2. Typical Objectives of Plant Operation
1. Protect people
2. Protect Environment
3. Protect Equipment
4. Maintain Smooth operation
5. Achieve Product rates and quality
6. Profit = optimising first five
7. Monitoring & diagnosis
These are Achieved Through Process Control…
2
3. Distributed Control System (DCS)
DCS (Distributed Control System) is a computerized control system
used to control the production line in the industry
DCS was introduced in 1975 by Honeywell (TDC2000) and Yokogawa
(CENTUM)
Other vendors: ABB (Bailey etc), Foxboro, Emerson (Fischer,
Rosemount etc)
3
4. DCS Architecture
Process Transmitters and Actuators
Data Highway
(Shared Communication Facilities)
......
Data
Storage Unit
Host
Computer
System
Consoles
PLC
4-20 mA
Local
Console
Local
Control
Unit
4-20 mA
Local
Control
Unit
Local
Console
4
5. Fieldbus Technology
Introduced 1988 but underwent many
development
Standard IEC61158 introduced in
1999
Based upon smart devices installed
in the field.
Uses data highway to replace wires
for signal transfer.
Can mix sensors, transmitters, and
control valves from different vendors
CEAG
I/O
P5001 0
... 150 bar
•Foundation Fieldbus (FF)
•Profibus (Process Field Bus)
•Others: ControlNet, P-Net, SwiftNet ,
WorldFIP, Interbus, EtherCAT, SERCODS etc
5
8. We desire independent protection layers, without common-
cause failures - Separate systems
sensors
SIS system
i/o i/o………….
sensors
Digital control system
i/o i/o………….
DCS handles controls
and alarms functions.
PLC handles SIS and
Alarms associated with SIS
Redundancy
8
9. Control Diagram of a Typical Control Loop
Controller
F1
T1
T
F
F2
T2
TC
Actuator
System
TT
Sensor
System
9
21. Why are some valves Fail-Opened, While
Others Fail-Closed
21
22. Typical response of Control Valves
A. Quick-Opening
B. Linear
C. Square-root
D. Equal Percentage
Percentage of
Maximum flow
Percentage of Stem Travel
A
B
D
C
Why do we need different shapes of plugs in the
control valves ?
22
23. Motor Speed Control
DC Motor Speed Control
– Adjust the power of motor by varying current or
voltage
AC Motor Speed Control (3 Phase Motor)
– Adjust the power of motor by varying the frequency of
the AC cycles
Steam Driven Turbine
– Adjust the turbine speed to adjust the pumping rates
23
24. Safety Features
Alarms & Enunciators
Interlocks
– To isolate the impact of process failures from one
section from another
Rupture Disks, Pressure Relieve Valves, etc
24
26. How Reliable are Those Instruments?
Reliability can be estimated using the
following equation
t
eR
Here R is reliability, is the annual failure
frequency (failure/year) and t is time (year)
t
eRp
11
The failure probability can then be estimated:
Here p is the annual probability of failure
26
27. Safety Integrity Level (SIL)
A SIL is a measure of safety system performance, in
terms of probability of failure on demand (PFD). The
higher the SIL is, the more reliable or effective the
system is.
Every Safety Instrumented Function (SIF) has a SIL
classification guided by the IEC 61508 standard
ANSI/ISA S84.01 and IEC 61508 require that companies
assign a target SIL for any new or retrofitted SIS.
Three sector specific standards have been released
using the IEC 61508 framework, IEC 61511 (process),
IEC 61513 (nuclear) and IEC 62061 (manufacturing).
27
28. SIL and PFD
Safety Integrity
Level (SIL)
PFD
(Low Demand Mode)
PFD
(High Demand Mode)
1 > 10-2 to < 10-1 > 10-6 to < 10-5
2 > 10-3 to < 10-2 > 10-7 to < 10-6
3 > 10-4 to < 10-3 > 10-8 to < 10-7
4 > 10-5 to < 10-4 > 10-9 to < 10-8
PFD - Probability of Failure on Demand per year
• Low Demand Mode – intermittent operation (less than once a
year)
• High Demand Mode – Continuous operation or systems that
operates more than once a year
28
30. How to Assign SIL Level?
PFD requirement typically determine by the
PHA Team. Based on this, required SIL is
identified.
There are various methodology available e.g.
HSE Research report no 216 as well as others
30
31. Typical Product SIL (General Motors)
Product SIL Suitability
Level
FL4000 Flame Detector (Multi-
Spectral IR)
3
FL3111 Flame Detector (UV) 2
S100C Combustible gas detector 3
Field Mounted Display 2
TA102A Controller 2
31