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ESD Training Module
ESD Training Module
PREPARED BY KAMDAR K J
DATE-23/06/2000
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INDEX
1.0 INTRODUCTION
7.0 SECURITY
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EMERGENCY SHUTDOWN SYSTEM
1.0 INTRODUCTION
Jamnagar Refinery Complex has about 25 nos of Emergency Shutdown System used for
the controlling of different plant units like CPP,Aomatics,PP, Crude, FCC etc. Shut
down system is used for interlocking , sequence of operation startup and shutdown of
the units.
Tricon is the one which we are using as Emergency Shut Down system and is supplied
by Triconex, USA, which is part of the Invensys group Companies.
The other make PLC’s which we are using in our complex are Allen Bradley,
Siemens ,hitachi, Telemechanique.
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PROGRAMMABLE
LOGIC
CONTROLLER
INPUTS OUTPUTS
MACHINE OR
PROCESS
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1.3 Advantages of PLC over the conventional relay logic
PLCs being programmable devices can be easily reprogrammed for the changed
requirements with minimum efforts and time whereby the relay based systems will need
much wiring changes and new instrument additions for the same changes to be carried
out. Conventional relay logic is a hardwired circuit with electromagnetic relays, timers
etc.
PLC’s and operator terminals eliminate the requirement for multiple instruments such
as timers, counters, trip amplifiers ,indicators, pushbuttons, annunciators ,switches etc.
The integration of number of instruments reduces the space requirements.
1.4 Why Triconex PLC is used as Emergency Shut Down system?
Tripple modular redundant processor increases the reliability and hence the availability
of the system
Extensive diagnostics
TUV safety certified system
Fault tolerance is the ability to detect transient and to take appropriate corrective
action on-line. With fault tolerance, there is an increase in the safety and an increase in
the availability of the controller and the process being controlled.
The Tricon provides fault tolerance through Triple Modular Redundant (TMR)
architecture. The system consists of three identical system legs. Each leg independently
executes the control program in parallel with the other two legs. Hardware voting
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mechanism qualify and verify all the digital inputs and outputs from the field. Analog
inputs are subject to a mid value selection process.
Each leg is isolated from each other’s. Hence, no single point failure in any leg
can pass to another. If a hardware failure occurs in one leg, the other two legs override
the fault leg.
TMR architecture
Withstands harsh industrial environment
Replacing an I/O module does not disturb field wiring
Supports upto 118 I/O modules and optional communication modules that interfaces
with modbus masters and slaves, Foxboro and Honeywell DCS systems and other
tricons on Peer-to Peer network.
Provides supports for remote I/O modules upto twelve kilometers from the main
chassis
Provides integral on-line diagnostics
Supports Hotspare I/O modules for critical applications.
Standalone control system but also considerd for centralised configuration and
monitoring
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Scan time is around 100 msec
3.1.0 Hardware
The Tricon supports Digital Input, Output, analog input/Output and Thermocouple input
cards etc. and Communication cards.
The Input/Output cards used in our Refinery complex are
3.2.0 Chassis
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2. Expansion Chassis
3. Remote Extender chassis
A tricon can include upto 15 chassis, housing any combination of I/O modules.
The total standard cable length which can be used to join a set of main and expansion
chassis is 30 meters(100 feet)
The remote Extender chassis enable the the system to extend to remote location up to
12 kilometers from the main chassis by using RXM modules which can support
Multimode as well as Single mode fiber optic cable.
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1. Dos based workstation called Multi system workstation, which supports ladder logic
programming language. This is the one, which we are using in our refinery complex.
Every I/O module houses the circuitry for three independent legs. Each leg on the
input reads the process data and passes the information to its respective main processor.
The three processors communicate with each other using a proprietary high-speed bus
system called TRIBUS.
The tribus votes digital input data, compares output data and sends copies of
analog Input data to each main processor.
The main processors execute the control program and sends O/P generated by the
control program to the output modules. Output voting is done in output modules.
For each I/O module the system can support an optional hotspare module. If
present the hotspare takes control if a fault is detected on the primary module during
operation. The hotspare position is also used for on-line system repairs.
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The Input data is assembled into a table in the main processor. The individual
input table in each processor is transferred to the neighboring processor over tribus.
The 32 bit main processor executes the control program in parallel with the
neighboring processor modules.
The control program generates a table of output values, which are based on the
table of input values according to the customer-defined rules built in to the application.
The I/O communication processor in the main processor manages the transmission of
output values to the output modules and the out put voting is being done in the O/P
module.
The Model 3006 main processor which we are using in the refinery complex
provides 2 MB RAM each, for fully expandable Version-9 Tricon system. The RAM is
used for the Programs, Seq. Of Event Data’s and I/O data, Diagnostics and
communication buffers.
I/O Bus : 375 KB, triplicated I/O bus transfers data between I/O modules and the main
processor. It is an RS 485 communication.
Communication Bus 2Mb bus runs between communication modules like ACM,
EICM etc and the Main processor.
3503E (TMR) is the model of the digital input module used in the ESD systems
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5.3.2 Digital Output Module
Every output module houses the circuitry for three identical legs which are
isolated like digital input card. All the output modules use special quadruplicated O/P
circuitry (2OO3 voting) which votes and gives the output.
3604E (TMR) is the model of the Digital Output module used in the entire refinery
ESD system.
In the analog inputs the mid value is used by the control program. Incase of
duplex mode the average value is taken.
By the use of communication modules like EICM, ACM and NCM the Tricon
can interface with modbus Masters and slaves, other Tricons in Peer-to-Peer networks
and Honeywell and Foxboro I/A series DCS systems.
Each tricon module can activate the system integrity alarm. The front panel of each
module provides indicators that show the status.
All the internal diagnostics and alarm data is available for remote logging and report
generation.
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6.2 International approval
The tricon system is regularly evaluated by third party agencies and is certified to meet
the standards. Tricon Version-9 is TUV approved.
TUV Rheinland certificate ensures the functionality of Tricon systems for critical
process applications requiring maximum safety and uninterrupted operation. The
Version-9, which is being used in refinery, is TUV certified.
Tricon supports Sequence of events. This can be used for trip analysis. During
each scan the main processor inspect designated discrete variables for change of state
known as Events.When an event occurs, the main processor saves the variables current
state and time stamp in an area of memory called a buffer, which is part of an SOE
block. The SOE block is configured by using the Tristation.
7.0 Security
The Tricon operational modes can be selected by the key switch, which is
Installed in the upper left corner of the main chassis.
1. Remote mode: which is used for Ladder monitoring, Change values, diagnostics
and external Host read write.
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2. Program mode : In addition to the remote mode functions, SOE configuration can
be done in this mode.
3. Run mode: only for monitoring purpose. No Program change is allowed in this
mode.
4. Halt mode: to halt the processor from executing the program. This can be
overridden by the software disable option and it is disabled in Jamnagar refinery.
8.1 Maintenance
8.1.1 Procedure for downloading Changes
After down loading a control program to a tricon one should save the program
file. If one cannot find an exact copy on the harddisk of Tristation PC (may be due to
harddisk failure or file corruption) you can use the backup.
If no such back-up copies are available, doing Download All is the only option to
get connected with tricon.
Before start making any change to the control program, check the free memory.
Addition and Deletion of Chassis or changing of chassis type is not possible using
Download change. It requires Download all.
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8.1.2 Procedure for controlling and changing existing program
Whenever a control program is changed even in minor way, all changes should
be controlled by a safety change control committee
Procedure
There are two types of versions which represents the control program
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Example
LOGIC DESCRIPTION :
WHEN ANY ONE OF THE TX’S OR BOTH THE TX’S ARE HEALTHY (NOT IN TRIP
CONDN)
THEN THE TRIP BIT WILL BE HEALTHY( 1- STATE ). F416015 COIL FOR THIS EX.
LOGIC.
AT THIS CONDN. THE LOGIC WILL EXECUTE AS 1OO2 LOGIC ( WHEN THE 2ND TX
GOES
TO TRIP CONDN. THE TRIP BIT(F416015 ) WILL GO TO TRIP CONDITION ( 0 STATE ).
THERE IS AN OPTIONAL DELAY TIMER GIVEN FOR THIS CONDN PRESENTLY SET
AT 30 SECS.
( T160114 TIMER FOR 416FT015A TX).
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SCALING OF 416FT015A & B TRANSMITTER (120.0- HISCALE AND 0.0- LOW SCALE)
+---------------------------------------------------------------------------+
-|Y16015A=AIN(F16015A,120.0,0.0); |
|Y16015B=AIN(F16015B,120.0,0.0); |
|DATA04=30; |
+---------------------------------------------------------------------------+
+===========================================================================+
| 416FT015A MOS LOGIC |
+===========================================================================+
416FT015A 416FT015A
MOS CNFM MOS SET FBK
BIT FROM
DCS
416FT015A 416FT015A
MOS SET BIT MOS SET FBK
FROM DCS
S16015A Q16015A
---] [---+---------------------------------------------------------------(RST)
MAIN MOS
ENABLD FROM
CONSOLE
H400005
---]/[---+
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+===========================================================================+
| 416FT015B MOS LOGIC |
+===========================================================================+
416FT015B 416FT015B
MOS CNFM MOS SET FBK
BIT
416FT015B 416FT015B
MOS SET BIT MOS SET FBK
S16015B Q16015B
---] [---+---------------------------------------------------------------(RST)
MAIN MOS
ENABLD
H400005
---]/[---+
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+===========================================================================+
| TRIP BIT GENERATION LOGIC FOR 416FT015A & 416FT015B TX'S |
+===========================================================================+
FL LL IN 416FT015A
GASLINE FD MOS SET FBK
TO REACTR
FL LL IN 416FT015B
GASLINE FD MOS SET FBK
TO REACTR
416FT015A
MOS SET FBK
416FT015B
MOS SET FBK
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+===========================================================================+
| FINAL TRIP BIT GENERATION |
+===========================================================================+
/B TRIP BIT
M160101 F416015
---]/[-------------------------------------------------------------------( )
+===========================================================================+
| TRANSMITTER DISCREPANCY FOR 416FT015A & 416FT015B |
+===========================================================================+
416FT015B 416FT015A/B
MOS SET FBK DISCRPNCY
416FT015A |
MOS SET FBK
|
T160101 T160102 Q16015A |
---]/[-------] [-------]/[---+
|
416FT015A
MOS SET FBK
|
Q16015A
---] [-----------------------+
|
416FT015B
MOS SET FBK
|
Q16015B
---] [-----------------------+
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START-UP-OVERRIDE LOGIC GENERATION AND IMPLEMENTATION.
STRIP RBLR PULSE TIMER
HTR F.G
STARTUP
O.RIDE
H221079 T210510
---] [-------------------------------------------------------------------(PLS)
20000
T210510 XL21079
---] [-------------------------------------------------------------------( )
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2oo3 LOGIC MODEL ( REF ONLY )
LOGIC DESCRIPTION :
WHEN ANY TWO OF THE TX’S OR ALL THE THREE TX’S ARE HEALTHY (NOT IN TRIP CONDN)
THEN THE TRIP BIT WILL BE HEALTHY( 1- STATE ). P415115 COIL FOR THIS EX. LOGIC.
AT THIS CONDN. THE LOGIC WILL EXECUTE AS 2OO2 LOGIC ( ie OTHER TWO TX’S SHOULD GO
TO TRIP CONDN. TO CAUSE THE TRIP ACTION THEN ONLY THE TRIP BIT(P415115 ) WILL GO TO
TRIP CONDITION ( 0 – STATE ).
IF THE TRIP IS ON HIGH HIGH THEN THE TX FAULT(E15015A FOR 415PT115A TX) WILL MAKE
THE TX TO TRIP CONDITION WHEN THE PARTICULAR TX FAILS/ CABLE CUT.
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SCALING OF 415 PT 115 A/ B / C
+---------------------------------------------------------------------------+
-|Y15115A=AIN(P15115A,60.0,0.0); |
|Y15115B=AIN(P15115B,60.0,0.0); |
|Y15115C=AIN(P15115C,60.0,0.0); |
|DATA08=34; |
+---------------------------------------------------------------------------+
+===========================================================================+
| 415PT115A MOS LOGIC |
+===========================================================================+
415PT115A 415PT115A
MOS CNFM MOS SET FBK
BIT
415PT115A 415PT115A
MOS SET BIT MOS SET FBK
S15115A Q15115A
---] [---+---------------------------------------------------------------(RST)
MAIN MOS
ENABLD
H400005
---]/[---+
+===========================================================================+
| 415PT115B MOS LOGIC |
+===========================================================================+
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415PT115B 415PT115B
MOS CNFM MOS SET FBK
BIT
415PT115B 415PT115B
MOS SET BIT MOS SET FBK
S15115B Q15115B
---] [---+---------------------------------------------------------------(RST)
MAIN MOS
ENABLD
H400005
---]/[---+
+===========================================================================+
| 415PT115C MOS LOGIC |
+===========================================================================+
415PT115C 415PT115C
MOS MOS SET FBK
SET/CLEAR
BIT
S15115C Q15115C
---] [---+---------------------------------------------------------------(RST)
MAIN MOS
ENABLD
H400005
---]/[---+
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+===========================================================================+
| TRIP BIT GENERATION FOR 415PT115A,415PT115B & 415PT115C TX'S |
+===========================================================================+
LPG HEADR
PR HH
Y15115A T150111
---]>=[------------------------------------------------------------------(TDE)
DATA08 0
LPG HEADR
PR HH
Y15115B T150113
---]>=[------------------------------------------------------------------(TDE)
DATA08 0
LPG HEADR
PR HH
Y15115C T150115
---]>=[------------------------------------------------------------------(TDE)
DATA08 0
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+===========================================================================+
| FINAL TRIP BIT GENERATION BY ( 2OO3 VOTING) |
+===========================================================================+
415PT115A/B
/C TRIP BIT
+===========================================================================+
| TRANSMITTER FAULT 415 PT115 A / B / C |
+===========================================================================+
P15115A E15115A
---]<[-------------------------------------------------------------------( )
650
P15115B E15115B
---]<[-------------------------------------------------------------------( )
650
P15115C E15115C
---]<[-------------------------------------------------------------------( )
650
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+===========================================================================+
| TRANSMITTER DISCREPANCY LOGIC |
+===========================================================================+
+===========================================================================+
| SELECTION OF MID VALUE OF 415PT115A/B/C |
+===========================================================================+
+---------------------------------------------------------------------------+
-|M150111=MEDSEL(Y15115A,Y15115B,Y15115C); |
+---------------------------------------------------------------------------+
+-----------------------------------------------------------------+
-----------|MAX1=60;MIN1=0.0;SPAN= MAX1 - MIN1; |
+-----------------------------------------------------------------+
+---------------------------------------------------------------------------+
-|M15115A = PERDEV(M150111,Y15115A,SPAN,0.05); |
+---------------------------------------------------------------------------+
+---------------------------------------------------------------------------+
-|M15115B = PERDEV(M150111,Y15115B,SPAN,0.05); |
+---------------------------------------------------------------------------+
+---------------------------------------------------------------------------+
-|M15115C = PERDEV(M150111,Y15115C,SPAN,0.05); |
+---------------------------------------------------------------------------+
415PT115A/B
/C
DISCRPNCY
M15115A A415115
---] [-------------------------------------------------------------------( )
415PT115A/B
/C
DISCRPNCY
M15115B B415115
---] [-------------------------------------------------------------------( )
415PT115A/B
/C
DISCRPNCY
M15115C C415115
---] [-------------------------------------------------------------------( )
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