PLC Based Annunciation System
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Transcript of PLC Based Annunciation System
Fasih Ahmed
University of Engineering And Technology, Taxila
PLC Based Annunciation System
Objective
Replacement of Obsolete Annunciation System with Programmable Logic
Controller(PLC) based annunciation system for Ammonia Compressors 101-J, 103-J and
105-J.
Agenda of Presentation• Overview of Ammonia plant.• Basics of Annunciation system.• Problems with the current Annunciation system.• Variants for the current system.• Overview of the assigned project.
Overview of Ammonia plant and manufacture.
• Ammonia Plant was installed in 1976.• Present plant production capacity is 960 tons
per day.• The designer of ammonia plant is Kellogg
International Corporation (KIC).• Haber’s Process.
Basics of Annunciation System.
“A signal designed to alert, inform, guide or confirm deviations from acceptable system status.”
Graphical Overview of Annunciation System
Parts of an Annunciation System.1- Annunciation Panels.
2- Recorders
3- Annunciation Modules
Problems with the current installed annunciation system.
• No spares are there for annunciation modules.• Annunciation modules are not reliable as they have passed
their lifetime. • The probability of fault is more in annunciation modules.• Large number of annunciation modules are required in an
annunciation system.• Maintenance of current installed annunciation modules is not
very easy.• Cannot accommodate changing system environment.
Implementation of PLC Based Annunciation Systemon 101-J, 103-J 105-J.
Project Implementatio
n I/O Listing
Select the vendor
and type of PLC
Logic And Graphics Developm
ent
Listing of BOMTesting Training
I/O Listing.
• On the basis of project I/Os the type of PLC is selected.• For this particular project there are total 80
inputs and 76 outputs.• Number of Analog and Digital I/Os are selected
on the basis of requirement of the project.
Hardware Selection.
• For this particular project ALLEN BRADLEY PLC is selected for installation based on inventory optimization.• The suitable type or model of PLC selected is
named as MicroLogix 1100.• The MicroLogix 1100 has 10 Digital Inputs and 2
Analog Inputs.
Continued
Logic Implementation Software.
• RSLogix 500, Revision 7.0 or later.• Factory Talk Gateway.• Two communications ports
RS-232/485 communication port (Channel 0)
Ethernet port (Channel 1).
Listing of Project BOM
• Bill of material for the required hardware should be made in order to make a purchase request (PR) from the industry.• The budget required for installation of the
desired project is approximately 4 million rupees.
Testing and Training
• Test Run.• Training
Operation
Instrument
Legend:
T1
T3
PROJECT TIMELINE
T4
T1
T2
T3
T4
T5
T6
T7
T8
Procurement
Logic development
Graphics development
Integration of graphics with logic
Field Execution
Simulation and verification
T9
Test Run
Training
Procurement
MOC Approval
Logic development
Graphics development
T5
Integration of graphics with logic
T6
Simulation and verification
T7 T8 T9
Field execution
Test Run
Training
T2
MOC Approval
Substitutes for Annunciation modules.
• Experion HS by Honey Well .• SIMATIC PCS 7 by Siemens • Bulletin 1756 ControlLogix® I/O modules.• HART(Highway Addressable Remote Transducer)
Protocol.• FOUNDATION Fieldbus.
HART ProtocolHighway Addressable Remote Transducer ( HART ) is a bidirectional communication on analogue wires
for sending and receiving digital data .
Benefits of HART.• Quickly verify and validate control loop and device configuration.• Use remote diagnostics to reduce unnecessary field checks.• Avoid the high cost of unscheduled shutdowns or process
disruptions.• Minimize the impact of deviations by gaining new, early warnings.• Enable automated record keeping of compliance data.• Facilitates automated safety shutdown testing.• Can communicate with DCS.
Fieldbus Foundation H1.
• FOUNDATION H1 fieldbus designed primarily for process industries is a real-time digital communication network designed specifically for process control applications.
• No need of 4-20mA analog signal. • All control decisions take place inside the field devices.• High speed Network ( H2 ), later replaced by Ethernet
technology (HSE) .• Low speed Network ( H1) .
Benefits of Foundation H1
• Reduced Hardware Requirements.
• Reduces signal distortion.• High Signal Integrity.
• Greater Signal Fidelity.• Elimination of I/O cards.• Reduced Device Count.• Elimination of Virtual Marshalling.
Any Questions ?
Thank You