MEP201

Mechanical Engineering Drawing

1st semester 2005-2006

SR
Kale
Lecture

Control Diagrams

Control Drawings - Background

Pre-requisites
Schematic, P&I drawings
Control philosophy
About the plant
From equipment/package manufacturers
Team: All designers (EE, ME, ChE, I&C, )
Output
Wiring of control cables
Governing logic for control software
development
Interdisciplinary: Chem, EE, Aero, BioMed, ..
Controls (2005)

Control Drawings - Types

Sequence Control
Sequence Control drawings
Interlock Drawings
Block Interlock Diagrams
ON/OFF : If then

Modulating Control
Control Logic Diagram (feedback, modulating type)
Sense feedback signal, Set point Controller
(PID) Output signal Device Feedback signal

Controls (2005)

Sequence Control
Drawings /
Block Interlock Diagram /
Interlock Diagrams
Controls (2005)

Sequence Control Drawings

(Block) Interlock Diagram
Schematic
Control philosophy
Incorporate instruments in schematic to
generate P & I drawing
Interlock diagram

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Sequence Control Diagram Basics

Logic from process designer & eqpt.
manufacturer:
What are the safe operating limits?
What action to take if safe limits are exceeded?
Logic or its execution not unique

Within the limits, automatic control system

operates.
Sequence control supercedes automatic control.
ON-OFF control
Signal processing via relays and/or software
Controls (2005)

Sequence Control Diagram

Objectives
Operate equipment and system within safe
limits.
Auto start / stop of equipment

WHY?
Avoid damage to equipment (expensive repairs)
Initiate automatic protective action in case of
malfunction.
Avoid plant shut down by switching to stand-by
device.
Safely shut-down system even if all safety backups dont work.
Safe start-up and shut-down of system.
Controls (2005)

Interlock diagram - Elements

CONDITION

PS1

L.O. SUPPY PR.

LOGIC

ACTION

L1

ON

LAMP

I.D.

I.D.
Parameter

Device
Value

Action

Connect with lines

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Logic Gates
AND

&

OR

OR

NOT
TIME DELAY
On delay/Off delay Period T

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Bearing Lube Oil Schematic

BEARING

LUBE OIL
TANK

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Bearing Lube Oil System

Requirements (order by importance):

Oil pressure at inlet

Indication on gauge
Generate alarm if low
Generate signal to trip turbine if low low
Oil temperature at inlet
Indication on gauge
generate alarm if high
Oil flow rate
Measure (?) expensive not really needed
Visual indication of flow
Oil level in tank
Indication
Alarm if low
Power supply is available for pump
Indication
Voltage and current drawn

Controls (2005)

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Bearing Lube Oil I & C Diagram

BEARING

SG
PI1
TI1

LUBE OIL
TANK

L4

L3
L
LS1

LI1

H
TS1

L1

L2
RLY1
L

PS1

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LL
PS2

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Interlock: Bearing L.O. system

CONDITION

LOGIC

PS1

L.O. SUPPY PR.

PS2

L.O. SUPPY PR.

LL

ACTION
L1

L.O. PR. L -LAMP

ON

RLY1 FRANCIS TURBINE TRIP

L2

L.O. PR. LL -LAMP

ON

TS1

L.O. SUPPLY TEMP.

L3

L.O. TEMP. H -LAMP ON

LS1

L.O. TANK LEVEL

L4

L.O. T. LVL L -LAMP ON

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Domestic water booster system

Booster pump, ground tank, overhead tank
Pump to start if
Overhead tank is empty AND Ground tank has enough
water

Pump to stop if
Overhead tank is full OR Ground tank is empty

Indications to operator (panel lights or PLC

display):
Overhead tank - Full, Empty.
Ground tank Full, Empty.
No power supply.
Pump status Running, Stopped.

Controls (2005)

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Domestic Booster Schematic

H
LS4

GROUND
LEVEL
TANK

L
LS3

OVERHEAD
TANK
H
LS1

GROUND
LEVEL
GROUND
TANK

L
LS2

LEVEL
TANK

BOOSTER
PUMP

Controls (2005)

4 Signals
One motor.
RELAYS

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Interlock: Domestic water

system

CONDITION
LS1

G/L TANK LEVEL

LOGIC

LS3

O/H TANK LEVEL

LS2

G/L TANK LEVEL

LS4

O/H TANK LEVEL

ACTION

SW1

BOOSTER PUMP

ON

SW1

BOOSTER PUMP

OFF

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Domestic water system - Alternate

Domestic water system
LS1

GROUND TANK LEVEL LOW

&
LS2

GROUND TANK LEVEL HIGH

LS3

OVERHEAD TANK LEVEL LOW

START PUMP

STOP PUMP
LS4

OVERHEAD TANK LEVEL HIGH

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Diesel engine of DG set/Loco

Diesel engine
On engine start signal (key) energize starter motor if
Water temperature is OK AND Fuel tank is not empty

After starting if
Lube oil pressure is low after 3 seconds, then SHUT-OFF
(TIME DELAY)

Engine is running, then SHUT-OFF if

Lube oil pressure falls to 3 bar(g) OR
Jacket water temperature rises to 105 oC OR
Speed increases to 1545 RPM OR
Speed decreases to 1425 RPM.

Controls (2005)

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Air conditioner (window/split)

After power switch is turned ON
Wait 2 minutes then start compressor (TIME DELAY)

Switch-off running compressor if

Cool space temperature falls to oC

Switch-on compressor if
Cool space temperature rises to oC AND
2 minutes have elapsed since compressor was shutoff (TIME DELAY)
SET POINT OFFSET for cut out/cut in

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Airplanes
Airplanes
(ref.: aeroPeru603/Air Crash Investigation)
Auto-pilot gets engaged if
2 out of 3 readings of altitude/speed are
same.
(TWO OUT OF THREE LOGIC)
IF NOT, fly the plane manually

Controls (2005)

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Francis turbine
Francis Turbine (Badagrah Nala)
2 x 100 % Lube oil pumps, give START signal to
stand-by pump if

Turbine is running AND

L.O. level in tank in NOT low AND
Standby pump is available AND
(Other pump has been switched OFF OR
Lube oil header pressure is LOW)

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Set point values

Geyser thermostat
* switch is in the power line itself.
Set-point is say 55 oC
At water temp. 55 oC, power is switched off.
At what temp. is it switched on?

If at 55 oC then ??? Confusion!

Therefore: one switch for one sensing only,
i.e. one TS for HIGH and another TS for LOW.
And, offset cut-out and cut-in
HIGH set at 55 oC + T, and LOW set at 55 oC T.
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Sequence Control Diagram

Examples

BFP of CCPP : start and trip permissive

Standby BFP of CCPP : start permissive
Representation on P&I diagram
Typical interlock diagram - CCPP

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Sequence Control Haywire

Equipment damage
Equipment/device does not start or shut-off

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Sequence control - Summary

Outcome:

Details of signal sources

Signal connections
Control logic for programming and hardware
Merge with layouts to generate control cable
routing, its length and size (BoM)
Modify piping drawings to accommodate
instruments/switches
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Modulating Control

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Automatic Control System

Automatic modulating control
Dynamic real-time control
Sense signals (parameters)
Generate control signal
Adjust control device
Feedback control loops
Every machine has its control system
P-based, PLC-based, DAS
Expensive, need maintenance, critical.
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Automatic controls- Example

Control loop #1 (CCPP steam system) :Flow control
Control loop #2 (CCPP steam system) : Pressure & t
emperature control

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Automatic controls - Elements

Name and symbol
Controller output not taken as input for
sensing resulting action, e.g. signal produced
for adjusting valve stem. As a result of this
action what is the position of the valve
stem?
Sense valve stem position with a position
sensor.

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Automatic controls
More in course MEL312 Control Theory &
Applications

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