AECH2251
Instrumentation & Control Lab
Lab 10 - Project
Control Systems – Plant Operations
(Pilot plant – Building#9)
Due Date: Thursday, 21st Nov 2024 @ 08:00am
This Project has an overall weightage of 10%
Task 1: Work as a team of assigned members at Operation Training Plant
in 9.1.43 (Pilot plant, Building # 9, full PPE required). Your objective is to
control the hot water temperature coming out of the heat exchanger at a
set point of 50°C. (Follow the prestart up checks, start up, operation and
shut down procedures as per the SOP of the Plant). Your project report
should identify the different control valves and control schemes used for
controlling the process variables, discuss different types of control valves,
components and their functions and how these control valves function to
achieve the desired results.
Task 2: Student groups are expected to prepare and submit a report
based on above tasks on the Process plant operation facilities and
present their findings in a short presentation (10 minutes) to the rest of
the class.
Team members:
Name UDST ID#
Noman Abdulghafoor 60304656
Yassin AlsayedAhmed 60095807
2
Muhammad Haiqal bin Khairulzane 60306084
Introduction
In any industry, heating and cooling is an essential process through which we
can achieve many products, safer working of plants and other processes.
However, this process can be dangerous and must be controlled in a very precise
way to ensure the safety of equipment as well as the working personal. For this
reason, we make use of automated controlling system in plants such as DCS and
modular automation.
In case of our plant, it is a Module type package plant (MTPP) and the main
process it carries out is boiling and cooling of water by means of valves, different
equipment and control scheme to maintaining a steady process. All these
processes are controlled through Distributed Control System (DCS).
Equipment used in the plant:
1. Controllers
· Level Indicator Controllers: LIC-100, LIC-200, LIC-300.
· Pressure Indicator Controllers: PIC-110, PIC-210, PIC-410.
· Flow Indicator Controllers: FIC-120, FIC-220, FIC-501.
· Temperature Indicator Controllers: TIC-501, TIC-600, TIC-700.
2. Valves
· Level Control Valve: LCV-100, LCV-200, LCV-300.
· Pressure Control Valve: PCV-110, PCV-210, PCV-400.
· Flow Control Valve: FCV-120, FCV-220, FCV-501.
· Temperature Control Valve: TCV-501, TCV-600, TCV-700.
3. Tanks
· Tank 1: Has a capacity of 1780 liters.
· Tank 2: Has a capacity of 1780 liters.
· Tank 3: Has a capacity of 1780 liters.
· Tank 4: Has a capacity of 6672 liters.
4. Pumps
· Pump 1: Centrifugal pump (Attached to Tank 1).
· Pump 2: Mono progressive cavity positive displacement pump
(Attached to Tank 1).
· Pump 3: Centrifugal pump (Attached to Tank 2)
· Pump 4: Mono progressive cavity positive displacement pump
(Attached to Tank 2).
· Pump 5: Vertical multistage centrifugal pump (Attached to
Tank 3).
· Pump 6: Gear positive displacement pump (Attached to Tank
3)
· Pump 7: Centrifugal pump (Attached to Tank 4).
· Pump 8: Sliding vane positive displacement pump (Attached
to Tank 4)
5. Heat Exchanger
· HE-05
6. Chiller
· C-07
7. Heater
· H-06
Controllers
· Level Indicator Controllers:
o LIC-100 – level Indicator Controller in loop 100
Feed forward control
Connects to the Level transmitter LT100C and controls
the FCE LCV 100
o LIC-200 - level Indicator Controller in loop 200
Feed Forward control
Connects to the Level transmitter LT200C and controls
the FCE LCV 200
o LIC-300 - level Indicator Controller in loop 300
Feed forward control
Connects to the Level transmitter LT300A and controls
the FCE LCV300
· Pressure Indicator Controllers:
o PIC-110 - Pressure Indicator Controllers in loop 110
Feedback control
Connects to the Pressure transmitter PT110 and controls
the FCE PCV 110
o PIC-210 - Pressure Indicator Controllers in loop 210
Feedback control
Connects to the Pressure transmitter PT210 and controls
the FCE PCV 210
o PIC-410 - Pressure Indicator Controllers in loop 410
Feedback control
Connects to the Pressure transmitter PT410
· Flow Indicator Controllers:
o FIC-120 - Flow Indicator Controllers in loop 120
Feedback control
Connects to the Flow transmitter FT120B and controls
FCE FCV120
o FIC-220 -Flow Indicator Controllers in loop 220
Feedback control or Cascade Control
Connects to the Flow transmitter and controls FCE
FCV220
o FIC-501a - Flow Indicator Controllers in loop 501a
Ratio Control
Connects to Flow transmitter 501a (FT501a) and
controls FCE FCV 501a
· Temperature Indicator Controllers:
o TIC-501 - Temperature Indicator Controllers in loop 501
Ratio control
Controls FCE TCV 501
o TIC-600 - Temperature Indicator Controllers in loop 600
Feedback control
Connects to the temperature transmitter 600 (TT600)
and control the heater (H-06)
o TIC-700 - Temperature Indicator Controllers in loop 700
Feedforward control
Connects to the temperature transmitter 700 (TT700)
and controls the chiller (C-07)
PRV(pressure relief valve) : is a type of safety valves used to control or limit
the pressure in a system
PIC send signals to the controller than there is an overpressure in the
system, then the controller send and signals to the pressure relief valve to
relieve some of the pressure and went back to normal , so PRV is count as
an safety valve
Conclusion
In conclusion, we see how this whole process plant is working on different
transmitters, controllers, and final control elements (valves) to ensure the
process remains within the parameters and the desired flow and
temperature is achieved. As seen in the P&ID and explained in the report,
this plant contains many kinds of valves each of which has its own
significance in controlling the process, maintaining a steady
flow/pressure/temperature, and ensuring the safety of the equipment and
the working personal, all while being controller automatically through
some kind of control scheme. Thus, this plant gives us a good overview of
a modern-day heating and cooling plant with its working and controls.
