This document discusses the role of controls and instrumentation (C&I) engineers in industry. It describes how C&I is used to monitor, record, and control various process parameters. It also outlines the types of local instruments used for measuring pressure, temperature, flow, and level. The document discusses remote instruments, remote panels, and the products used in C&I. It provides examples of industries that employ C&I engineers, such as power, process, refinery, cement, and paper. Finally, it recommends ways for students to improve their skills in areas like AutoCAD, HMI software, and embedded systems.
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Why Controls &
Instrumentation?
To monitor/record/control various parameters
like
Pressure,Differential pressure
Temperature,Differential Temperature
Flow (Solid,Liquid,Gas)
Level ,Vibration,Speed
Electrical parameters like volt,Amp,power,PF
To generate Alarms / Trip in case of abnormal
conditions.
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Facilitate data analysis
Facilitate automatic control of various
parameters.
Remote monitoring & operation
Interface with ERP for MIR
Ensure equipment and operating
personnel safety.
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ELECTRICALS
To provide Drives for Mechanical
Equipment
To feed & control Power to various
equipments
To facilitate starting and stopping of
various equipments in sequential way
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C & I PRODUCTS
Local Instruments
Remote Instruments
Remote Panels
Instrument Cables
Electrical Equipments
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Temperature Measurements
Glass Tube Thermometer
Mercury in Steel Dial Gauge
Resistance Temperature Detector
Thermocouple (Type K,N,T,B,S)
Temperature Transmitters
Temperature Switch
LOCAL INSTRUMENTS
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LOCAL INSTRUMENTS
FLOW MEASUREMENT
Pitot Tube - Gas Application
Aerofoil - Gas Application
Positive Displacement Meter
Coriolis mass flow meter
Ultrasonic flow meter
Turbine Flow Meter
Orifice Plate/venturi Assembly
Flow Nozzle
Variable area/Rotameter
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LOCAL INSTRUMENTS
LEVEL MEASUREMENTS
Direct Level Gauge
Electronic Water level Indicator
Dp Transmitters
RF type/Radar type/Nucleonic
FLAME SCANNERS
VIBRATION MONITORS
GAS ANALYSERS
Proximity sensors
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FIELD TO REMOTE PANEL
SIGNAL TRANSMISSION
* 4 -20 mA CURRENT SIGNAL
* HIGH WAY ADDRESSABLE
REMOTE TRANSMISSION (HART)
* DIGITAL BUS
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REMOTE PANELS
PROGRAMMABLE LOGIC
CONTROLLERS
DISTRIBUTED CONTROL SYSTEM
(DCS) WITH OPERATOR CONSOLE
SUPERVISORY CONTROL & DATA
ACQUISITION (SCADA)
These Panels execute Analog and Digital
controls.
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Compiled by Sri Koppikar CE-Mktg
T O T A L C O N T R O L S O L U T I O N S
ELECTRONICS DIVISION, BANGALORE
JAN 2006
Distributed
Processing Unit
(DPU)
I/O Modules
8 pack rack
(DPU4F and I/O)
Eight-pack rack
I/O Bus
Connector
Field 24V
Field 48V
System 24V
I/O Bus
Connectors
Remote Processing
Unit (RPU)……..
System Cabinets
System introduction… Control level
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I/Osignals
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REMOTE PROCESSING UNITS (RPUs)
TYPICAL CONFIGURATION DIAGRAM
Redundant 100 Mbps maxNET
REMOTE I/O
FIBRE OPTIC
LINK
REMOTE maxVUE
• Serverless Configuration • Scalable…as large as required
Plant information network
PLANT SUB-
SYSTEMS
maxLINK
maxSTATIONS
ENGINEER’S
STATION / maxSTORIAN
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Manufacturing Function
Managing PCB shop,Assembly & wiring shop
Loading of software & Functional testing
Environmental Testing
Periodic calibration of instruments
Coordination with MM for components
Labour Management
Coordination with statutory authorities
Safety Management
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R&D Function
R&D proposal & approval
Development of instruments & Systems
Patent/Copy Right
Embedded/PC,PLC based/Custom IC development
Field Testing/Proving
Type testing at reputed labs
Documentation & Knowledge Management
Transfer knowhow to manufacturing
Performance feed back & improvement
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E & C Function
Erect the instruments/sensors/panels
as per the documents
Earthing,illumination installation
Cable tray laying/supporting
Cable laying / terminations/connection
Field calibration
Checking of total system
Handing over documentation
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m
m
RECOMMENDATIONS……
•LEARN & PRACTICE
• -AUTOCAD
• -HMI SOFTWARE LIKE INTELUSION
•READ INSTRUMENATAION HAND BOOK
BY LIPTAK
•EACH STUDENT TO OWN ONE MC KIT &
DEVELOP SKILLS IN EMBEDDED SYSTEM
•SPEND ONE HOUR IN INTERNET DAILY &
RECORD YOUR FINDINGS
•REGISTER IN PLANT WEB UNIVERSITY
IN EMERSON WEBSITE & GET
CERTIFICATE (FREE)
• EACH STUDENT TO GIVE LECTURE
ON ADVANCED TOPIC PERIODICALLY
