Ffbl Internship 2009

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INTERNSHIP REPORT 2009

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Cover page

FAUJI FERTILIZER BIN QASIM LTD.

Summer Internship Report

Submitted By:

Wahab uddin Nazar

4th Year Electronics Engineering

Quaid‐E‐Awam University of sciences and Technology

Nawabshah

Submitted To:

The Technical Training Centre

FAUJI FERTILIZER BIN QASIM LIMITED

Date of Submission: July 15, 09


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ACKNOWLEDGEMENT

I am very thankful to Allah for the successful completion of my four week internship the FFBL which is

one of the largest and growing Fertilizer Complex in Pakistan .During my internship I have learnt about

the Fertilizer industry, and its environment. As my field is related to instrument I have learnt about PLC`s.

Distributed Control System, Emergency Shutdown System , various types of instrument and many more

which is helpful in my future practical life as a professional Engineer. I learnt about the FFBL as an

organization, job handling procedures, maintenance and repairing procedures, job environment in FFBL

especially including E & I Department.

I am thankful to ENGR Rao Jameel (Trainer Engineer) who guide us to understand the environment and

rules of the in FFBL , ENGR Ammanullah Khan , ENGR Iqbal , ENGR Amjad khan ,Amir Tunio in

Instrument section CCR who instruct and guide me in orientation of Urea Plant and provide me many

important material and information which helps me apply my knowledge and built own my Technical

skills ,ENGR Muhammad Aniq , ENGR Ali provide a healthy environment When I study about DAP plant.

The technician and other staff of Instrument Department greatly cooperated, guided and helped me to

lead to a successful training of four weeks.


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PREFACE

This report is based on the training at in different plants of FAUJI FERTILIZER BIN QASIM LTD providing

necessary knowledge for carrying out various kind of instruments maintenance and repair work .

The aim to write this report is to share a meaningful material and concepts about the field of

instrumentation and its application in industry.


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INDEX

SERIAL # CONTENT PAGE#

1 Title Page ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1

2 Cover Page‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2

3 Acknowledgement‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐3

4 Preface‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐4

5 Index‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐5

6 An introduction of Fauji fertilizer bin Qasim Limited‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐6

7 Safety‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐7

8 Complex Description‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐9

9 Instrumentational Safety‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐9

I0 Utilities & Power Generation‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐11

11 Ammonia Plant‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐14

12 Urea Plant‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐19

13 DAP Plant‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐25

14 Scope of Instrumentation in FFBL‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐27

15 Control Systems of FFBL‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 37

16 Mentorship of FFBL‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐45


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AN INTRODUCTION OF FAUJI FERTILIZER BIN QASIM LIMITED

FFBL is one of the largest granular Urea and Dap fertilizer complex in Pakistan, built at the cost of US$469 Million in November 1993, located in Eastern Zone of Bin Qasim. The plant is approximately 45 km south east to Karachi City and it is connected to National High way.

FFBL is one and only Fertilizer complex in the Pakistan producing DAP (DI‐AMONIUM PHOSPHATE) .It is the soul producer of Urea and Dap in the country and forms part of Fauji group, one of the largest conglomerates of Pakistan. FFBL and FFC jointly holds 63% of Urea and 51% of DAP share of Pakistani fertilizer market.

FFBL increases its product capacity which is higher than the designed parameters.

PRODUCTION DESIGN ONWARDS Granular Urea 1670 MT/Day 1900 MT/Day DAP 1350 MT/Day 2230 MT/Day Ammonia 1270 MT/Day 1570 MT/Day

There are many features of FFBL that make it distinct from any other Fertilizer complex in Pakistan. It is the first granulated Urea plant and the first generating 60 HZ 110v power. Most modern state of the art instrumentation system like Distributed Control system (DCS) and Programmable logic Control (PLC) are applied on plant site.

FFBL is now close seeking Certification for following Quality Standards, which will continuously improving the company`s operation.

ISO 90012000 (QAULITY MANAGEMENT SYSTEM)

ISO 14001 (ENVIRONMENT MANAGEMENT SYSTEM)

OHSAS (OCCUPATONAL HEALTH AND SAFETY ASSESSMENT SERIES)


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SAFTEY

Safety is the first priority in the FFBL. Safety is a measure of success in any work. It means constant evaluation of thing, we do and how we go about doing them so that we won`t get harm, they our equipment’s condition will not contribute to an accident. In FFBL safety is considered equal to production.

Safety priorities of FFBL

Employs Company assets environmental

PERSONEL PROTECTIVE EQUIPMENTS:

Following Equipments are available for personal protection.

⊗ Safety helmets and shoes should be worn at plant site during working and any other activity. ⊗ Googols for protection against liquids and gases ⊗ Gloves for protection against acid and alkaline solution and heat ⊗ Respiration Mask with filters for duct and poisonous gases(H2S,NH3,Natural Gas etc) ⊗ Compressed air mask for protection against CO ⊗ Ear plugs for protection against mask ⊗ Draggers equipment (Tubes and Sniffer) for measurement of poisonous gases like

CO,H2S,NH3,Natural gas)

WORK PERMIT PROCEDURE

The FFBL is controlled by Operation Department and no work can be carried out by an unauthorized persons and Department. Any work which is related to concern Department is carried by his permission of maintenance and technical service Department. The permission is sought on a presubscribed format known as work permit.

Types of Work Permits:

COLD WORK PERMIT

This is required when urgent or routine repairs/inspection is to be carried out and job doesn’t involve a flame or spark


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HOT WORK PERMIT

It is require for jobs as lighting all naked flames, fires, exposed material including electric aces and sparks, electronic and gas welding/cutting, blow lamps and tar heating.

VESSEL ENTRY PERMIT

This is required one or more persons to enter in to any confined space such as tower/vessel/storage tank, excavation more than 1.5 deep, column, reactor, piping will 1m, sewers etc.

EXCAVATION

This permit is issued to cover all excavation work inside the plant


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COMPLEX DISCRIPTION

FFBL complex includes the following process units, offsite and on site.

PROCESS UNITS:

The process Units are

1. Ammonia Plant 2. DAP Plant 3. Urea Plant 4. Utilities & Power Generation.

FINAL PRODUCT RAW MATERIAL & CHEMICAL STORAGE:

Final product storage & bagging Facilities Ammonia Storage (5000 MT/Day) Phosphoric Acid , Sulfuric Acid storages Nitrogen Storage Unit

OFF SITES AND OTHER BUILDINGS

Fire water Natural gas Station Effluent Treatment Facility

BUILDING INCLUDING

Control Room and electrical Room

Laboratory

Technical service Building

Ware house and Workshop Technical Training Center Administration Building OCEA


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Instrumental Safety

Safety is the back bone of any Process industry. The instrumentation plays an important role in the startup, shutdown and working procedure of a process industry. Before installing, handling and application of instruments we should keep in mind some safety precautions. For the safe instrumentation I met the Engineers and staff of Instrumentation Section and discuss about the safety issues in Instrumentation. They share many important safety precautions and issues to me which helped me through my internship in handling and analyzing different instruments in plant site of FFBL.I like to share some important points for the study of safety issues in Instrumentation.

SAFTETY PRECAUTIONS:

Make sure that the tools you are using is in good condition because it not only important for your safety but also the screw and bolts can`t damaged and faulty when you apply that tools Check the voltages with the help of multimeter when instrument is removed or installed from the connection even if it is sure that the Loop is dead. When you remove any sort of electric wire when it is 24v or 110v it should by insulate with insulating tape Before working in a process line first find the temperature and pressure of the line After issuing the Job permit when you starting your relevant Job your first work to find where is the nearest SAFE ASSEMBLY POINT and the location of water showers During the uninstallation of pressure gauge the process line should not be depressurized .Drain the whole process and make proper isolation with the help of isolating valves. Keep in mind that the thermo wall is not disturbed while the uninstallation of Temperature Indicator is carried out. Keep the thermo well in the process line because when we disconnect the Temperature Indicator the high pressure comes outside which is very harmful and dangerous Protect your self while handling and testing the IGNITOR because there is a chance of an accident due to high voltages For the installation or maintenance of scanner/ignitor it is necessary to issue a hot permit for this job Make sure that there is no Auto Cut while working on a machine or motor. It is better to Rack out from sub station While working in acidic/caustic area of Utilities relevant type of safety suit must be worn. Lead suit must be worn while working in Radio Active source of Area Safety from the hazardous gases like Ammonia & Chlorine, gas mask should be worn to avoid accidents


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Utilities and Power Generation

Utilities plays an important role in the running of whole plant it gives all basic inputs according to the required input of different plants located at FFBL . Following are the Storage systems of Utilities.

Gas Turbines (Electrical power at 60 Hz frequency)

Emergency Diesel Generator

Demineralization Plant

Steam Generation System

Instrument & Service Air System

Cooling Water System

Waste Water Treatment

Nitrogen Storage

Utilities production unit

Power generation consisting of two 26.3 MW (ISO rating) gas turbine generators. Emergency power generation consisting of one 2MW emergency diesel generator a no no.2 oil uploading & storage.

Water processing consisting of storage basin, raw water clarification & filtration and demineralization units.

Sulphuric acid and caustic unloading and storage. Cooling water system Boiler feed water consisting of one gas fired heat recovery steam generator (HRSG) and one gas fired auxiliary boiler

Compressed air unit consisting of three air compressors ,two air dryers and one instrument air receiver Chilled and hot water plant consisting of two steam absorption chillers and one hot water system Natural gas system consisting of knockout drums and pressure reducing &distribution system Natural gas consisting of knockout drums and pressure reducing and distribution systems Storm sewer system consisting of one storm water impoundment and underground gravity collection and discharge system

Storm sewer system consisting of one collection basin, underground gravity collection and discharge system.

Chemical severs system consisting of one collection basin, underground collection, and discharge system and evaporation pond.

Fire protection system consisting of fire water storage ,hydrants and carbon di‐oxide system


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Utility Control ROOM

Control room has following control units:

1. Power and steam generation control 2. Water board 3. Boiler I. Auxiliary II. HRSG

4. Gas Turbine I. Gas turbine control (Mark V) II. Electrical GT

Fuel Gas Control System

• Fuel gas Stop/ratio and control valve assembly is used to control fuel gas supply • Both are servo controlled by signal from the SPEEDTRONIC control panel and actuated by single acting

hydraulic cylinders moving against spring loaded plugs • It is the gas control valve that controls the desired flow fuel in response to the command voltage .To enable

it to do this in a predictable y , the stop/ratio valve is designed to maintain a predetermined pressure Components of Fuel Gas Control System:

The fuel gas control system contains the following components:

1. Gas supply pressure switch 2. Stop/ratio valve assembly 3. Three redundant fuel gas pressure transducers 4. Control valve assembly :four linear variable differential transformer 5. Two servo type valves 6. Dump valves: three pressure gauges

Cooling tower

Cooling tower has ten cells.cell#1,2&3 are dedicated for Urea, Dap and utilitiea,Cell # 5,6,7,8,9 & 10 are dedicated for NH3 plant.Cell#4 is a spare cell common for both the networks.


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Ammonia Plant

Ammonia Plant is the heart of FFBL or any other fertilizer company because this plant is responsible for Ammonia production and also Carbon Dioxide which is used in the manufacturing of Urea or in other words a shutdown of ammonia plant means a shutdown of whole fertilizer company. Following are the names of some of the major equipment under ammonia plant.

Furnace (Primary Reformer). Secondary Reformer. Heat Exchangers (Shell & Tube, Flat Plate, Finned Type). Boiler. Start up Furnace. Start up Heater and many more.

AMMONIA PLANT DESCRIPTION:

Design: Bechtel 1965 vintage. Single Front‐End and Two parallel Back‐End Loops.

Process:

o Braun, U.S.A.

Plant History:

o Shutdown at USA : Jul 1992

o Relocated : Apr 1996

o Re‐commissioned: Nov 1998

o Revamped: May 2007

Capacity:

Design: 1,270 MTPD

Post BMR: 1,570 MTPD


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Ammonia Manufacturing Process:

Natural Gas Compression

Desulphurization Primary Reforming

Secondary Reforming

High Temperature Shift Converters

Low Temperature Shift Converters

Absorption Meth nation Syn. Gas Compressor

Ammonia Converter


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MODICON PLC

PROGRAMMING SOFTWARE (MODSOFT):

• DOS based programming software • Offline program development • Online program maintenance • Combine mode programming • I/O module health and status monitoring • Modsoft Supports Modbus, Mod bus plus and Ethernet for Communication with other devices

Controller

PROCESS UNDER CONTROL

COMMUNICATION

PROCESSOR

I/P MODULE O/P MODULE


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MODICON QUANTUM SERIES

o Remote I/O Processor

o Hot Standby Processor

o Power supply for I/O and RIO

o Remote I/O Module

o I/P Module

o O/P module

o Power Supply

o Programmable controller


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SERIALLY LINKED:

Modicon is serially linked with 2 systems I. Distributed Control System II. Vibrating Monitoring System

• Max. no. of Drops 31 • Max. no. of segments 32 • Max. no. of I/P 16384 • Max. no. of O/P 16384 • Use memory 48k • Scan Time 1ms

SAFTEY INTERLOCKS

• Input relay is used for on/off signal duplication. • Output relay is 24 VDC fail safe relay used to control 120 V AC actuator (solenoid valve or motor).

O/P relay is used to communicate with DCS is included in card • "4~20 mA duplicate" is an analog signal duplication module • "Red" is I/O column means redundant card fail safe type.

INPUT HAS THE FOLLWING FEATURES:

• Redundant used for safety signal. I. F3236 testable (16 Folds) II. 73237 testable with line monitoring (8 Folds)

• Non‐Redundant used for MOS,POS and non Safety signals

I. F3236 testable (16 folds)

OUTPUT HAS FOLLOWING FEATURE:

• Redundant used for safety signal I. F3230 testable (8 folds)

• Non‐redundant for safety panel signalization. I. F3322 testable (16 folds)

• Non‐redundant used for signal exchange with DCS I. F3322 with rely module (8 folds)


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Urea Plant

There are two sections in Urea plant

1. Urea Wet

2. Urea Dry

Urea wet section designed based on Co2 Stripping process of Stamicarbon , Netherlands and Urea Dry

section designed is based on the Fluidized Bed Granulation technology from Hydro Fertilizer

Technology(HFT),Belgium.Comissioned in April,1999.Urea Plant`s design capacity is 1670 MT/Day ant

actual is 1900 MT/Day.

Urea Plant Description:

Process:

o Urea Wet Stamicarbon, Holland o Urea Dr Hydro Agri, Belgium

Capacity:

o Design 1,670 MTPD o Current 1,920 MTPD

Raw Material:

o Ammonia 1,110 MTPD o Carbon Dioxide 1,480 MTPD o Urea Formaldehyde 18.0 MTPD


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STORAGE TANK LEVEL INSTRUMENTATION

Enraf 854 liquid level guage includes a calibration chamber, A local indicator and a transmitter .The 4~20mA signal is transmitted to the DCS.

Level switch (displacer type level switch) used for the measurement of the level of the liquid. Level indicator has float level gauge DP Level Indicator:DP TX with nitrogen bubbler sptum Temperature Instrumentation:9 RTD temperature elements mounted on storage tank.3 elements mounted in inner tank shell.6 element mounted in annular space as outer tank bottom will generate alarm at DCS if the temperature below 31 c.

Radiation Type LT: Its working principle is based on physical law attenuation of nuclear radiation as it passes through matter. The absorption of gamma radiation follows an exponential law. A beam of ray with original intensity Lo is weakened as it passes through matter having the thickness and density.

Solid Flow Meter: Supply excitation for flow meter transducing element (LVDT or Load cell).Material flowing through the flow meter is directed towards sensing plate. The sensing plate deflects horizontally proportional to material flow. The horizontal deflection is applied to the transducing element which produces a signal proportional to material flow.

FLOW METERS:

Following are some types of flow meters which are used as an instrument at plant:

• Variable Area: For liquid & gases • Magnetic: For Liquids/without solid contacts • Electromagnetic: For liquids/with out contacts • Mass: Measure of fluids without independent measure of density & volume • Ultrasonic: For non‐contact materials. Especially used for hazardous area • Vortex: For Volumetric flow rate of gases and vapors • Miniature: For low gas and fluid quantities

Motors:

Two Voltage level Type Motors are used

1. Medium Voltage Motor 2. Low Level Voltage Motor

Medium Voltage Motor drive on 24 KVA while Low Voltage Motors drive on 480 V.


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HIMA PLC: EMERGENCY SHUTDOWN SYSTEM

It Consist of on 19 inch central rack, 5 units high and up to 16 I/O racks in the 19 inch size.

Central rack has following parts:

• One or two Microprocessor controlled central modulus • At a time three co‐processor modulus, can be assigned to each central module. • 2 includes RS485 (2 on central module and 2 on each of up to 3 co‐processor) allows the

connection of other suptum respective to built up bus system with PLC master with a transmitter rate of up to 57600bps.

• 1 to 3 power supply modulus 24 VDC / 5 VDC to generate the voltage operating for the central module and the control voltage for the I/O modulus.

• Power supply monitoring module with battens to buffer the RAM area and the real‐time clock on the central modulus

ONE I/O RACK CONTAINS:

• Up to 4 power distribution modulus to protect the I/O circuit. • One coupling module to connect the I/O bus, with fail‐safe switch off of the watch dog

signal with care of fault • Maximum of 16 slots for input and output modulus for binary, digital and analog signals

ELOP System Software & Operating System for Programming & operation:

• HIMA and DCS communicating with MODUS protocol, the two suptum are interconnected by RS

232/485 interface converter. • Global alarms and permissive are transmitted via this link. • Field devices are connected by hard wired links to shutdown system. This satisfies related data is

read by one PLC and is shared with other PLC`s over HIBUS FS protocol over HIMA System bus. • The ELOP and PLESY station are connected via H7505 interface converter over ELOP and PLESY

bus respectively. • Consider a situation with field switch actuation. This signal is received through hard wired links

PLC generates an O/P and shutdown the process via field SOV`s and relays to return the system to the safe state with in milliseconds.

• Then it transmits data over PLESY bus for logging and arching and to ELOP station over ELOP bus. This data is also conveyed to DCS for alarm updating. In this way HIMA guarantee reliable plant operation and ensure safe operation


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CETRAL MODULE F8630:

• HD64180H Microprocessor with 10 MHZ clock frequency. • Static memory in EPROM and CMOS RAM • 2 interfaces RS485 up to 57600bps. • Fail safe watch dog

CO‐PROCESSOR MODULE F8621:

• HD64180 Microprocessor with 10 MHz clock frequency • RAM for PLC master Project • 2 Interfaces RS485 • Dual port RAM (DPR)


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DAP PLANT

The DAP plant design is based on double pipe reactor(DPR)AZF process from Grande Paroisse, France.Comissioned in November 1988.DAP Plant design capacity is 1350MT/DAY and actual is 1500 MT/DAY

DAP PLANT DESCRIPTION:

Process:

o Base Plant: AZF Grande Paroisse, France

o Revamp: Jacobs Engineering, U.S.A.

Capacity:

o Design: 1,350 MTPD o Post Revamp: 2,230 MTPD

Raw Material:

o Ammonia: 450 MTPD o Phosphoric Acid: 1,750 MTPD o Sulphuric Acid: 92 MTPD o Sand: 117 MTPD o Coating Oil: 10 MTPD

Manufacturing Process Of DAP Plant:

1. Dual pipe Reactors 2. Granulation 3. Drying 4. Screening 5. Cooling 6. Product Coating 7. De‐dusting & Off gases scrubbing 8. Storage/Bagging


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SCOPE OF INSTRUMENTATION IN FFBL

As we know that the FFBL is a chemical process industry so it is very essential to measure, calculate and control variables so instrumentation is a building block of any process industry. In FFBL process variables are measured by different kind of instruments located at the Plant site.

Instrumentation:

Below is a list of some of Instruments, I studied during my stay at different Plants of FFBL.

Flow Measurement:

The Instrument below is used to measure flow. It has a flow sensor that measure flow and communicate it.

Flow control system

The Instrument below is used for flow measurement without touching any liquid. It can be used to measure hazardous liquids like sulfuric acids or Phosphoric acid.


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P&ID study .

The diagram below is called P&ID.It helps us understand the process from Instrument to the control system.


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Speed Sensor

The diagram below show a speed sensor. As wheel of any vehicle revolve, it produces proportional EMF is solenoid. The strength of EMF is directly proportional to speed. That is how it communicates an effective signal for speed measurement.

Pressure Gauge

A Pressure measurement Instrument based on Bourden tube. Bourden tube turn in direct proportion to pressure applied. The pointer of meter attached to Bourden tube move on scale directly proportion to pressure applied. This is how, we measure pressure.


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Relay:

Relay is a switch that switches on/off in proportion to signal applied. On execution of applied signal, it turns on or off and helps us control some another device.

As coil in picture is energized, the position of switch changes and switch changes it orientation from one position to another position.

Liquid Level measurement

The Instrument below is used for level measurement. As level of liquid changes, position of rope changes and rope moves pointer along its scale. To sum up, Pointer moves in direct proportion to float pointer.


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The same above rule is applied on below system. The rise in flow produces a change is position of angular sensor and this change is appeared on meter.

Ultrasonic Level measurement:

The ultrasonic system is composed of transmitter and a receiver. The transmitters send a signal that is received by receiver. The time the signal takes is directly proportional to height of liquid.


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Diaphragm type valve

The instrument below is used to switch position of devices with flow measurement. As flow increases, it changes position of compressor and in turn on or off devices.

Valves and regulators

The picture below shows a regulator that reduces flow of some fluid but regulates it and prevents jerks.


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Pressure Relief Valve:

The Instrument below indicates a pressure safety valve. The valve open as pressure increases a pre‐set set point and in that way it helps us in safety precautions.

Resistive Transmitter:

The transmitter below is used to transmit change in pressure via a change is resistance. It changes it resistance with change is pressure and hence the voltage across it changes. This change in voltage is transmitted to control system.


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Installation of Orifice plate

Orifice plate is installed in pipe. Orifice plate is installed is such a way that it changes pressure across some point and helps us calculate differential pressure. The differential pressure helps

Annubar:

The instrument below is called Annubar.It helps us judge differential pressure. Orifice plate does not help us judge differential pressure across a point but it helps us be rising level in tubes.

One can say that

Annular = Orifice plate + Monometer.


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Level Measurement

The instrument below is used to indicate whether level has crossed two particular points or not.

Thermocouple and its Installation;

The instrument below is a thermocouple adjoined to a transmitter.

Thermocouple produces a temperature in direct proportion to temperature and transmit is to transmitter. Transmitter takes this signal, amplify it a bit and transmit it to control system.


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Bourden tube

The device below is called Bourden tube and it bends itself in proportion to pressure applied. The pointer is attached to a scale and hence it produces a change is scale in proportion to pressure applied.

Linear variable differential Transmitter:

A electromachanical mechanism that provides a voltage reference that is proportional to the movement or displacement of a core inside a coil (I to 5 volts AC).


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CONTROL SYSTEM OF FFBL

The control Philosophy of FFBL

Control System

Control system is a collection of electronic devices & equipment which are in place to ensure the stability, accuracy & smooth transition of a process or a manufacturing activity.AS we know FFBL is a Process industry so the process control is very mean to it for the production and as well as the safety of Employs, company assets and environment.

Process control:

The regulation of process parameters to with in specified target parameters through the manipulation of the control variable

CONTROL SYSTEM

DISTRIBUTED COTROL SYSTEM

SIEMEN ALLEN BRADLEY HIMA HS‐52 MODICON QUANTUM SERIES

PLC`S


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A TYPICAL PROCESS CONTROL

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Plant controls scheme or philosophy varies from plant to plant but normally it depends on type of process, size of hardware and software configuration to handle process I/O signals.

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PROGRAMMABLE LOGIC CONTROLLER (PLC)

A solid state control device that can be programmed to control process or machine operation.

In an automated system, the PLC is commonly regarded as the heart of the control system. With a control application program (stored within the PLC memory) in execution, the PLC constantly monitors the state of the system through the field input devices feedback signal. It will then base on the program logic to determine the course of action to b carried out at the field input devices.

It consists of five basic components

1. Process 2. Memory(RAM ,ROMEPROM,EEPROM) 3. INPUT/OUTPUT Modules 4. Power supply 5. Programming devices

INPUT:

Intelligence of PLC lies in the signals from sensors, actuators & field devices.

Push buttons

Keypads

Toggle switches

Proximity switches

Piezoelectric sensors

Level sensors


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Interfaced to PLC through PLC INPUT MODULES


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OUTPUTS:

Motors,

Solenoids

Relays indicators

Buzzers

LEDs

Can control a simple pick & place function to a complex servo positioning system.

Output devices are interfaced through OUTPUT MODULES


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Programmable Logic Controllers (PLCs) is dedicated Control system and used in :

1‐ Emergency Shutdown System (ESDS) 2‐ Logical and loop controls, ON / OFF valves, motor: start / stop

commands 3‐ Equipment local emergency stop (belt conveyor, elevator) 4‐ Main pumps start / stop 5‐ Fail safe operation

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Mentorship of FFBL

Engineers, technicians and Operators put all efforts to help me learn faster, quicker and deeper.

FFBL provided me with all resources, necessary in this learning process.

Documents

Ffbl Internship 2009