehicle to the improvement of the internship program.
INTRODUCTION TO FFC
For an agricultural country like Pakistan, Urea carries a paramount importance. Keeping this in view
Fertilizer Company (FFC) was incorporated in 1978 as a private limited company with a vision to acquire
self - sufficiency in fertilizer production in the country. This was a joint venture between
(a leading charitable trust in Pakistan
is the leading urea producing compan
commenced commercial production of urea in 1982 with annual capacity of 570,000 metric tons.
plant of the FFC is located at GOTH MACHI in SADIQABAD.
After the excellent performance and the successful achievements of
second plant at the same place in the year 1993. First pla
plant is called the EXPANSION UNIT.
635,000 metric tons of urea.
In the year 2002, FFC acquired ex
Mirpur Mathelo, District Ghottki from National Fertilizer Corporation
process of the Government of Pakistan. It has annual production capacity of 574,000 metric tons
urea which has been revamped to 718,000 metr
SAFETY TRAINING
FFC produces about 60 % of market’s urea producti
only result in decrease of company production and sale but
market. This may affect the country’s agriculture growth
followed by price hiking.
FFC ensures safe work environment by providing safety training
all personnel on plant. As per the company pol
personnel on plant receive safety training prior taking
responsibilities
The training comprised of:
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
recommendations are also given. Therefore the report gives a number of comments and
recommendations on the internship program. It is hoped that this report would serve as a cardinal
to the improvement of the internship program.
INTRODUCTION TO FFC
For an agricultural country like Pakistan, Urea carries a paramount importance. Keeping this in view
was incorporated in 1978 as a private limited company with a vision to acquire
sufficiency in fertilizer production in the country. This was a joint venture between
Pakistan) and Haldor Topsoe A/S of Denmark.Fauji Fertilizer Company Ltd
is the leading urea producing company in the Pakistan, with brand name “SONA UREA”
commenced commercial production of urea in 1982 with annual capacity of 570,000 metric tons.
TH MACHI in SADIQABAD.
After the excellent performance and the successful achievements of the first plant, FFC installed
second plant at the same place in the year 1993. First plant is called the BASE UNIT and
UNIT. This enhanced Production capacity with annual capacity of
In the year 2002, FFC acquired ex Pak Saudi Fertilizers Limited (PSFL) Urea Plant situated at
tki from National Fertilizer Corporation (NFC) through privatization
process of the Government of Pakistan. It has annual production capacity of 574,000 metric tons
urea which has been revamped to 718,000 metric tons urea in 200
SAFETY TRAINING
FFC produces about 60 % of market’s urea production. Not preparing for plant safety may
only result in decrease of company production and sale but also in shortage of fertilizer in
market. This may affect the country’s agriculture growth and thus shortage of food
FFC ensures safe work environment by providing safety training to
the company policy all news
e safety training prior taking charge of their
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
recommendations are also given. Therefore the report gives a number of comments and
recommendations on the internship program. It is hoped that this report would serve as a cardinal
For an agricultural country like Pakistan, Urea carries a paramount importance. Keeping this in view Fauji
was incorporated in 1978 as a private limited company with a vision to acquire
sufficiency in fertilizer production in the country. This was a joint venture between Fauji Foundation
.Fauji Fertilizer Company Ltd
“SONA UREA”.FFC
commenced commercial production of urea in 1982 with annual capacity of 570,000 metric tons. First
the first plant, FFC installed the
nt is called the BASE UNIT and the second
This enhanced Production capacity with annual capacity of
Urea Plant situated at
(NFC) through privatization
process of the Government of Pakistan. It has annual production capacity of 574,000 metric tons
or plant safety may not
fertilizer in
and thus shortage of food for public
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� Importance of Safety at Plant
� Use of Personal Protective Equipment
� Use of Fire Extinguishers
� Ammonia Disaster
PERSONAL PROTECTIVE EQUIPMENT
Personal protective equipment (P.P.E) must not be
regarded as a substitute for safe working practices. Minimum
personal protective equipment is as follow.
• Safety Helmet
• Safety boot/shoes
• Escape respirator (Half Face Mask)
• Ear protection (designated areas)
• Safety Spectacles.
The correct use, care and regular cleaning of the above equipment is the
responsibility of each individua
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
afety at Plant
Use of Personal Protective Equipment
Use of Fire Extinguishers
PERSONAL PROTECTIVE EQUIPMENT
.P.E) must not be
substitute for safe working practices. Minimum
personal protective equipment is as follow.
Escape respirator (Half Face Mask)
Ear protection (designated areas)
“Your life is precious”
The correct use, care and regular cleaning of the above equipment is the
responsibility of each individual.
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
“Your life is precious”
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INSTUMENTATION & CONTROL ORIENTATION
TOPIC
� Introduction to instrumentation & control.
� Sample Control Loop.
� Introduction to Documentation,
� Types of instruments.
� Introduction to Intrinsic Safety.
CO-
ENGR.ENGR.ENGR.ENGR. MUHAMMAD FAHAD SAEMUHAMMAD FAHAD SAEMUHAMMAD FAHAD SAEMUHAMMAD FAHAD SAE
INSTRUMENTATION
Instrumentation is the art of measuring the value of some plant parameter
temperature to name a few and supplying a signal that is proportional to the measured
output signals are standard signal and can then be processed by other equipment to provide
alarms or automatic control. There are a number of standard
plant are the 4-20 mAmps Electronic
CONTROL TECHNOLOGY Control of the processes in the plant is an essential part of the plant operation. There must be enough
water in the boilers to act as a heat sink for the reactor but there must not be water flowing
the boilers towards the turbine. The level of the boiler must be kept within a certain range. The heat
transport pressure is another critical parameter that must be controlled. If it is too high the system will
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
INSTUMENTATION & CONTROL ORIENTATION
Introduction to instrumentation & control.
ple Control Loop.
Introduction to Documentation, Drawings, P & I’s.
Types of instruments.
Introduction to Intrinsic Safety.
-ORDINATOR
MUHAMMAD FAHAD SAEMUHAMMAD FAHAD SAEMUHAMMAD FAHAD SAEMUHAMMAD FAHAD SAEEDEDEDED
Instrumentation is the art of measuring the value of some plant parameter Pressure, flow, level or
temperature to name a few and supplying a signal that is proportional to the measured parameter. The
standard signal and can then be processed by other equipment to provide
alarms or automatic control. There are a number of standard signals; however, those most common in the
Electronic signal and 3-15 psi pneumatic signal.
Control of the processes in the plant is an essential part of the plant operation. There must be enough
water in the boilers to act as a heat sink for the reactor but there must not be water flowing
the boilers towards the turbine. The level of the boiler must be kept within a certain range. The heat
transport pressure is another critical parameter that must be controlled. If it is too high the system will
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
INSTUMENTATION & CONTROL ORIENTATION
EDEDEDED
, flow, level or
parameter. The
standard signal and can then be processed by other equipment to provide indication,
signals; however, those most common in the
Control of the processes in the plant is an essential part of the plant operation. There must be enough
water in the boilers to act as a heat sink for the reactor but there must not be water flowing out the top of
the boilers towards the turbine. The level of the boiler must be kept within a certain range. The heat
transport pressure is another critical parameter that must be controlled. If it is too high the system will
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
P a g e | 6
burst, if it is too low the water will boil. Either condition impairs the ability of the heat transport system to
cool the fuel.
The usual objective of control theory is to calculate solutions for the proper corrective action from the
controller that result in system stability, that
it.
The first automatic feedback controller used in an industrial process was James Watt’s flyball governor,
developed in 1769 for controlling the speed of a steam engine.
CONTROL LOOP A control system consists of subsystems
� A simple control loop
A simple closed loop control requires feedback; information sent back direct from the
process or system to a controller which manipulates it keeping set point in view and
produces the corresponding output to control f inal control element.
Feedback control is a fundamental fact of modern industry and society. Driving an automobile is a
pleasant task when the auto responds rapidly to the driver’s commands. Many cars have power steering
and brakes, which utilize hydraulic amplifiers for amplification of the fo
wheel.
A simple block diagram of an automobile steering control system is shown,
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
ater will boil. Either condition impairs the ability of the heat transport system to
The usual objective of control theory is to calculate solutions for the proper corrective action from the
controller that result in system stability, that is, the system will hold the set point and not oscillate around
The first automatic feedback controller used in an industrial process was James Watt’s flyball governor,
the speed of a steam engine.
of subsystems and plants(processes) assembled to control output of process.
A simple control loop
A simple closed loop control requires feedback; information sent back direct from the
process or system to a controller which manipulates it keeping set point in view and
the corresponding output to control f inal control element.
is a fundamental fact of modern industry and society. Driving an automobile is a
pleasant task when the auto responds rapidly to the driver’s commands. Many cars have power steering
and brakes, which utilize hydraulic amplifiers for amplification of the force to the brakes or the steering
A simple block diagram of an automobile steering control system is shown,
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
ater will boil. Either condition impairs the ability of the heat transport system to
The usual objective of control theory is to calculate solutions for the proper corrective action from the
is, the system will hold the set point and not oscillate around
The first automatic feedback controller used in an industrial process was James Watt’s flyball governor,
and plants(processes) assembled to control output of process.
A simple closed loop control requires feedback; information sent back direct from the
process or system to a controller which manipulates it keeping set point in view and
is a fundamental fact of modern industry and society. Driving an automobile is a
pleasant task when the auto responds rapidly to the driver’s commands. Many cars have power steering
rce to the brakes or the steering
A simple block diagram of an automobile steering control system is shown,
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The desired course is compared with a measurement of the actual course in order to generate a measure
of the error .This measurement is obtained by visual and tactile(body movement) feedback. There is an
additional feedback from the feel of the steering wheel by
the hand (sensor)
A basic, manually controlled closed-
regulating the level of fluid in a tank is shown in Figure
.The input is a reference level of fluid that the operator is
instructed to maintain.(This reference is memorized by the
operator.) The power amplifier is the operator, and the
sensor is visual .The operator compares the actual level
with the desired level and opens or closes the valve
(actuator), adjusting the fluid flow out,
desired level.
Introduction to Documentation, Drawings,
P & I's: Documentation is done to keep the recordinstruments & Chemical being used in plant. All the departments in the industry have their own literature about their concern things and they go through the literature of all the things that they need to use, to repair or install. Here in instrument department all the instruments have their records collected in files with their vendor's name and specifications. In industry we keep the records of following:
� History cards (Switches, Transmitters, Valves, P SV's).� Calibration cards. � Warehouse Documents which includes MOR (Manual Order
Request), MRF (Material Reservation Form), MIV (Material IssueVoucher), MWR (Maintenance Work Request).
� Set point changing form � Cabinet daily monitoring form� Power supply load checking� DCS vibration probe history etc.
In industries there are some field places whethis purposed designers make drawings on big Sheets that shows all the process and instruments involve in those processes. A line diagram that helps us to understand the whole process including funeach instrument is called Process & Instrument diagrams.
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Dawood University of Engineering & Technology
The desired course is compared with a measurement of the actual course in order to generate a measure
obtained by visual and tactile(body movement) feedback. There is an
additional feedback from the feel of the steering wheel by
-loop system for
regulating the level of fluid in a tank is shown in Figure
.The input is a reference level of fluid that the operator is
instructed to maintain.(This reference is memorized by the
operator.) The power amplifier is the operator, and the
sensor is visual .The operator compares the actual level
and opens or closes the valve
(actuator), adjusting the fluid flow out, to maintain the
Introduction to Documentation, Drawings,
Documentation is done to keep the record of all the things,
plant. All the departments in the industry have their own literature about their concern things and they go through the literature of all the things that they need to use, to repair or install. Here in instrument department all the instruments have
ecords collected in files with their vendor's name and specifications.
In industry we keep the records of following: History cards (Switches, Transmitters, Valves, P SV's).
Warehouse Documents which includes MOR (Manual Order MRF (Material Reservation Form), MIV (Material Issue MWR (Maintenance Work Request).
Cabinet daily monitoring form Power supply load checking DCS vibration probe history etc.
In industries there are some field places where the loops of a system is long Enough to understandesigners make drawings on big Sheets that shows all the process and instruments involve
in those processes. A line diagram that helps us to understand the whole process including funcalled Process & Instrument diagrams.
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
The desired course is compared with a measurement of the actual course in order to generate a measure
obtained by visual and tactile(body movement) feedback. There is an
industry have their own literature about their concern things and they go through the literature of all the things that they need to use, to repair or install. Here in instrument department all the instruments have
re the loops of a system is long Enough to understand .For esigners make drawings on big Sheets that shows all the process and instruments involve
in those processes. A line diagram that helps us to understand the whole process including function of
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
P a g e | 8
TYPES OF INSTRUMENTS
Here in FFC MM we use several types of instruments that have their specific function and use according to the requirements .The major instruments which weTransmitters, Thermocouples, E /P, Speed Probes, Vibration Probes, Pressure gauges, Controllers, Recorders, Indicators, Switches, Temperature Indicators local, Petitioners’, Pressure switches Analyzers, SOV's, Tachometers.
FIELD INSTRUMENT
TOPIC
� Level, Flow, Pressure &Temperature measuring techniques
instrument being used.
� Switches (Level, Flow,
� Float type level indicator
� Transmitters & I/P’s
� SOV’s
� Analyzers
CO-
EEEENGR.UMAIR AKBARNGR.UMAIR AKBARNGR.UMAIR AKBARNGR.UMAIR AKBAR
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
TYPES OF INSTRUMENTS
Here in FFC MM we use several types of instruments that have their specific function and use according to the requirements .The major instruments which we use here are: Transmitters, Thermocouples, E /P, Speed Probes, Vibration Probes, Pressure gauges, Controllers, Recorders, Indicators, Switches, Temperature Indicators local, Petitioners’, Pressure switches Analyzers,
FIELD INSTRUMENTATION
Pressure &Temperature measuring techniques
instrument being used.
Flow, Temperature & Pressure)
Float type level indicator
Transmitters & I/P’s
-ORDINATOR
NGR.UMAIR AKBARNGR.UMAIR AKBARNGR.UMAIR AKBARNGR.UMAIR AKBAR
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
Here in FFC MM we use several types of instruments that have their specific function and use according
Transmitters, Thermocouples, E /P, Speed Probes, Vibration Probes, Pressure gauges, Controllers, Recorders, Indicators, Switches, Temperature Indicators local, Petitioners’, Pressure switches Analyzers,
Pressure &Temperature measuring techniques &
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PRESSURE Pressure is probably one of the most commonly measured variables in the Power plant. It includes the
measurement of steam pressure; feed water pressure, condenser
many more.
In many ways, pressure is the primary
� Flow (measuring pressure drop across restriction by creating differential pressure)
� Level (measuring the pressure c
“Pressure is the force exerted by fluid or gas and it is transmtted in all directions throughout the
fluid /gas.”
Pressure acts on surface area of vessel or chamber in which it is confined.
Mathematically
Pressure is actually the measurement of force acting on area of surface. We could represent this as:
Force = Pressure / Area
Pressure scale
Pressure varies depending on altitude above sea level, weather pressure fronts and other conditions. The
measure of pressure is, therefore, relative and pressure measurements are stated as either gauge or
absolute. Gauge pressure is the unit we encounter in everyday work (e.g., tire ratings are in gauge
pressure). A gauge pressure device will indicate zero pressure wh
(i.e., gauge pressure is referenced to atmospheric pressure). Absolute pressure includes the effect of
atmospheric pressure with the gauge pressure. An absolute pressure indicator would indicate
atmospheric pressure when completely vented down to atmosphere
Absolute Pressure = Gauge Pressure + Atmospheric Pressure
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Dawood University of Engineering & Technology
Pressure is probably one of the most commonly measured variables in the Power plant. It includes the
measurement of steam pressure; feed water pressure, condenser pressure, lubricating oil pressure and
primary element in many of the process measurement, such as:
Flow (measuring pressure drop across restriction by creating differential pressure)
Level (measuring the pressure created by vertical fluid column)
Pressure is the force exerted by fluid or gas and it is transmtted in all directions throughout the
Pressure acts on surface area of vessel or chamber in which it is confined.
Pressure is actually the measurement of force acting on area of surface. We could represent this as:
Pressure varies depending on altitude above sea level, weather pressure fronts and other conditions. The
f pressure is, therefore, relative and pressure measurements are stated as either gauge or
absolute. Gauge pressure is the unit we encounter in everyday work (e.g., tire ratings are in gauge
pressure). A gauge pressure device will indicate zero pressure when bled down to atmospheric pressure
(i.e., gauge pressure is referenced to atmospheric pressure). Absolute pressure includes the effect of
atmospheric pressure with the gauge pressure. An absolute pressure indicator would indicate
n completely vented down to atmosphere - it would not indicate scale zero.
Absolute Pressure = Gauge Pressure + Atmospheric Pressure
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Dawood University of Engineering & Technology
Pressure is probably one of the most commonly measured variables in the Power plant. It includes the
pressure, lubricating oil pressure and
, such as:
Flow (measuring pressure drop across restriction by creating differential pressure)
Pressure is the force exerted by fluid or gas and it is transmtted in all directions throughout the
Pressure is actually the measurement of force acting on area of surface. We could represent this as:
Pressure varies depending on altitude above sea level, weather pressure fronts and other conditions. The
f pressure is, therefore, relative and pressure measurements are stated as either gauge or
absolute. Gauge pressure is the unit we encounter in everyday work (e.g., tire ratings are in gauge
en bled down to atmospheric pressure
(i.e., gauge pressure is referenced to atmospheric pressure). Absolute pressure includes the effect of
atmospheric pressure with the gauge pressure. An absolute pressure indicator would indicate
it would not indicate scale zero.
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PRESSURE MEASURING DEVICES
� BAROMETER: For measuring atmospheric pressure.
� MANOMETER: An instrument that measures pressure in terms of height of a column of liquid. It
has three types:
a) U-shaped Manometer
b) Inclined Manometer
c) Ring Shaped Manometer
BOURDON TUBES: Bourdon tubes are circular
with oval cross sections. The pressure of the medium acts on
the inside of the tube. The outward pressure on the oval cross
section forces it to become rounded. Because of the curvature
of the tube ring, the bourdon tube
the direction of the arrow.
� BELOWS: Bellows type elements are constructed of tubular
membranes that are convoluted around the
membrane is attached at one end to the source and at the other end to an indicating device or
instrument. The bellows element can provide
the arrow when input pressure is applied.
� DIAPHARAM: A diaphragm is a circular
pressure fixture around the circumference. The pressure medium is on one
indication medium is on the other. The deflection that is created by pressure in the vessel would
be in the direction of the arrow indicated.
PRESSURE TRANSMITTERSMost pressure transmitters are built around the pressure capsule concept. They are usually capable of
measuring differential pressure (that is, the Note difference between a high pressure input and a low
pressure input) and therefore, are usually called DP
cells.
Capacitance Type Pressure Transmitter
A capacitance cell measures changes in capacitance. The capacitance of
the capacitance of a capacitor is directly proportional to the area of the
metal plates and inversely proportional to the distance between them. It
also depends on a characteristic of t
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PRESSURE MEASURING DEVICES
For measuring atmospheric pressure.
An instrument that measures pressure in terms of height of a column of liquid. It
Bourdon tubes are circular-shaped tubes
The pressure of the medium acts on
the inside of the tube. The outward pressure on the oval cross
section forces it to become rounded. Because of the curvature
of the tube ring, the bourdon tube then bends as indicated in
Bellows type elements are constructed of tubular
membranes that are convoluted around the circumference. The
membrane is attached at one end to the source and at the other end to an indicating device or
instrument. The bellows element can provide a long range of motion (stroke) in the direction of
the arrow when input pressure is applied.
A diaphragm is a circular-shaped convoluted membrane that is attached to the
pressure fixture around the circumference. The pressure medium is on one side and the
indication medium is on the other. The deflection that is created by pressure in the vessel would
be in the direction of the arrow indicated.
PRESSURE TRANSMITTERS Most pressure transmitters are built around the pressure capsule concept. They are usually capable of
measuring differential pressure (that is, the Note difference between a high pressure input and a low
pressure input) and therefore, are usually called DP transmitters or DP
Capacitance Type Pressure Transmitter
A capacitance cell measures changes in capacitance. The capacitance of
the capacitance of a capacitor is directly proportional to the area of the
metal plates and inversely proportional to the distance between them. It
also depends on a characteristic of the insulating material between them.
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Dawood University of Engineering & Technology
An instrument that measures pressure in terms of height of a column of liquid. It
membrane is attached at one end to the source and at the other end to an indicating device or
a long range of motion (stroke) in the direction of
shaped convoluted membrane that is attached to the
side and the
indication medium is on the other. The deflection that is created by pressure in the vessel would
Most pressure transmitters are built around the pressure capsule concept. They are usually capable of
measuring differential pressure (that is, the Note difference between a high pressure input and a low
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This characteristic, called permittivity is a measure of how well the insulating material increases the ability
of the capacitor to store charge.
Two capacitors are joined together in such a way that they have
diaphragm. High and low pressures are applied at the two sides of the diaphragm which causes it to
deflect from high to low pressure side. This deflection causes a change in the capacitance of the
capacitors. Thus difference of pressure is converted into difference of capacitance.
Potentiometric Pressure Transmitter
It also works on the similar principle but uses a variable resistor to
measure pressure instead of capacitance. Two chambers are jo
with a common diaphragm and applied with high and low pressure.
Difference of pressure causes diaphragm to move a little towards
lower pressure side. As a result needle attached with it, moves over a
potentiometer changing its resistance between elect
Thus difference of pressure causes a corresponding change in the
resistance. Figure shows a similar assembly where a spring is used to
produce a constant pressure on one side of diaphragm.
Linear Variable differential Transformer
LVDT also works on the similar principle for measuring differential
pressure. Diaphragm is connected to an extension rod.
The extension control rod is made of a metal suitable for acting as
the movable core of a transformer. Moving the extension
primary and secondary windings of a transformer causes the
inductance between the two windings to vary, there
output voltage proportional to the position of the
extension.
FLOW
“The quantity of fluid passing a given point in a specific period of time is called
BASIC FLOW MESURING METHOD
There are various methods used to measure the flow rate of steam, water, lubricants, air, etc., in a
nuclear generating station.
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This characteristic, called permittivity is a measure of how well the insulating material increases the ability
C=E A / D
Two capacitors are joined together in such a way that they have one plate in common which is actually a
diaphragm. High and low pressures are applied at the two sides of the diaphragm which causes it to
deflect from high to low pressure side. This deflection causes a change in the capacitance of the
ifference of pressure is converted into difference of capacitance.
Potentiometric Pressure Transmitter
It also works on the similar principle but uses a variable resistor to
measure pressure instead of capacitance. Two chambers are joined
with a common diaphragm and applied with high and low pressure.
Difference of pressure causes diaphragm to move a little towards
lower pressure side. As a result needle attached with it, moves over a
potentiometer changing its resistance between electrical contacts.
Thus difference of pressure causes a corresponding change in the
resistance. Figure shows a similar assembly where a spring is used to
produce a constant pressure on one side of diaphragm.
Linear Variable differential Transformer
works on the similar principle for measuring differential
pressure. Diaphragm is connected to an extension rod.
is made of a metal suitable for acting as
Moving the extension between the
primary and secondary windings of a transformer causes the
inductance between the two windings to vary, there by varying the
output voltage proportional to the position of the control rod
“The quantity of fluid passing a given point in a specific period of time is called
its flow rate.”
BASIC FLOW MESURING METHOD
There are various methods used to measure the flow rate of steam, water, lubricants, air, etc., in a
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This characteristic, called permittivity is a measure of how well the insulating material increases the ability
one plate in common which is actually a
diaphragm. High and low pressures are applied at the two sides of the diaphragm which causes it to
deflect from high to low pressure side. This deflection causes a change in the capacitance of the
“The quantity of fluid passing a given point in a specific period of time is called
There are various methods used to measure the flow rate of steam, water, lubricants, air, etc., in a
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P a g e | 12
Rate of flow is measured by the differential pressure method. Some form of restriction is placed in the
pipeline to create a pressure drop. The pressure before the restriction is higher than after restriction or
downstream. Such a reduction in pressure will cause an increase in the fluid velocity because the same
amount of flow must take place before the restriction as after it. Velocity will vary directly with the flow and
as the flow increases a greater pressure differential will occur
differential pressure across a restriction, one can measure the rate of flow.
ORIFACE PLATE
An Oriface plate is used to make a abrupt change in the pipe area and simply
consist of circular plate usually inserted between pipe flanges.
differential which is usually measured at upstream trapping and downstream trapping.
The downstream pressure is lower than
permanent loss in pressure called the head loss. This can be as high as 50% of
upstream pressure. In application where this
used.
The high and low-pressure taps of the primary device (orifice type shown) are fed by sensing lines to a
differential pressure (D/P) cell. The output of the D/P cell acts on a pressure to milliamps transducer,
which transmits a variable 4-20 ma signal.
In actuality the differential pressure increases in proportion to the square of the flow rate.
We can write this as:
In other words the flow rate (Q) is proportional; to the square root of the differential pressure.
Volumetric Flow Rate = Q
To convert the signal from the flow transmitter
one has to obtain or extract the square root of the signal from the flow transmitter.
extractor is an electronic (or pneumatic) device that takes the square root of the signal from the fl
transmitter and outputs a corresponding linear flow signal.
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Rate of flow is measured by the differential pressure method. Some form of restriction is placed in the
pipeline to create a pressure drop. The pressure before the restriction is higher than after restriction or
tion in pressure will cause an increase in the fluid velocity because the same
amount of flow must take place before the restriction as after it. Velocity will vary directly with the flow and
as the flow increases a greater pressure differential will occur across the restriction. So by measuring the
differential pressure across a restriction, one can measure the rate of flow.
An Oriface plate is used to make a abrupt change in the pipe area and simply
inserted between pipe flanges. This produces a pressure
differential which is usually measured at upstream trapping and downstream trapping.
is lower than the upstream pressure; the orifice causes
he head loss. This can be as high as 50% of
application where this cannot be tolerated, a venture tube is
pressure taps of the primary device (orifice type shown) are fed by sensing lines to a
pressure (D/P) cell. The output of the D/P cell acts on a pressure to milliamps transducer,
20 ma signal.
In actuality the differential pressure increases in proportion to the square of the flow rate.
∆P ∝∝∝∝ Q2
In other words the flow rate (Q) is proportional; to the square root of the differential pressure.
Volumetric Flow Rate = Q ∝∝∝∝ α ∆P
To convert the signal from the flow transmitter, to one that is directly proportional to the flow
one has to obtain or extract the square root of the signal from the flow transmitter.
extractor is an electronic (or pneumatic) device that takes the square root of the signal from the fl
transmitter and outputs a corresponding linear flow signal.
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Rate of flow is measured by the differential pressure method. Some form of restriction is placed in the
pipeline to create a pressure drop. The pressure before the restriction is higher than after restriction or
tion in pressure will cause an increase in the fluid velocity because the same
amount of flow must take place before the restriction as after it. Velocity will vary directly with the flow and
across the restriction. So by measuring the
This produces a pressure
pressure taps of the primary device (orifice type shown) are fed by sensing lines to a
pressure (D/P) cell. The output of the D/P cell acts on a pressure to milliamps transducer,
In actuality the differential pressure increases in proportion to the square of the flow rate.
In other words the flow rate (Q) is proportional; to the square root of the differential pressure.
one that is directly proportional to the flow-rate,
one has to obtain or extract the square root of the signal from the flow transmitter. The square root
extractor is an electronic (or pneumatic) device that takes the square root of the signal from the flow
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� Flange Taps : Flange taps are the most widely used pressure tapping location
for orifices
A three-valve manifold has to be used to protect the DP capsule from being over
Orifice Plate with Flange Taps and Three Valve Manifold
VENTURI TUBE The orifice plate produces a large head loss.
of its gradually curved inlet and outlet cones, almost no permanent pressure drop occurs. This design
also minimizes wear and plugging by allowing the flow to sweep suspended solids through without
obstruction.
The Venturi tube normally uses a specific reduction
where it becomes heavy and excessively
large amounts of suspended solids, it creates l
orifice plate. The differential pressure taps in the Venturi
pipe diameters. The Venturi tube has good accuracy but has a high cost.
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Flange taps are the most widely used pressure tapping location
valve manifold has to be used to protect the DP capsule from being over
ranged.
with Flange Taps and Three Valve Manifold
The orifice plate produces a large head loss. If this is unacceptable a venturi tube can be used. Because
of its gradually curved inlet and outlet cones, almost no permanent pressure drop occurs. This design
also minimizes wear and plugging by allowing the flow to sweep suspended solids through without
Venturi tube normally uses a specific reduction in tube size, and is not used in larger diameter pipes
and excessively long. The advantages of the Venturi tube are its ability to handle
large amounts of suspended solids, it creates less turbulence and hence less insertion loss than the
orifice plate. The differential pressure taps in the Venturi tube are located at the minimum and maximum
has good accuracy but has a high cost.
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Flange taps are the most widely used pressure tapping location
valve manifold has to be used to protect the DP capsule from being over-
with Flange Taps and Three Valve Manifold
venturi tube can be used. Because
of its gradually curved inlet and outlet cones, almost no permanent pressure drop occurs. This design
also minimizes wear and plugging by allowing the flow to sweep suspended solids through without
size, and is not used in larger diameter pipes
long. The advantages of the Venturi tube are its ability to handle
loss than the
tube are located at the minimum and maximum
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PITOT TUBE
Pitot tubes also utilize the principles captured In Bernoulli’s equation, to measure flow. Most pitot tubes actually consist of two tubes. One, the low pressure tube measures the static pressure in the pipe. The second, the high pressure tube is inserted in the pipe in such a way that the flowing fluid is stopped in the tube. The pressure in the highthe static pressure in the system plus a pressure dependant on the force required stopping the flow.Pitot tubes are more common measuring liquid flows. They suffer from a couple of problems. The pressure differential is usually small and hard to measure. The differing flow velocities across the pipe make the accuracy dependent on the flow profile of the fluid and the position of the pitot in the pipe.
ANNUBAR
An annubar is similar to a pitot tubemeasures the difference between the The volumetric flow is calculated from that difference using the pipe inside diameter,
The biggest difference between an annubaracross a section of a pipe or duct. In this way, the annubar averages the differential pressures encountered accounting for variations in flow acrossthe tip is located at a point in the pipe cross section where the flowing velocity is close to the average velocity.
BASIC FLOW MESURING METHODVery simple systems employ external sight glasse
the fluid. Others utilize floats connected to variable potentiometers or rheostats that will change the
resistance according to the amount of motion of the float. This signal is then inputted to transmi
send a signal to an instrument calibrated to read out the height or volume.
The level of liquid inside a tank can be determined from the pressure reading if the weight density of the
liquid is constant. Differential Pressure (DP) capsules are t
the pressure at the base of a tank.
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also utilize the principles captured Bernoulli’s equation, to measure flow.
Most pitot tubes actually consist of two tubes. One, the low pressure tube measures the static pressure in the pipe. The second, the high pressure tube is inserted in
e in such a way that the flowing fluid is stopped in the tube. The pressure in the high-pressure tube will be the static pressure in the system plus a pressure dependant on the force required stopping the flow. Pitot tubes are more common measuring gas flows that liquid flows. They suffer from a couple of problems. The pressure differential is usually small and hard to measure. The differing flow velocities across the pipe make the accuracy dependent on the flow profile of the fluid and
pitot tube used to measure the flow of gas or liquid in a pipe. measures the difference between the static pressure and the flowing pressure of the media in the pipe.
is calculated from that difference using Bernoulli's principle and taking into account
annubar and a pitot tube is that an annubar takes multiple samples across a section of a pipe or duct. In this way, the annubar averages the differential pressures encountered accounting for variations in flow across the section. A pitot tube will give a similar reading if the tip is located at a point in the pipe cross section where the flowing velocity is close to the average
LEVEL
BASIC FLOW MESURING METHOD Very simple systems employ external sight glasses or tubes to view the height and hence the volume of
the fluid. Others utilize floats connected to variable potentiometers or rheostats that will change the
resistance according to the amount of motion of the float. This signal is then inputted to transmi
send a signal to an instrument calibrated to read out the height or volume.
The level of liquid inside a tank can be determined from the pressure reading if the weight density of the
liquid is constant. Differential Pressure (DP) capsules are the most commonly used devices to measure
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The pitot tube of the media in the pipe. and taking into account
and a pitot tube is that an annubar takes multiple samples across a section of a pipe or duct. In this way, the annubar averages the differential pressures
the section. A pitot tube will give a similar reading if the tip is located at a point in the pipe cross section where the flowing velocity is close to the average
s or tubes to view the height and hence the volume of
the fluid. Others utilize floats connected to variable potentiometers or rheostats that will change the
resistance according to the amount of motion of the float. This signal is then inputted to transmitters that
The level of liquid inside a tank can be determined from the pressure reading if the weight density of the
he most commonly used devices to measure
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P a g e | 15
� Glass Level Gauge The glass level gauge or sight glass is to liquid level
measurement as manometers are to pressure
measurement: a very simple and effective technology for
direct visual indication of process level.
In its simplest form, a level gauge is nothing more than a
clear tube through which process liquid may be seen.
The following photograph shows a simple example of a
sight glass level gauge:
� Bubbler Level Measurement System
If the process liquid contains suspended solids or is
chemically corrosive or radioactive, it is desirable to
prevent it from coming into direct contact with the level transmitter. In these cases,
a bubbler level measurement system, which utilizes a purge gas, can
shown in Figure, a bubbler tube is immersed to the bottom of the v
the liquid level is to be measured. A gas (called purge gas) is allowed to pass
through the bubbler tube. Consider that the tank is empty. In this case, the gas will
escape freely at the end of the tube and therefore the gas pressure inside
bubbler tube (called back pressure) will be at atmospheric pressure.
the liquid level inside the tank increases, pressure exerted by the liquid at the base
of the tank (and at the opening of the bubbler tube) increases.
pressure of the liquid in effect acts as a seal, which restricts the escape of, purge
gas from the bubbler tube. As a result, the gas pressure in the bubbler tube will
continue to increase until it just balances the hydrostatic pressure (P = SXH) of the
liquid. At this point the backpressure in the bubbler tube is exactly the same as the
hydrostatic pressure of the liquid and it will remain constant until any change in the liquid level occurs.
Any excess supply pressure will escape as bubbles through the liquid
� Ultrasonic Level Transmitter Ultrasonic level instruments measure the distance from the transmitter
(located at some high point) to the surface of a process material located
further below. The time-of-light for a sound pulse indicates this distance,
and is interpreted by the transmitter electronics as process level. These
transmitters may output a signal corresponding either to the fullness of the
vessel (fillage) or the amount of empty space remaining at the top of a
vessel (ullage).
������� � ���
The instrument itself consists of an electronics module containing all the power, computation, and signal processing circuits; plus an ultrasonic transducer to send and receive the sound waves. This transducer is typically piezoelectric in nature, being thsound waves, radio frequency and laser are also used to measure level in a tank.
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The glass level gauge or sight glass is to liquid level
measurement as manometers are to pressure
measurement: a very simple and effective technology for
direct visual indication of process level.
In its simplest form, a level gauge is nothing more than a
clear tube through which process liquid may be seen.
The following photograph shows a simple example of a
Bubbler Level Measurement System
If the process liquid contains suspended solids or is
e, it is desirable to
prevent it from coming into direct contact with the level transmitter. In these cases,
a bubbler level measurement system, which utilizes a purge gas, can be used. As
, a bubbler tube is immersed to the bottom of the vessel in which
the liquid level is to be measured. A gas (called purge gas) is allowed to pass
through the bubbler tube. Consider that the tank is empty. In this case, the gas will
escape freely at the end of the tube and therefore the gas pressure inside the
bubbler tube (called back pressure) will be at atmospheric pressure. However, as
the liquid level inside the tank increases, pressure exerted by the liquid at the base
of the tank (and at the opening of the bubbler tube) increases. The hydrostatic
sure of the liquid in effect acts as a seal, which restricts the escape of, purge
gas from the bubbler tube. As a result, the gas pressure in the bubbler tube will
continue to increase until it just balances the hydrostatic pressure (P = SXH) of the
. At this point the backpressure in the bubbler tube is exactly the same as the
hydrostatic pressure of the liquid and it will remain constant until any change in the liquid level occurs.
Any excess supply pressure will escape as bubbles through the liquid.
Ultrasonic Level Transmitter Ultrasonic level instruments measure the distance from the transmitter
(located at some high point) to the surface of a process material located
light for a sound pulse indicates this distance,
nd is interpreted by the transmitter electronics as process level. These
transmitters may output a signal corresponding either to the fullness of the
vessel (fillage) or the amount of empty space remaining at the top of a
��� ��� � � ������
The instrument itself consists of an electronics module containing all the power, computation, and signal processing circuits; plus an ultrasonic transducer to send and receive the sound waves. This transducer is typically piezoelectric in nature, being the equivalent of a very high-frequency audio speaker. Besides sound waves, radio frequency and laser are also used to measure level in a tank.
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hydrostatic pressure of the liquid and it will remain constant until any change in the liquid level occurs.
The instrument itself consists of an electronics module containing all the power, computation, and signal processing circuits; plus an ultrasonic transducer to send and receive the sound waves. This transducer
frequency audio speaker. Besides
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� Capacitive Level Measurement Capacitive level instruments measure electrical capacitance of a conductive rod ins
process vessel. As process level increases, capacitance increases between the rod and the vessel walls,
causing the instrument to output a greater signal. The basic principle behind capacitive level instruments
is the capacitance
The amount of capacitance exhibited between a metal rod inserted into the vessel and the metal walls of
that vessel will vary only with changes in
interior surface area of the vessel is fixed, as is the area of the rod once installed), only changes in ε or d
can affect the probe's capacitance.
Open Tank Level MeasurementThe simplest application is the fluid level in an open tank. Figure shows a typical open tank level
measurement installation using a pressure capsule level transmitter. If the tank is open to atmosphere,
the high-pressure side of the level transmitter will be connected to the base of the tank while the low
pressure side will be vented to atmosphere. In
this manner, the level transmitter acts as a
simple pressure transmitter. We have:
����� � ���� � � � �
���� � ���� Differential pressure
∆� � ����� � ���� � � �
The level transmitter can be calibrated to output
4 mA when the tank is at 0% level and 20 mA
when the tank is at 100% level.
Closed Tank Level Measurement
Should the tank be closed and a gas or vapors exists on
top of the liquid, the gas pressure must
for. A change in the gas pressure will cause a change in
transmitter output. Moreover, the pressure exerted by the
gas phase may be so high that the hydrostatic pressure of
the liquid column becomes insignificant. Compensation
can be achieved by applying the gas pressure to both the
high and low-pressure sides of the level transmitter. This
cover gas pressure is thus used as a back pressure or
reference pressure on the low pressure side of the DP cell.
We have:
� �� � ��� � !
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Capacitive Level Measurement Capacitive level instruments measure electrical capacitance of a conductive rod inserted vertically into a
process vessel. As process level increases, capacitance increases between the rod and the vessel walls,
causing the instrument to output a greater signal. The basic principle behind capacitive level instruments
" �#$
%
The amount of capacitance exhibited between a metal rod inserted into the vessel and the metal walls of
that vessel will vary only with changes in permittivity (ε), area (A), or distance (d). Since A is constant (the
vessel is fixed, as is the area of the rod once installed), only changes in ε or d
can affect the probe's capacitance.
Open Tank Level Measurement The simplest application is the fluid level in an open tank. Figure shows a typical open tank level
ent installation using a pressure capsule level transmitter. If the tank is open to atmosphere,
pressure side of the level transmitter will be connected to the base of the tank while the low
be vented to atmosphere. In
ner, the level transmitter acts as a
simple pressure transmitter. We have:
�
� �
The level transmitter can be calibrated to output
4 mA when the tank is at 0% level and 20 mA
Closed Tank Level Measurement
Should the tank be closed and a gas or vapors exists on
top of the liquid, the gas pressure must be compensated
for. A change in the gas pressure will cause a change in
transmitter output. Moreover, the pressure exerted by the
gas phase may be so high that the hydrostatic pressure of
the liquid column becomes insignificant. Compensation
d by applying the gas pressure to both the
pressure sides of the level transmitter. This
cover gas pressure is thus used as a back pressure or
reference pressure on the low pressure side of the DP cell.
! � &
��' � ���
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erted vertically into a
process vessel. As process level increases, capacitance increases between the rod and the vessel walls,
causing the instrument to output a greater signal. The basic principle behind capacitive level instruments
The amount of capacitance exhibited between a metal rod inserted into the vessel and the metal walls of
ermittivity (ε), area (A), or distance (d). Since A is constant (the
vessel is fixed, as is the area of the rod once installed), only changes in ε or d
The simplest application is the fluid level in an open tank. Figure shows a typical open tank level
ent installation using a pressure capsule level transmitter. If the tank is open to atmosphere,
pressure side of the level transmitter will be connected to the base of the tank while the low-
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Differential Pressure
The effect of the gas pressure is cancelled and only the pressure due to the hydrostatic head of the liqui
is sensed. When the low-pressure impulse line is connected directly to the gas phase above the liquid
level, it is called a dry leg.
A full dry leg installation with three-valve manifold is shown in Figure. If the gas phase is
condensate will form in the low pressure impulse line resulting in a column of liquid, which exerts extra
pressure on the low-pressure side of the transmitter. A technique to solve this problem is to add a
knockout pot/condensing bottle below the transmit
condensate in the knockout pot will ensure that the impulse line is free of liquid.
In a wet leg system, the low-pressure impulse line is completely filled with liquid (usually the sa
as the process) and hence the name wet leg. A level transmitter, with the associated three
manifold, is used in an identical manner to the dry leg system. At the top of the low pressure impulse line
is a small catch tank. The gas phase or v
tank, with the inclined interconnecting line, maintains a constant hydrostatic pressure on the low
side of the level transmitter. This pressure, being a constant, can easily be compe
calibration.
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∆� � � �� � ��' � ! � &
The effect of the gas pressure is cancelled and only the pressure due to the hydrostatic head of the liqui
pressure impulse line is connected directly to the gas phase above the liquid
Dry Leg System
valve manifold is shown in Figure. If the gas phase is
condensate will form in the low pressure impulse line resulting in a column of liquid, which exerts extra
pressure side of the transmitter. A technique to solve this problem is to add a
knockout pot/condensing bottle below the transmitter in the low pressure side. Periodic draining of the
condensate in the knockout pot will ensure that the impulse line is free of liquid.
Wet Leg System pressure impulse line is completely filled with liquid (usually the sa
as the process) and hence the name wet leg. A level transmitter, with the associated three
manifold, is used in an identical manner to the dry leg system. At the top of the low pressure impulse line
is a small catch tank. The gas phase or vapors will condense in the wet leg and the catch tank. The catch
tank, with the inclined interconnecting line, maintains a constant hydrostatic pressure on the low
side of the level transmitter. This pressure, being a constant, can easily be compensated for by
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The effect of the gas pressure is cancelled and only the pressure due to the hydrostatic head of the liquid
pressure impulse line is connected directly to the gas phase above the liquid
valve manifold is shown in Figure. If the gas phase is condensable,
condensate will form in the low pressure impulse line resulting in a column of liquid, which exerts extra
pressure side of the transmitter. A technique to solve this problem is to add a
ter in the low pressure side. Periodic draining of the
pressure impulse line is completely filled with liquid (usually the same liquid
as the process) and hence the name wet leg. A level transmitter, with the associated three-valve
manifold, is used in an identical manner to the dry leg system. At the top of the low pressure impulse line
apors will condense in the wet leg and the catch tank. The catch
tank, with the inclined interconnecting line, maintains a constant hydrostatic pressure on the low-pressure
nsated for by
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Measurement & control of temperature are possibly the most common operation in process control.
PRINCIPLES OF TEMPERAURE MEASUREMENT
There in general four types of temperature
temperature dependent:
• Expansion of substance with temperature, which produces change to length, volume &
pressure. In this simplest for this is the common in glass thermometer.
• Changes in electrical resistance
• Change in contact potential
• Change in radiated energy with temperature optical & radiation pyrometers.
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TEMPERATURE & control of temperature are possibly the most common operation in process control.
PRINCIPLES OF TEMPERAURE MEASUREMENT
There in general four types of temperature sensor based on following physical properties, which are
Expansion of substance with temperature, which produces change to length, volume &
pressure. In this simplest for this is the common in glass thermometer.
Changes in electrical resistance with temperature, used in thermostats and RTD’s
Change in contact potential between dissimilar metals with temperature, thermocouples.
Change in radiated energy with temperature optical & radiation pyrometers.
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& control of temperature are possibly the most common operation in process control.
on following physical properties, which are
Expansion of substance with temperature, which produces change to length, volume &
and RTD’s.
metals with temperature, thermocouples.
Change in radiated energy with temperature optical & radiation pyrometers.
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� REISTANCE TEMPERATURE DETECTERS (RTD):
resistance is directly proportional to its change in temperature and is linear over a range of
temperatures. This constant factor called the temperature coefficient of electrical resistance.
The RTD can actually be regar
varies with temperature. The Platinum RTD’s are constructed with a resistance of 100 ohm
at 0 Celsius and are often reoffered to as PT
a)RTD using Wheatstone Bridge
To detect the small variations of resistance of the RTD, a temperature transmitter in the form of a Wheatstone bridge is generally used. The circuit compares the RTD value with three known and highly accurate resistors. In this circuit, when the current flow in the meter is zero (the voltage at point A equals the voltage at point B) the bridge is said to be in null balance. This would be the zero or set point on the RTD temperature output. As the RTD temperature increases, the voltage read by the voltmeter increases. If a voltage transducer replaces the voltmeter, a 4proportional to the temperature range being monitored, can be generated.
b) Three Wire RTD
A problem arises when the RTD is installed some distance away from the transmitter. Since the connecting wires are long, resistance of the wires changes as ambient temperature fluctuates. The variations in wire resistance would introduce an error in the transmitter. To eliminate this problem, a three-wire RTD is used. The connecting wires (w1, w2, w3) are made the same length and therefore the same resistance. The power supply is connected to one end of the RTD and the top of the Wheatstone bridge. It can be seen that the resistance of the right leg of the Wheatstone bridge ileg of the bridge is R3 + RW3 + RTD. Since RW1 = RW2, the result is that the resistances of the wires cancel and therefore the effect of the connecting wires is eliminated. Failure Modes: • An open circuit in the RTD or in the wiring between the RTD and the bridge will cause a high temperature reading. • Loss of power or a short within the RTD will cause a low temperature reading.
� THERMOCOUPLE
WORKING PRINCIPLE:
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REISTANCE TEMPERATURE DETECTERS (RTD): For most metals the change in electrical
resistance is directly proportional to its change in temperature and is linear over a range of
temperatures. This constant factor called the temperature coefficient of electrical resistance.
The RTD can actually be regarded as a high precision wire wound resistor whose resistance
. The Platinum RTD’s are constructed with a resistance of 100 ohm
at 0 Celsius and are often reoffered to as PT-100 sensors.
resistance of the RTD, a temperature transmitter in the form of a Wheatstone bridge is generally used. The circuit compares the RTD value with three known and highly accurate resistors. In
low in the meter is zero (the voltage at point A equals the voltage at point B) the bridge is said to be in null balance. This would be the zero or set point on the RTD
temperature increases, the voltage read increases. If a voltage transducer replaces the voltmeter, a 4-20 mAmps signal, which is
proportional to the temperature range being monitored, can be generated.
wire RTD is used.
therefore the same resistance. The power supply is connected to one end of the RTD and the top of the Wheatstone bridge. It can be seen that the resistance of the right leg of the Wheatstone bridge is R1 + R2 + RW2. The resistance of the left leg of the bridge is R3 + RW3 + RTD. Since RW1 = RW2, the result is that the resistances of the wires cancel and therefore the effect of the connecting wires is eliminated.
in the RTD or in the wiring between the RTD and the bridge will cause a high
• Loss of power or a short within the RTD will cause a low temperature reading.
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ost metals the change in electrical
resistance is directly proportional to its change in temperature and is linear over a range of
temperatures. This constant factor called the temperature coefficient of electrical resistance.
ded as a high precision wire wound resistor whose resistance
. The Platinum RTD’s are constructed with a resistance of 100 ohm
20 mAmps signal, which is
power supply is connected to one end of the RTD and the top of the Wheatstone bridge. It can be seen s R1 + R2 + RW2. The resistance of the left
leg of the bridge is R3 + RW3 + RTD. Since RW1 = RW2, the result is that the resistances of the wires
in the RTD or in the wiring between the RTD and the bridge will cause a high
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When two dissimilar metals are twisted together at one end and if this end is heated
other end are ket at lower temperature T2, the current will flow around circuit. The current depends on the
metals and the temperatures T1 & T2.This ph
known as SEE BACK EFFECT. Device using this effect are
called THERMOCOUPLES.
The end that is in contact with the process is called the hot or
measurement junction. The one that is kept at constant
temperature is called cold or reference junctio
The relationship between total circuit voltage (emf) and the
emf at the junctions is:
Circuit emf = Measurement emf
If circuit emf and reference emf are known, measurement emf can be calculated and the relative
temperature determined. To convert the emf generated by a thermocouple to the standard 4
signal, a transmitter is needed.
Failure Modes:
• An open circuit in the thermocouple detector means that there is no path for current flow, thus it
will cause a low (off-scale) temperature reading.
• A short circuit in the thermocouple detector will also cause a low temperature reading because it
creates a leakage current path to the ground and a smaller measured voltage.
When thermocouple is exposed
difference of temperature.
Thermal Wells
The process environment where temperature mo
often not only hot, but also pressurized and po
corrosive or radioactive. To facilitate removal of the tem
sensors (RTD and TC), for examination or replacement and to prov
mechanical protection, the sensors are
wells.
Thermocouple types
� Bimetallic Thermometer
A bimetallic strip is constructed by bonding two metals with different coefficients of thermal expansion. If heat is applied to one end of the strip, the metal with the higherexpansion will expand more readily than the lower one. As a result, the whole metallic strip will bend in the direction of the metal with the lower coefficient. One main advantage of the bimetallic
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When two dissimilar metals are twisted together at one end and if this end is heated to temperature
ket at lower temperature T2, the current will flow around circuit. The current depends on the
metals and the temperatures T1 & T2.This phenomenon is
Device using this effect are
The end that is in contact with the process is called the hot or
measurement junction. The one that is kept at constant
temperature is called cold or reference junction.
The relationship between total circuit voltage (emf) and the
Circuit emf = Measurement emf - Reference emf
If circuit emf and reference emf are known, measurement emf can be calculated and the relative
temperature determined. To convert the emf generated by a thermocouple to the standard 4
An open circuit in the thermocouple detector means that there is no path for current flow, thus it
scale) temperature reading.
A short circuit in the thermocouple detector will also cause a low temperature reading because it
a leakage current path to the ground and a smaller measured voltage.
exposed to atmosphere it will show zero voltage because there is no
The process environment where temperature monitoring is required is
not only hot, but also pressurized and possibly chemically
radioactive. To facilitate removal of the temperature
for examination or replacement and to provide
sensors are usually mounted inside thermal
A bimetallic strip is constructed by bonding two metals with different coefficients of thermal expansion. If heat is applied to one end of the strip, the metal with the higher coefficient of expansion will expand more readily than the lower one. As a result, the whole metallic strip will bend in the direction of the metal with the lower coefficient. One main advantage of the bimetallic
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to temperature T1 &
ket at lower temperature T2, the current will flow around circuit. The current depends on the
If circuit emf and reference emf are known, measurement emf can be calculated and the relative
temperature determined. To convert the emf generated by a thermocouple to the standard 4-20 mA
An open circuit in the thermocouple detector means that there is no path for current flow, thus it
A short circuit in the thermocouple detector will also cause a low temperature reading because it
zero voltage because there is no
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strip is that it can be used to operate ovcoil (for larger swing) and placed on an adjustable pivot. Another common configuration of the bimetallic strip is coiled in a helix to increase the swing or displacement similar to the coil aboshape, the strip is more rugged and less subject to vibration.
� Thermostat
Like the RTD, the thermistor is also a temperature sensitive resistor. Of the major categories of sensors, the thermistor exhibits by far the largest parameter change with temperature. Thermistors are generally composed of semiconductor materials. Although positive temperature coefficient units are available, most thermistors have a negative temperature coefficienttheir resistance decreases with increasing temperature. The negative TC can be as large as several percent per degree Celsius, allowing the thermistor circuit to detect minute changes in temperature which could not be observed with an RTD or thermocouple circuit. The price we pay for this increased sensitivity is loss of linearity. The thermistor is an extremely non-linear device.
� PYROMETERS Pyrometer, an instrument for measuring temperature.pyrometer and the radiation pyrometer.sufficiently hot, it will give off visible light, ranging from dull red to blueenough to glow, however, it gives off infrared radiation.
An optical pyrometer determines the temperature of a very hot object by the color of the visible light it gives off. The color of the light can be determined by comparing it with the color of an electrically heated metal wire. In one type of pyrometer, the temperature of the wire is varied by varying the strength of the current until the operator of the instrument deterobject. A dial, operated by the current that heats the wire, indicates the temperature.
A radiation pyrometer determines the temperature of an object from the radiation (infrared and, if present, visible light) given off by the object. The radiation is directed at a heatthermocouple, a device that produces an electric current when part of it is heated. The hotter the object, the more current is generated by the thermocouptemperature.
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strip is that it can be used to operate over a range of temperatures when the strip is fashioned into a coil (for larger swing) and placed on an adjustable pivot. Another common configuration of the bimetallic strip is coiled in a helix to increase the swing or displacement similar to the coil aboshape, the strip is more rugged and less subject to vibration.
Like the RTD, the thermistor is also a temperature sensitive resistor. Of the major categories of sensors, the thermistor exhibits by far the largest parameter change with temperature. Thermistors are generally composed of semiconductor materials.
h positive temperature coefficient units are available, most negative temperature coefficient (TC):i.e.
their resistance decreases with increasing temperature. The negative TC can be as large as several percent per degree
ng the thermistor circuit to detect minute changes in temperature which could not be observed with an RTD or thermocouple circuit. The price we pay for this increased sensitivity is loss of linearity. The thermistor is
an instrument for measuring temperature. Two common types of pyrometers are the optical pyrometer and the radiation pyrometer. A heated object gives off electromagnetic radiation. If the object is
visible light, ranging from dull red to blue-white. Even if the object is not hot enough to glow, however, it gives off infrared radiation.
An optical pyrometer determines the temperature of a very hot object by the color of the visible light it The color of the light can be determined by comparing it with the color of an electrically heated
metal wire. In one type of pyrometer, the temperature of the wire is varied by varying the strength of the current until the operator of the instrument determines that the color of the wire matches the color of the object. A dial, operated by the current that heats the wire, indicates the temperature.
A radiation pyrometer determines the temperature of an object from the radiation (infrared and, if present, sible light) given off by the object. The radiation is directed at a heat-sensitive element such as a
thermocouple, a device that produces an electric current when part of it is heated. The hotter the object, the more current is generated by the thermocouple. The current operates a dial that indicates
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er a range of temperatures when the strip is fashioned into a
coil (for larger swing) and placed on an adjustable pivot. Another common configuration of the bimetallic strip is coiled in a helix to increase the swing or displacement similar to the coil above. In this
thermocouple circuit. The price we pay for this increased sensitivity is loss of linearity. The thermistor is
Two common types of pyrometers are the optical A heated object gives off electromagnetic radiation. If the object is
white. Even if the object is not hot
An optical pyrometer determines the temperature of a very hot object by the color of the visible light it The color of the light can be determined by comparing it with the color of an electrically heated
metal wire. In one type of pyrometer, the temperature of the wire is varied by varying the strength of the mines that the color of the wire matches the color of the
A radiation pyrometer determines the temperature of an object from the radiation (infrared and, if present, sensitive element such as a
thermocouple, a device that produces an electric current when part of it is heated. The hotter the object, le. The current operates a dial that indicates
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VIBRATION & SPEED MONITORING
TOPICSTOPICSTOPICSTOPICS
� Measuring Methods.
� Study of Different Monitoring Equipment.
� (Bentley Nevada-3500 & 7200)
� Study of Loop Drawings & Installations at FFC
INTRODUCTION TO VIBRATION MONITORING SYSTEMMost of us are familiar with vibration; a vibrating object moves to and fro, back and forth. A vibrating
object oscillates.
Vibration amplitude may be measured as a displacement, a velocity, or acceleration. Vibration amplitude
measurements may either be relative, or absolute.
MEASUREMENT OF VIBERTION
Unlike most process measurements, the measurement of a rotating machine’s vibration is primarily for the
benefit of the process equipment rather than the process itself. Vibration monitoring on a compressor, for
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VIBRATION & SPEED MONITORING
Measuring Methods.
Study of Different Monitoring Equipment.
3500 & 7200)
Study of Loop Drawings & Installations at FFC-MM plant.
CO-ORDINATOR
ENGR.UMAIR AKBARENGR.UMAIR AKBARENGR.UMAIR AKBARENGR.UMAIR AKBAR
INTRODUCTION TO VIBRATION MONITORING SYSTEMMost of us are familiar with vibration; a vibrating object moves to and fro, back and forth. A vibrating
Vibration amplitude may be measured as a displacement, a velocity, or acceleration. Vibration amplitude
measurements may either be relative, or absolute.
VIBERTION
Unlike most process measurements, the measurement of a rotating machine’s vibration is primarily for the
benefit of the process equipment rather than the process itself. Vibration monitoring on a compressor, for
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VIBRATION & SPEED MONITORING
MM plant.
INTRODUCTION TO VIBRATION MONITORING SYSTEM Most of us are familiar with vibration; a vibrating object moves to and fro, back and forth. A vibrating
Vibration amplitude may be measured as a displacement, a velocity, or acceleration. Vibration amplitude
Unlike most process measurements, the measurement of a rotating machine’s vibration is primarily for the
benefit of the process equipment rather than the process itself. Vibration monitoring on a compressor, for
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instance may very well be useful in extendin
to the control of the process.
PARAMETERS TO MEASURE
� Radial Vibration
Shaft dynamic motion or casing vibration which is measured in a direction perpendicular to the shaft axis,
often called lateral vibration.
� Thrust Position
The average position, or change in position, of a rotor in the axial direction with respect to some fixed
reference. Typically, the reference is the thrust bearing support structure or other casing member to which
the probe is mounted. The probe may observe the thrust collar directly or some other integral, axial shaft
surface, as long as it is within about 305 mm (12 inches) of the thrust bearing.
Vibration measurement
� Non-contact Method
a) Eddy current probe/ proximity probe (displacement transducer)
� Contact method
b) Velocity probe (LVDT: Velocity
c) Acceleration probe (accelerometer:
PROXIMITY PROBE
Proximity transducer converts the mechanical vibrations to an electrical signal that is proportional to displacement of vibration. The proximity transducer is used to directly measure rotor movement in both axial and radial planes.
Vibration measurement units at the output of the proximitor are expressed in mils or micrometer peak to peak. The standard Bently Nevada Corporation proximity transducer scale factor is 200mV/mil (7.87V/mm) for the 8mm 3300 system.
This system consists of three individual parts
� Probe � Extension Cable � Proximity Driver (Oscillator
Driver)
The proximity driver is an electronic device that performs two basic functions:
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instance may very well be useful in extending the operating life of the compressor, but little to the benefit
PARAMETERS TO MEASURE
Shaft dynamic motion or casing vibration which is measured in a direction perpendicular to the shaft axis,
The average position, or change in position, of a rotor in the axial direction with respect to some fixed
reference. Typically, the reference is the thrust bearing support structure or other casing member to which
he probe is mounted. The probe may observe the thrust collar directly or some other integral, axial shaft
surface, as long as it is within about 305 mm (12 inches) of the thrust bearing.
measurement technique
probe/ proximity probe (displacement transducer)
probe (LVDT: Velocity transducer)
probe (accelerometer: piezoelectric device
Proximity transducer converts the mechanical vibrations to an electrical signal that is proportional to displacement of vibration. The proximity transducer is used to directly measure rotor movement in both
nits at the output of the proximitor are expressed in mils or micrometer peak to peak. The standard Bently Nevada Corporation proximity transducer scale factor is 200mV/mil (7.87V/mm) for the 8mm 3300 system.
This system consists of three individual parts:
Oscillator Demodulator
The proximity driver is an electronic device that performs two basic functions:
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g the operating life of the compressor, but little to the benefit
Shaft dynamic motion or casing vibration which is measured in a direction perpendicular to the shaft axis,
The average position, or change in position, of a rotor in the axial direction with respect to some fixed
reference. Typically, the reference is the thrust bearing support structure or other casing member to which
he probe is mounted. The probe may observe the thrust collar directly or some other integral, axial shaft
Proximity transducer converts the mechanical vibrations to an electrical signal that is proportional to displacement of vibration. The proximity transducer is used to directly measure rotor movement in both
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• Generates the radio frequency (RF) signals using an oscillator circuit• Conditions the RF signal to
Once proximitor power up, it will generate a RF signal at specific frequency. This frequency is dependent on the of the probe coil and capacitance value of extension and probe cable.the probe coil, which creates a RF field around the probe tip. The RF field is proportional to the coil diameter in the probe tip and input voltage to the proximitor.
When conductive material is present in RF field, eddy current flows in the surface of thaamplitude is at maximum when distance between probe and material is minimum and vice versa. The rapid movement of the target causes the RF signal to modulate. The demodulator circuit deals with slow or fast changing amplitude in the same way
FAMILIZATION TO BENTLY NEVADA
Bentley Nevada thrust & vibration monitoring
use in large number large industrial turbine installation around the world.
The 7200 Series monitoring system was
from 1975 until the introduction of the 3300 Series System in 1989. The system has now reached “phase
5” obsolescence which means it is no longer supported by the manufacturer. However, Paramount
Electronics will be able to continue to repair these units for many years to come.
The same is true for the 1800, 2201, 5000, 7000, 9000, 11000 Series Monitor Systems
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Generates the radio frequency (RF) signals using an oscillator circuit Conditions the RF signal to extract usable data using demodulator circuit
Once proximitor power up, it will generate a RF signal at specific frequency. This frequency is dependent on the of the probe coil and capacitance value of extension and probe cable. The RF signal emitted from the probe coil, which creates a RF field around the probe tip. The RF field is proportional to the coil diameter in the probe tip and input voltage to the proximitor.
When conductive material is present in RF field, eddy current flows in the surface of thaamplitude is at maximum when distance between probe and material is minimum and vice versa. The rapid movement of the target causes the RF signal to modulate. The demodulator circuit deals with slow or fast changing amplitude in the same way.
FAMILIZATION TO BENTLY NEVADA
monitoring system was originally manufacture by bently Nevada & is in
use in large number large industrial turbine installation around the world.
The 7200 Series monitoring system was BENTLY NEVADA’S full-featured "flagship" monitoring system
from 1975 until the introduction of the 3300 Series System in 1989. The system has now reached “phase
5” obsolescence which means it is no longer supported by the manufacturer. However, Paramount
lectronics will be able to continue to repair these units for many years to come.
The same is true for the 1800, 2201, 5000, 7000, 9000, 11000 Series Monitor Systems
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Once proximitor power up, it will generate a RF signal at specific frequency. This frequency is dependent The RF signal emitted from
the probe coil, which creates a RF field around the probe tip. The RF field is proportional to the coil
When conductive material is present in RF field, eddy current flows in the surface of that material. RF amplitude is at maximum when distance between probe and material is minimum and vice versa. The rapid movement of the target causes the RF signal to modulate. The demodulator circuit deals with slow
ently Nevada & is in
featured "flagship" monitoring system
from 1975 until the introduction of the 3300 Series System in 1989. The system has now reached “phase
5” obsolescence which means it is no longer supported by the manufacturer. However, Paramount
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HONEYWELL ESD SYSTEM
TOPICSTOPICSTOPICSTOPICS
� Familiarization with Honeywell FSC PLC.
� Troubleshooting PLC
PROGRAMMABLE LOGIC CONTROLLER
Programmable logic controllers (PLCs) are the control hubs for a wide variety of automated
processes. Programmable logic controllers are used
from machining to automated assembly. They were designed to
circuits for machine control. PLCs have been gaining popularity on the factory floor and wi
remain predominant for some time to come. Other areas of application of PLCs are industrial automation
and control of industrial equipment. Most of this is because of the advantages they offer:
� Cost effective & Flexible
� Computational abilities
� Troubleshooting aids
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HONEYWELL ESD SYSTEM
Familiarization with Honeywell FSC PLC.
Troubleshooting PLC
CO-ORDINATOR
EEEENGRNGRNGRNGR .... SYED UMAIR HUSSAINSYED UMAIR HUSSAINSYED UMAIR HUSSAINSYED UMAIR HUSSAIN
PROGRAMMABLE LOGIC CONTROLLER
Programmable logic controllers (PLCs) are the control hubs for a wide variety of automated
Programmable logic controllers are used extensively in diverse industrial applications ranging
ssembly. They were designed to replace the necessary sequential relay
PLCs have been gaining popularity on the factory floor and wi
some time to come. Other areas of application of PLCs are industrial automation
and control of industrial equipment. Most of this is because of the advantages they offer:
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Programmable logic controllers (PLCs) are the control hubs for a wide variety of automated systems and
industrial applications ranging
replace the necessary sequential relay
PLCs have been gaining popularity on the factory floor and will probably
some time to come. Other areas of application of PLCs are industrial automation
and control of industrial equipment. Most of this is because of the advantages they offer:
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� Reliable components
One may very correctly ask that why not to use a personal computer for these tasks in place a
specialized PLC. The answer is very simple; PLC
� Is intended for use on factory floors & in harsh environments
� Is more durable & Less expensive
� Can be placed in remote or rugged industrial locations
� Can perform at a high level for many years.
� Can withstand shock, vibration, humidity, EMI, RFI, dust, mist, and splash
� Can also be used for compiling data coming from many source
network
STANDARD PLC VS INDUSTRIAL SAFETY PLC
There are three fundamental differences between a safety
architecture, inputs, and outputs.
� ARCHITECTURE
A PLC has one microprocessor which execu
RAM for making calculations, ports for communications and I/O
contrast, a safety PLC has redundant
by a watchdog circuit and a synchronous detection circuit.
� INPUTS
Standard PLC inputs provide no internal means for testing the functionality of the input circ
contrast, Safety P LCs has an internal ‘output’ circuit associated with each input for the purpose of
‘exercising’ the input circuitry. Inputs are driven both high and low for very short cycles during runtime to
verify their functionality.
� OUTPUTS
The PLC has one output switching d
point after each of two safety switches located behind the output driver and a third test point downstream
of the output driver. E ach of the two safety switches is
is detected at either of the two safety switches due to switch or microprocessor failure, or at the test point
downstream from the output driver, the operating system of a safety
system failure. At that time, a safety
equipment shutdown.
EMERGENCY SHUTDOWN SYSTEM
Emergency shut-down system (ESD) or Safety Instrumented Systems (SIS) is defined as a system designed to respond to conditions in the plant which may be hazardous in them or, if no action was taken, could eventually give rise to a hazard. The ESD must generate the correct outputs to mitigate the hazardous consequences or prevent the hazard.
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One may very correctly ask that why not to use a personal computer for these tasks in place a
The answer is very simple; PLC
Is intended for use on factory floors & in harsh environments
le & Less expensive
Can be placed in remote or rugged industrial locations
Can perform at a high level for many years.
Can withstand shock, vibration, humidity, EMI, RFI, dust, mist, and splash
Can also be used for compiling data coming from many sources and uploading on a computer
STANDARD PLC VS INDUSTRIAL SAFETY PLC
There are three fundamental differences between a safety PLC and a standard PLC in terms
has one microprocessor which executes the program, a Flash area which stores the program,
rts for communications and I/O to detect and control the machine. In
has redundant microprocessors, Flash and RAM that are continuously monitored
by a watchdog circuit and a synchronous detection circuit.
Standard PLC inputs provide no internal means for testing the functionality of the input circ
an internal ‘output’ circuit associated with each input for the purpose of
‘exercising’ the input circuitry. Inputs are driven both high and low for very short cycles during runtime to
one output switching device, whereas a safety PLC digital output logic circuit contains a test
point after each of two safety switches located behind the output driver and a third test point downstream
of the output driver. E ach of the two safety switches is controlled by a unique microprocessor. If a failure
is detected at either of the two safety switches due to switch or microprocessor failure, or at the test point
downstream from the output driver, the operating system of a safety PLC will automatically acknowledge
ailure. At that time, a safety PLC will default to a known state on its own, facilitating an orderly
EMERGENCY SHUTDOWN SYSTEM
down system (ESD) or Safety Instrumented Systems (SIS) is defined as a system ond to conditions in the plant which may be hazardous in them or, if no action was taken,
could eventually give rise to a hazard. The ESD must generate the correct outputs to mitigate the hazardous consequences or prevent the hazard.
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One may very correctly ask that why not to use a personal computer for these tasks in place a
s and uploading on a computer
in terms of
tes the program, a Flash area which stores the program,
to detect and control the machine. In
AM that are continuously monitored
Standard PLC inputs provide no internal means for testing the functionality of the input circuitry. By
an internal ‘output’ circuit associated with each input for the purpose of
‘exercising’ the input circuitry. Inputs are driven both high and low for very short cycles during runtime to
output logic circuit contains a test
point after each of two safety switches located behind the output driver and a third test point downstream
ique microprocessor. If a failure
is detected at either of the two safety switches due to switch or microprocessor failure, or at the test point
automatically acknowledge
default to a known state on its own, facilitating an orderly
down system (ESD) or Safety Instrumented Systems (SIS) is defined as a system ond to conditions in the plant which may be hazardous in them or, if no action was taken,
could eventually give rise to a hazard. The ESD must generate the correct outputs to mitigate the
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Safety instrumented systems are separate and independent from regularare composed of similar elements, includingFailure and/or spurious trips could result in expensive procedural and downtime consequences. Thus, the reliability on safety and availability, need to be tested periodically before the next maintenance, but not interrupt the operation. Due to the critical nature of such systems ESD system are typically composed of sensors, logic solvers and final control elements. The actuated shutdown valve is expected to remain static in one position for a long period of time and reliarises, i.e. to spring into safe mode position.
Emergency Shutdown System at FFC
The ESD system installed at FFC plant is manufactured by Honeywell which they called as
Control (FSC) system. This system satisfies
highly reliable, high-integrity safety system for safety
Total Plant Solution (TPS) system, integrated into Plant Scale, or in sta
system forms the basis for functional safety
the environment combined with optimum availability for plant operation.
HONEYWELL FAIL
BASIC ARCHITECTURE
The basic architecture of the FSC system. Two major system parts can be distinguished:
• the Central Part, and
• The Input/output interfaces.
� Central Part
The Central Part (CP) is the heart of designed for safety-critical applications which can be tailored to the needs of any application.important Central Part modules are: a) Control Processor: reads the processuser in graphical Functional Logic Diagrams (FLDs). The results of the control program are then transmitted to the output interfaces.
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stems are separate and independent from regular distributed control systemsare composed of similar elements, including sensors, logic solvers, actuators and support systems.Failure and/or spurious trips could result in expensive procedural and downtime consequences. Thus, the reliability on safety and availability, need to be tested periodically before the next maintenance, but not
pt the operation. Due to the critical nature of such systems ESD system are typically composed of sensors, logic solvers and final control elements. The actuated shutdown valve is expected to remain static in one position for a long period of time and reliably operate only when an emergency situation arises, i.e. to spring into safe mode position.
Emergency Shutdown System at FFC
The ESD system installed at FFC plant is manufactured by Honeywell which they called as
em satisfies SIL3 standard. The Honeywell Fail Safe Control system is a
integrity safety system for safety-critical control applications. As part of Honeywell's
system, integrated into Plant Scale, or in stand-alone applications, the FSC
functional safety, thus providing protection of persons, plant equipment and
the environment combined with optimum availability for plant operation.
HONEYWELL FAIL-SAFE CONTROL (FSC)
ARCHITECTURE
system. Two major system parts can be distinguished:
Input/output interfaces.
Basic Architecture of FSC
The Central Part (CP) is the heart of the FSC system. It is a modular microprocessor system specifically critical applications which can be tailored to the needs of any application.
important Central Part modules are: reads the process inputs and executes the control program as created by the
user in graphical Functional Logic Diagrams (FLDs). The results of the control program are then transmitted to the output interfaces.
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control systems but and support systems.
Failure and/or spurious trips could result in expensive procedural and downtime consequences. Thus, the reliability on safety and availability, need to be tested periodically before the next maintenance, but not
pt the operation. Due to the critical nature of such systems ESD system are typically composed of sensors, logic solvers and final control elements. The actuated shutdown valve is expected to remain
ably operate only when an emergency situation
The ESD system installed at FFC plant is manufactured by Honeywell which they called as Fail Safe
standard. The Honeywell Fail Safe Control system is a
critical control applications. As part of Honeywell's
alone applications, the FSC
, thus providing protection of persons, plant equipment and
system. Two major system parts can be distinguished:
the FSC system. It is a modular microprocessor system specifically critical applications which can be tailored to the needs of any application. The most
inputs and executes the control program as created by the user in graphical Functional Logic Diagrams (FLDs). The results of the control program are then
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b) Watchdog: monitors the operation and the operating conditions ooperation of the processor is monitored by verifying if the processor executes all its tasks within a pre-calculated time frame, which depends on the configuration. The operating conditions monitored include the data integrity power (both under voltage and overvoltage). If the Watchdog detects a fault in the operation of the Control Processor or its operating conditions, it will deactivate the safetyinterfaces of the FSC system, independent of the Control Processor status.
c) Communication Processor:computer equipment via serial communication links (uses RS232, RS485 protocols). Dedicated modules are also available which provide communication capabilities with other systems.
� Input/output Interfaces
The FSC system provides a wide range of digital and analog indifferent characteristics to meet the demands of a wide r There are two plant control systems:1) DISTRIBUTED CONTROL SYSTEM 2) EMERGENCY SHUT DOWN SYTEM
Distributed control system works under normal process conditions & ESD system brings the plant in safe shutdown conditions in case the process parameters go beyond their control limits. TYPICAL LOOP OF ESD:
Functional Logic Diagram (FLD)
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monitors the operation and the operating conditions of the Control Processor. The operation of the processor is monitored by verifying if the processor executes all its tasks within a
calculated time frame, which depends on the configuration. The operating conditions monitored include the data integrity of the processor memory and the voltage range of the supply power (both under voltage and overvoltage). If the Watchdog detects a fault in the operation of the Control Processor or its operating conditions, it will deactivate the safety
erfaces of the FSC system, independent of the Control Processor status.
Communication Processor: allows the FSC system to exchange information with other computer equipment via serial communication links (uses RS232, RS485 protocols). Dedicated
also available which provide communication capabilities with other systems.
The FSC system provides a wide range of digital and analog input and output interfaces, each different characteristics to meet the demands of a wide range of field equipment.
There are two plant control systems: 1) DISTRIBUTED CONTROL SYSTEM 2) EMERGENCY SHUT DOWN SYTEM
Distributed control system works under normal process conditions & ESD system brings the plant in safe case the process parameters go beyond their control limits.
PLC PROGRAMMING
Functional Logic Diagram (FLD)
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f the Control Processor. The operation of the processor is monitored by verifying if the processor executes all its tasks within a
calculated time frame, which depends on the configuration. The operating conditions of the processor memory and the voltage range of the supply
power (both under voltage and overvoltage). If the Watchdog detects a fault in the operation of the Control Processor or its operating conditions, it will deactivate the safety-critical output
allows the FSC system to exchange information with other computer equipment via serial communication links (uses RS232, RS485 protocols). Dedicated
also available which provide communication capabilities with other systems.
put and output interfaces, each with
Distributed control system works under normal process conditions & ESD system brings the plant in safe
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The FSC system's safety-critical control functions are determined by the safety functions assigned to the system for the specific application. The FSC user software supports the design of the control program by the user. The control functions are defined via graphical Functional Logic Diagrams (FLD). Functional Logic Diagram, which demonstrates the flexibility of the proFLD programming includes the facility of encapsulation or modularization using function blocks, which are comparable to subroutines in high-level programming languages. This allows function blocks to be used to create complex functions. Function blocks only need to be tested once and can then be reused without the need for testing them again.
An FLD is split into four main areas:
• the information area (bottom)
• the input area (left),
• the control function area (center)
• the output area (right) The FLD control function area, which is the central area of the FLD, contains the actual implementation of the control function. The function is realized by interconnecting predefined symbols which provariety of functions including logical, numerical and timefunctions, user-definable blocks are supported:
• Function Blocks — standard FLDs for repetitive use within the control program
• Equation Blocks — for tabular definition of complex functions, e.g. non
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critical control functions are determined by the safety functions assigned to the the specific application. The FSC user software supports the design of the control program by
the user. The control functions are defined via graphical Functional Logic Diagrams (FLD). Functional Logic Diagram, which demonstrates the flexibility of the programming technique used in FSC Navigator. FLD programming includes the facility of encapsulation or modularization using function blocks, which are
level programming languages. This allows function blocks to be used ate complex functions. Function blocks only need to be tested once and can then be reused without
Functional Logic Diagram
An FLD is split into four main areas:
control function area (center)
area, which is the central area of the FLD, contains the actual implementation of the control function. The function is realized by interconnecting predefined symbols which provariety of functions including logical, numerical and time-related functions. Apart from these standard
definable blocks are supported:
standard FLDs for repetitive use within the control program
or tabular definition of complex functions, e.g. non-linear equations
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critical control functions are determined by the safety functions assigned to the the specific application. The FSC user software supports the design of the control program by
the user. The control functions are defined via graphical Functional Logic Diagrams (FLD). Functional gramming technique used in FSC Navigator.
FLD programming includes the facility of encapsulation or modularization using function blocks, which are level programming languages. This allows function blocks to be used
ate complex functions. Function blocks only need to be tested once and can then be reused without
area, which is the central area of the FLD, contains the actual implementation of the control function. The function is realized by interconnecting predefined symbols which provide a
related functions. Apart from these standard
linear equations
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YOKOGAWA DCS
TOPICSTOPICSTOPICSTOPICS
� Familiarization with DCS
� Developing control algorithms
� Training & simulation using test function(troubleshooting)
Distributed control systemA distributed control system (DCS) refers to a control system usually of a manufacturing system, process
or any kind of dynamic system, in which the controller elements
but are distributed throughout the system with each component sub
controllers. The entire system of controllers is connected by networks for communication and monitoring.
DCS is a very broad term used in
a variety of industries, to monitor
and control distributed equipment.
A Distributed Control System is a
part of manufacturing industry.
DCS is used in industrial and civil
engineering applications to
monitor and control distributed
equipment with remote human
intervention. A DCS typically uses
custom designed processors as
controllers and uses both
proprietary interconnections and
communications protocol for
communication. Input and output
modules form component parts of the DCS.
sends information to output modules. The input modules receive information from input instruments in the
process (or field) and transmit instructions to the output instruments in the field. Computer
electrical buses connect the processor and modules through multiplexer or de
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YOKOGAWA DCS
n with DCS hardware, software & architecture.
Developing control algorithms
Training & simulation using test function(troubleshooting)
CO-ORDINATOR
ENGR.SYED UMAIR HUSSAINENGR.SYED UMAIR HUSSAINENGR.SYED UMAIR HUSSAINENGR.SYED UMAIR HUSSAIN
Distributed control system A distributed control system (DCS) refers to a control system usually of a manufacturing system, process
or any kind of dynamic system, in which the controller elements are not central in location (like the brain)
but are distributed throughout the system with each component sub-system controlled by one or more
controllers. The entire system of controllers is connected by networks for communication and monitoring.
modules form component parts of the DCS. The processor receives information from input modules and
sends information to output modules. The input modules receive information from input instruments in the
process (or field) and transmit instructions to the output instruments in the field. Computer
electrical buses connect the processor and modules through multiplexer or de-multiplexers. Buses also
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software & architecture.
Training & simulation using test function(troubleshooting)
A distributed control system (DCS) refers to a control system usually of a manufacturing system, process
are not central in location (like the brain)
system controlled by one or more
controllers. The entire system of controllers is connected by networks for communication and monitoring.
The processor receives information from input modules and
sends information to output modules. The input modules receive information from input instruments in the
process (or field) and transmit instructions to the output instruments in the field. Computer buses or
multiplexers. Buses also
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connect the distributed controllers with the central controller and DCS typically contains one or more
computers for control and mostly use bot
System (DCCS) in general provides: for communication.
YOKOGAWA DCS ARCHITECTURE
Presently, FFC is using DCS system manufactured by
Yokogawa a Japanese company. General architecture of
Yokogawa CS3000 is described as follows. It consists of the
following main parts:
1. FCS cabinets
2. Human interface machines (HIM)
3. Engineering work station (EWS)
All transmitters installed all over the plant sent their information
in the form of current signal to the DCS system. All the field
wires terminate at the nest which contains the I/O cards. Four of
the nest then connects to the one node interface unit (NIU).
These nodes then connect to the central processing unit called
Field Control Unit (FCU) through RI/O buses. Vnet cables
provide interface between FCS cabinets and to the Human
Interface Unit. HMI are also connected to each other over
Ethernet and also to Engineering work station (EWS). The
following completely illustrate the whole systems and
connections between different parts of it.
FIELD CONTROL STATION (FCS)
The FCS controls the plant. By the difference of used I/O modules, there are two models of the FCS;
namely the FCS for FIO and the FCS for RIO. In addition to the above models, there is t
FCS.
FCS for RIO
This FCS uses the Remote I/O (RIO) modules, which have many installation bases and M4 screw
terminals to connect signal cables. According to the application capacity, there are the standard model
and the enhanced model.
Human Interface Station (HIS)
The HIS is mainly used for operation and monitoring
process variables, control parameters, and alarms necessary for
users to quickly grasp the operating status of the
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connect the distributed controllers with the central controller and DCS typically contains one or more
computers for control and mostly use both propriety interconnections and protocols Distributed Control
System (DCCS) in general provides: for communication.
YOKOGAWA DCS ARCHITECTURE
Presently, FFC is using DCS system manufactured by
Yokogawa a Japanese company. General architecture of
CS3000 is described as follows. It consists of the
2. Human interface machines (HIM)
All transmitters installed all over the plant sent their information
gnal to the DCS system. All the field
wires terminate at the nest which contains the I/O cards. Four of
the nest then connects to the one node interface unit (NIU).
These nodes then connect to the central processing unit called
ough RI/O buses. Vnet cables
provide interface between FCS cabinets and to the Human
Interface Unit. HMI are also connected to each other over
Ethernet and also to Engineering work station (EWS). The
following completely illustrate the whole systems and
nnections between different parts of it.
The FCS controls the plant. By the difference of used I/O modules, there are two models of the FCS;
namely the FCS for FIO and the FCS for RIO. In addition to the above models, there is t
This FCS uses the Remote I/O (RIO) modules, which have many installation bases and M4 screw
terminals to connect signal cables. According to the application capacity, there are the standard model
Human Interface Station (HIS)
The HIS is mainly used for operation and monitoring – it displays
process variables, control parameters, and alarms necessary for
users to quickly grasp the operating status of the plant. It also
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connect the distributed controllers with the central controller and DCS typically contains one or more
h propriety interconnections and protocols Distributed Control
The FCS controls the plant. By the difference of used I/O modules, there are two models of the FCS;
namely the FCS for FIO and the FCS for RIO. In addition to the above models, there is the Compact type
This FCS uses the Remote I/O (RIO) modules, which have many installation bases and M4 screw
terminals to connect signal cables. According to the application capacity, there are the standard model
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incorporates open interfaces so that supervisory computers can access trend data messages, and
process data.
• Console Type HIS
This is a new console type human interface station, at which a general purpose PC is installed. There are
two types of console type HISs: one is enclosed
another is open display style, the configuration of which is selectable.
• Desktop Type HIS
This HIS uses a general purpose PC
CONTROL VALVES & PSV'sTOPICSTOPICSTOPICSTOPICS
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o that supervisory computers can access trend data messages, and
This is a new console type human interface station, at which a general purpose PC is installed. There are
two types of console type HISs: one is enclosed display style, the appearance of which is usual style, and
another is open display style, the configuration of which is selectable.
This HIS uses a general purpose PC
CONTROL VALVES & PSV's
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o that supervisory computers can access trend data messages, and
This is a new console type human interface station, at which a general purpose PC is installed. There are
display style, the appearance of which is usual style, and
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� Types and Terminology’s
� Testing and calibration procedures.
� Control Valves positioned, actuators & accessories.
ENGR.ENGR.ENGR.ENGR.
Control valves are valves used to control conditions such asby fully or partially opening or closing in response to signals received from point" to a "process variable" whose value is provided byconditions.
The opening or closing of control valves is done by mof electrical, hydraulic or pneumaticused to control the opening or closing of the actuator based on Electric, or Pneumatic Signals. These control signals, traditionally based on 3-15psi (0.2-1.0bar), more common now are 4-20mA signals for industry.
Types of Control Valve Bodies
1. Gate Valve
A Gate Valve is mainly use for on/off control. opens by lifting a round or rectangular gate/wedge out of the path of the fluid. The distinct feature of a gate valve is the sealing surfaces between the gate and seats are planar. The gate faces can form a wedge shape or they can be parallel. Gate valves are sometimes used for regulating flow, but many are not suited for that purpose, having been
designed to be fully opened or closed.
typical gate valve has no obstruction in the flow path, resulting in very low friction loss.
Gate valves are characterized as having either a rising or a nonrising stem. Rising stems provide a visual
indication of valve position. Nonrising stems are used where vertical space is limited or underground.
2. Globe Valve
Globe valves are named for their sphby an internal baffle which has an opening forming a seat onto which a movable disc can be screwed in to close (or shut) the valve. In globe valves, the disc is connected to a stem which is action. When a globe valve is manually operated, the stem is turned by a hand wheel. Although globe
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Terminology’s.
Testing and calibration procedures.
Control Valves positioned, actuators & accessories.
CO-ORDINATOR
ENGR.ENGR.ENGR.ENGR. SYED UMAIR HUSSAINSYED UMAIR HUSSAINSYED UMAIR HUSSAINSYED UMAIR HUSSAIN
Control Valves
to control conditions such as flow, pressure, temperatureby fully or partially opening or closing in response to signals received from controllers that compare a "
" to a "process variable" whose value is provided by sensors that monitor changes in such
The opening or closing of control valves is done by means pneumatic systems. Positioners are
used to control the opening or closing of the actuator based on Electric, or Pneumatic Signals. These control signals,
1.0bar), more common now
is mainly use for on/off control. It opens by lifting a round or rectangular gate/wedge out of the path of the fluid. The distinct feature of a gate valve is the sealing surfaces between the gate and seats are planar. The gate faces can form a wedge shape or they can
es are sometimes used for regulating flow, but many are not suited for that purpose, having been
designed to be fully opened or closed. When fully open, the
typical gate valve has no obstruction in the flow path, resulting in very low friction loss.
alves are characterized as having either a rising or a nonrising stem. Rising stems provide a visual
indication of valve position. Nonrising stems are used where vertical space is limited or underground.
Globe valves are named for their spherical body shape. The two halves of the valve body are separated by an internal baffle which has an opening forming a seat onto which a movable disc can be screwed in to close (or shut) the valve. In globe valves, the disc is connected to a stem which is operated by screw action. When a globe valve is manually operated, the stem is turned by a hand wheel. Although globe
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temperature, and liquid level controllers that compare a "set
that monitor changes in such
typical gate valve has no obstruction in the flow path, resulting in very low friction loss.
alves are characterized as having either a rising or a nonrising stem. Rising stems provide a visual
indication of valve position. Nonrising stems are used where vertical space is limited or underground.
erical body shape. The two halves of the valve body are separated by an internal baffle which has an opening forming a seat onto which a movable disc can be screwed in to
operated by screw action. When a globe valve is manually operated, the stem is turned by a hand wheel. Although globe
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valves in the past had the spherical bodies which gave them their name, many modern globe valves do not have much of a spherical shape, buan internal mechanism.
Globe valves are used for applications requiring throttling and frequent operation.
3. Butterfly Valve
A butterfly valve is a particular type of valve that uses circular vane or a disc as the shuthave a quick opening/closing quartercontrol the flow of liquid through a piping system. They typically pivot on axes perpendicular to the directionCompared with ball valves, butterfly valves do not have pockets to trap fluids when the valve is in the closed position. Butterfly valves are frequently used as throttling devices, controlling the levels of flow in various positions: entirely closed, entirely open or partially open. They can control various substances of air, liquid or solid currents and are situated on a spindle that allows for flow in a single direction.
4. Ball Valve
A ball valve (like the butterfly valve, one of a family of valves called quarter turn valves) is a valve that opens by turning a handle attached to a ball inside the valve. The ball has a hole, or port, through the middle so that when the port is in line with both ends of thclosed, the hole is perpendicular to the ends of the valve, and flow is blocked. The handle posiyou "see" the valve’sposition Ball valves are durable and usually work to achieve perfect shutoff even after years of disuse. They are therefore an excellent choice for shutoff applications (and are often preferred to globe valves and gate valves for this purpose). They do not offer the fine control that may be necessary in throttling applications but are sometimes used for
this purpose.
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valves in the past had the spherical bodies which gave them their name, many modern globe valves do not have much of a spherical shape, but the term globe valve is still often used for valves that have such
Globe valves are used for applications requiring throttling and frequent operation.
A butterfly valve is a particular type of valve that uses either a circular vane or a disc as the shut-off mechanism. Butterfly valves have a quick opening/closing quarter-turn mechanism that is used to control the flow of liquid through a piping system. They typically pivot on axes perpendicular to the direction of flow inside the flow chamber. Compared with ball valves, butterfly valves do not have pockets to trap fluids when the valve is in the closed position. Butterfly valves are frequently used as throttling devices, controlling the levels of flow in
positions: entirely closed, entirely open or partially open. They can control various substances of air, liquid or solid currents and are situated on a spindle that allows for flow in a single direction.
the butterfly valve, one of a family of valves called quarter turn valves) is a valve that opens by turning a handle attached to a ball inside the valve. The ball has a hole, or port, through the middle so that when the port is in line with both ends of the valve, flow will occur. When the valve is closed, the hole is perpendicular to the ends of the valve, and flow is blocked. The handle position lets you "see" the valve’sposition.
Ball valves are durable and usually work to fter years of disuse.
They are therefore an excellent choice for shutoff applications (and are often preferred to globe valves and gate valves for this purpose). They do not offer the fine control that may be necessary in
metimes used for
Ball Valve
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valves in the past had the spherical bodies which gave them their name, many modern globe valves do t the term globe valve is still often used for valves that have such
the butterfly valve, one of a family of valves called quarter turn valves) is a valve that opens by turning a handle attached to a ball inside the valve. The ball has a hole, or port, through the
e valve, flow will occur. When the valve is
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Solenoid Operated Valve (SOV)
Solenoid valves are electrically operated devices that control the flow of liquids. Solenoid valves are electro
mechanical devices that use a wire coil and a movable plunger, called a solenoid,
solenoid controls the valve during either the open or closed positions. Thus, these kinds of valves do not regulate
flow. They are used for the remote control of valves for directional control of liquids. Solenoid valves
main parts: the solenoid and the valve.
magnetic field acts upon the plunger,
There are two general types of solenoid valves: direct
a plunger that is in direct contact with the primary opening in the body. This plunger is used to open and close the
orifice. The pilot-operated solenoid valve works with a diaphragm rather than a plunger. This valve uses differential
pressure to control the flow of fluids. The air
the fluids to flow through.
Check Valves/Non-return Valves (NRV)
Check valves, also referred to as "non
fluid, air or gas to flow in only one direction. When the fluid moves in the pre
Any backflow is prevented by the moveable portion of the valve. A swinging disc, ball, plunger or poppet moves out
of the way of the original flow. Since these devices are slightly larger than the through hole, the pressure of
backflow will cause them to tightly seal, preventing reversal of flow. Gravity or a spring assists in the closing of the
valve.
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Solenoid valves are electrically operated devices that control the flow of liquids. Solenoid valves are electro
devices that use a wire coil and a movable plunger, called a solenoid, to control a particular valve. The
the valve during either the open or closed positions. Thus, these kinds of valves do not regulate
remote control of valves for directional control of liquids. Solenoid valves
After the coil receives a current, the actuating magnetic field is created. The
magnetic field acts upon the plunger, resulting in the actuation of the valve, either opening or closing it.
neral types of solenoid valves: direct-acting and pilot-operated. Direct-acting solenoid valves have
plunger that is in direct contact with the primary opening in the body. This plunger is used to open and close the
valve works with a diaphragm rather than a plunger. This valve uses differential
control the flow of fluids. The air-venting valve is opened to allow the pressure to equalize and permit
Valves (NRV)
Check valves, also referred to as "non-return" or "one-way directional" valves, are very simple valves that allow
fluid, air or gas to flow in only one direction. When the fluid moves in the pre-determined direction, the valve opens.
low is prevented by the moveable portion of the valve. A swinging disc, ball, plunger or poppet moves out
of the way of the original flow. Since these devices are slightly larger than the through hole, the pressure of
al, preventing reversal of flow. Gravity or a spring assists in the closing of the
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Solenoid valves are electrically operated devices that control the flow of liquids. Solenoid valves are electro-
to control a particular valve. The
the valve during either the open or closed positions. Thus, these kinds of valves do not regulate
remote control of valves for directional control of liquids. Solenoid valves have two
After the coil receives a current, the actuating magnetic field is created. The
resulting in the actuation of the valve, either opening or closing it.
acting solenoid valves have
plunger that is in direct contact with the primary opening in the body. This plunger is used to open and close the
valve works with a diaphragm rather than a plunger. This valve uses differential
venting valve is opened to allow the pressure to equalize and permit
way directional" valves, are very simple valves that allow
determined direction, the valve opens.
low is prevented by the moveable portion of the valve. A swinging disc, ball, plunger or poppet moves out
of the way of the original flow. Since these devices are slightly larger than the through hole, the pressure of
al, preventing reversal of flow. Gravity or a spring assists in the closing of the
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Positioner
Positioner is a device used to position a valve with regard to a signal. The positioner
compares the input signal (3-15 psi) with a mechanical feedback
then produces the force necessary to move the actuator output until the mechanical
output position feedback corresponds with the pneumatic signal value. There are three
modes of a positioned that it can be set:
• Fail to close
• Fail to open
• Last position
Regulator
A regulator is a device that regulates the supply of air from the supply line to some
device, e.g from 7 kg to 1.4kg.Regulator has two main parts
• Regulation Part: This includes a spring, compressed valve, diaphragm and
feedback system needed for regulation.
• Filter: This is the filtering part on the input used to filter any dust particles or moisture in the air.
Pressure Safety Valve (PSV)
A pressure safety valve is a valve mechanism for the automatic release of a substance from a
vessel, or other system when the pressure or temperature exceeds preset limits. It is a mechanical safety and last line
of protection against disaster in case both DCS a
compressors, pumps, etc from over pressure and from rupturing by bleeding the extra pressure on the atmosphere.
Its simplest example is the weight PSV on the pressure cooker used in homes for c
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Positioner is a device used to position a valve with regard to a signal. The positioner
15 psi) with a mechanical feedback link from the actuator.
then produces the force necessary to move the actuator output until the mechanical
output position feedback corresponds with the pneumatic signal value. There are three
modes of a positioned that it can be set:
A regulator is a device that regulates the supply of air from the supply line to some
device, e.g from 7 kg to 1.4kg.Regulator has two main parts
This includes a spring, compressed valve, diaphragm and
feedback system needed for regulation.
This is the filtering part on the input used to filter any dust particles or moisture in the air.
mechanism for the automatic release of a substance from a
when the pressure or temperature exceeds preset limits. It is a mechanical safety and last line
of protection against disaster in case both DCS and ESD system fails. These are used to protect vessels, tanks,
compressors, pumps, etc from over pressure and from rupturing by bleeding the extra pressure on the atmosphere.
Its simplest example is the weight PSV on the pressure cooker used in homes for cooking.
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It
the
This is the filtering part on the input used to filter any dust particles or moisture in the air.
mechanism for the automatic release of a substance from a boiler, pressure
when the pressure or temperature exceeds preset limits. It is a mechanical safety and last line
These are used to protect vessels, tanks,
compressors, pumps, etc from over pressure and from rupturing by bleeding the extra pressure on the atmosphere.
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PThis six week internship at production unit FFC MM developed an understanding of urea fertilizer
production especially to the field instrumentation and control technology. Experience and exposure was
not only limited to process flow but was
techniques and problem handling and troubleshooting.
The plant division and design, management and oper
safe and smooth process.
Literature review from TTC library, study of technical data and manuals of different
discussion with engineers and technical staff and visit to plant sit
cooperative coordination of management and staf
period.
Although, the internship program was good but I think there are some areas which can still be improved.
Schedule for entire internship should be planned on daily basis. Office and work environ
would help interns to build a professional attitude and eliminate the feeling of being left alone. Frequent
plant visits can make the Internship Program more Intriguing and help the interns to explore industry.
Library at Technical Training Center should be equipped with a computer section where Interns should be
provided with internet facility.
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
Personal Feedback This six week internship at production unit FFC MM developed an understanding of urea fertilizer
production especially to the field instrumentation and control technology. Experience and exposure was
imited to process flow but was widened to operating logics, process control & production
problem handling and troubleshooting.
The plant division and design, management and operation enhanced the concept and perspective about
Literature review from TTC library, study of technical data and manuals of different equipment
discussion with engineers and technical staff and visit to plant site added a sound knowledge. The
cooperative coordination of management and staff raised the morale in the journey of Lifelong
Although, the internship program was good but I think there are some areas which can still be improved.
Schedule for entire internship should be planned on daily basis. Office and work environ
would help interns to build a professional attitude and eliminate the feeling of being left alone. Frequent
plant visits can make the Internship Program more Intriguing and help the interns to explore industry.
enter should be equipped with a computer section where Interns should be
AN INTERNSHIP At FAUJI FERTILIZER COMPANY
Dawood University of Engineering & Technology
This six week internship at production unit FFC MM developed an understanding of urea fertilizer
production especially to the field instrumentation and control technology. Experience and exposure was
ol & production
perspective about
equipments,
knowledge. The
ifelong learning
Although, the internship program was good but I think there are some areas which can still be improved.
Schedule for entire internship should be planned on daily basis. Office and work environment exposure
would help interns to build a professional attitude and eliminate the feeling of being left alone. Frequent
plant visits can make the Internship Program more Intriguing and help the interns to explore industry.
enter should be equipped with a computer section where Interns should be