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Process Training Control System

- TDO/TEC/INS - JC Michaud. Process Training Control System. Set Point. PID Algorithm. P. Error. I. D. Measurement. Analog Sensors. Valves. Command. Control loop Philosophy. Uninterruptible Electrical 220VAC Power Supply . PLC or Controller.

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Process Training Control System

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  1. - TDO/TEC/INS - JC Michaud Process TrainingControl System

  2. Set Point PIDAlgorithm P Error I D Measurement Analog Sensors Valves Command Control loop Philosophy

  3. Uninterruptible Electrical 220VAC Power Supply PLC or Controller Hydraulic Power Unit or Instrument Air gas Compressor Unit Output Mod Digital Input Mod Analog Output Mod Analog Input Mod Digital CPU: Data processing Uninterruptible Electrical 24VDC Power Supply I/P EV Analogical Sensor PT,FT,TT,ST…. F&GD, Digital Sensor (Switches) PSL,LSL, … ZIO,ZIC,…. TT Control Valve PCV,TCV,FCV…. Safety Valve ESDV,SDV,…. Typical Instruments To be configured according to Project specifications: Control logic, Safety charts..Etc. 1- Safety valve Normally Active:Return in safe position (Opened or closed) when de energised : loss of Hydraulic or Instrument air or on failure power supply and/or control system failure. 2- Safety valve Normally Not Active:Not operational when de energised : loss of Hydraulic or Instrument air or on failure power supply and/or control system failure

  4. Uninterruptible Electrical 24VDC Power Supply Single PLC or Controller Triplicate PLC or Controller Watch Dog Watch Dog Watch Dog Analog Sensor Analog Sensor Analog Sensor Output Mod Digital Output Mod Digital Output Mod Digital Input Mod Analog Input Mod Analog Input Mod Analog CPU CPU CPU Hydraulic Power Unit or Instrument Air gas Compressor Unit Dual PLC or Controller & & & EV Safety Valve Normally active Safety Integrity Level Probability of a dangerous failure per year SIL 4 SIL3 SIL2 SIL1 Safety loop Philosophy for Normally Active System

  5. Uninterruptible Electrical 24VDC Power Supply Single PLC or Controller Triplicate PLC or Controller Watch Dog Watch Dog Watch Dog Analog Sensor Analog Sensor Analog Sensor Output Mod Digital Output Mod Digital Output Mod Digital Input Mod Analog Input Mod Analog Input Mod Analog CPU CPU CPU Hydraulic Power Unit or Instrument Air gas Compressor Unit Dual PLC or Controller & & & EV Safety Valve Normally Inactive Safety Integrity Level Probability of failure to perform on demand SIL 4 SIL3 SIL2 SIL1 Safety loop Philosophy for Normally InActive System

  6. HMI Control room Centralised Technical room Maint Interfaces PDS USS [SIL4] PSS [SIL2] PCS ESD [SIL3] F&G [SIL3] Packages CS Subsea Tele metry HCS ECS Metering Analyser DCS Technical rooms LocalHMI LocalHMI LocalHMI LocalHMI Training Simulator TSS ICSS Integrated Control and Safety System

  7. Input OutputMod PS B CPU A PS A CPU B Com B Com A Server B Server A ICSS Typical Design for Redundancies HMI Redundant Servers Redundant Networks Redundant CPU Non Redundant IO Cards Redundant Power Supply PLC or Controller PCS

  8. FO Cables with separate pathways ICSS Network A Communication Equipment Technical rooms Functional Arrangement Marshalling Cabinets 0,8m Redundant communication networks and equipment Controller ICSS Network B Communication Equipment 0,8m IO Cards Geographical Arrangement Incoming cables: armoured &flame resistant JB JB Field -Zone1 Area Valves Sensors Instrument & Controllers Typical Installation

  9. FO Cables with separate pathways ICSS Network A Communication Equipment Technical rooms Marshalling Cabinets 0,8m Redundant communication networks and equipment Controller ICSS Network B Communication Equipment 0,8m IO Cards Field Bus JB JB RIO RIO Field -Zone1 Area Valves Sensors Controller Technological Trend: Remote IO & Fieldbuses

  10. System Design Integration & Interfaces Management Standardisation of equipment Normalisation (ISO,….) Contracts design and timing scope of supply scope of works <-> SERVICES DVT Design Validation Test FAT Factory Acceptance Test Methodology SAT Factory Acceptance Test SPT Sustained Performance Test Main Engineering Issues General Specifications: GS SAF 261&371; GS INS 134,101,102,104,108,137,900 Operating Philosophy, Safety Philosophy,TFE “Typicals” Simplification of interfaces Clarification of contractors & vendors responsibilities !!! Importance of Requirements and Specifications !!!!!

  11. Abbreviations

  12. Rockwell (USA) FMC (USA) Allen Bradley Sprecher & Schur Kongsberg OS Smith Yokogawa (J) Johnson Controls Metso (FIN) Controle Bailey GTI Marex Neles Automation Jamesbury Rauma Valmet Automation Vendors Lists including main groups Emerson Electric (USA) Schneider (F/D) Allied Signal (USA) Honeywell Pepperl & Fuchs (TMR) Icotron KBC Profimatics Sacda Leeds & Northrup (Inst.) GERDS AEG Telefunken Merlin Gerin April Modicon Square D Telemecanique Rosemount Fisher Controls Joucomatic Leroy Somer Brooks Intellution Micromotion HD Baumann Exac Daniel Bettis Spectratek Dantorque Prime ABB (S/CH) Taylor Kent Introl CE Lummus Brown Boveri August Alfa Laval Elsag Bailey Bailey Controls Schlumberger Sereg Otic Fischer Porter Hartmann & Braun Degussa Applied Automation Invensys (UK) Siebe Foxboro Triconex Eckardt Schmitt Gestra Barber-Colman Leeds&Northrup(SCADA) Eurotherm Wonderware BTR Group

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