Assistant Engineer Design and Planning
Public Sector
Total years of experience :20 years, 4 Months
The project DCS (SUPCON ECS-700) will be used for monitoring of all plant parameters and Protection Systems. DCS will used to operate various plant equipment such as Electrical systems (CHINT), motors, control valves (metso valstone) and dampers (Festo Finland)
The Main Control Room is consist of Distributed Control System (DCS), Hardwired Mosaic Panels, Consoles, Protection System and SER (RTK 9000 TS) with reflash feature.
At this project the main focus was Surge Protection and minimum interference in control variables
I am involve in the following activities
1. A relational database using Microsoft Access has developed for an easy analysis and retrieval of data.
2. First of all I extracted the whole data from functional logic diagrams which were in AutoCAD format and provided by the Process and Operation Division to ensure the points logical and nominal dependencies.
3. All the equipment, valve/dampers and instrument were grouped independently.
4. All of the equipment were divided equally on each controller
5. All Valve/Dampers were divided equally on each distributor following logical dependence scheme on priority and nominal dependency scheme on probability basis.
6. All instruments (Transmitters, Switches, and RTDs etc.) were divided equally on each distributor following the logical, nominal and compensatory schemes for equivalent load sharing on each controller.
7. The probability scheme was spool base like same parameters on different controllers and different parameters on same controllers.
8. Special attention was given to instruments grounding scheme to have minimum interference.
9. Surge protection techniques have adopted to protect control system from high voltage surges.
10. Preparation of MCR Control Cabinets, Marshaling Cabinets, Mosaic Panels, Server Station, Engineering Station, SOE Consoles, Operators Consoles Layouts using AutoCAD
11. Preparation of MCR Cable Trays, Electrical Grounding, Instruments Grounding, Lighting Layouts using AutoCAD
12. Preparation of MCR False Ceiling, Wall Paneling, Aluminum Partitioning and False Ceiling Layouts using AutoCAD
13. Preparation of Mosaic Panels and Safety Consoles MIMICs using AutoCAD
14. Preparation of all Control, Electrical and Safety Points (terminating in MCR/RCR) database using Microsoft Access. The minimum information stored in the database about points are System, Loop, Area, IO Type and their terminating Process Network on which the instrument will be reside
15. Segregation of Protection and Normal Process instruments on their IO type wise using using MS Access/Excel
16. Equivalent division of all instruments on all three Process networks using using MS Access/Excel
17. Preparation of wiring diagrams and Cabling Schedule from field Instruments to JBs, JBs to Marshaling Cabinets, Marshaling Cabinets to Controllers, Marshaling and Controller cabinets to SER and Instrument Loop Diagrams (ILDs) using Bentley AutoPLANT Instrumentation and Wiring (P&IW) with Oracle 10g, MS Access and AutoCAD.
18. Assignment of IO points to all Signals
19. Preparation of Power supply drawing for the Control System Cabinets using AutoCAD.
20. Installation of Mosaic Panels, Marshaling cabinets, Control Cabinets, SER and Power Cabinet in MCR
21. Preparation of System wise Commissioning Lists of Control System
22. Printing of Cable Markers and different size Cable Sleeves using Tyco TE3124 printer
23. Printing of A0, A1 and A2 size drawings using HP DesignJet T1300 Postscript Plotter
24. Printing of A3 size drawings using HP Color LaserJet 5550 printer
This was a continuation of first Project we worked the Project DCS (Honeywell Experion PKS C200) and
PLC (ML200R Honeywell) was used for monitoring of all plant parameters, with parallel monitoring Protection System. Integrated with DCS, PLCs were used to operate various plant equipment such as Electrical systems (SIEMENS), motors, control valves (Flow Serve) and dampers (Balemo)
The Main Control Room was consist of Distributed Control System (DCS), Hardwired Mosaic Panels, Consoles, Protection System and SER (Sequential Event Recorder)
DCS philosophy was which was slightly changed from the previous one based on specific requirements having four separate and independent process networks.
• Process Network I
This process network includes two PLCs, one HLIU and one LC.
• Process Network II
This process network includes two PLCs, one HLIU.
• Process Network III
This process network includes two PLCs, one HLIU.
• Process Network IV
This process network is dedicated for electrical system and it will have one redundant PLC
The first three process networks were used to monitor triplicated redundant signals for safety systems as well as non-redundant signals from other systems.
As per layout the Operator and engineering stations were installed in front of hardwired mosaic panel. Protection consoles were placed adjacent to stations
One of the major design goals of DCS was to ensure a high level of system availability: first by increasing the meantime between failure (MTBF - 20 years) and secondly by lowering the meantime to repair by using redundant power supplies, networks and Controllers
I was involved in the following activities
1. Preparation of MCR Control Cabinets, Marshaling Cabinets, Mosaic Panels, Server Station, Engineering Station, SOE Consoles, Operators Consoles Layouts
2. Preparation of MCR Cable Trays, Electrical Grounding, Instruments Grounding, Lighting Layouts
3. Preparation of MCR False Ceiling, Wall Paneling, Aluminum Partitioning and False Ceiling Layouts
4. Preparation of Mosaic Panels and Safety Consoles MIMICs
5. Preparation of all Control, Electrical and Safety Points (terminating in MCR/RCR) database using Microsoft Access. The minimum information stored in the database about points are System, Loop, Area, IO Type, and their terminating Process Network on which the instrument will be reside
6. Preparation of Signals Lists of Electrical Systems using MS Access/Excel
7. Preparation of Instrument list residing of Mosaic Panels using MS Access/Excel
8. Preparation of Signals Lists for SER using MS Access/Excel
9. Preparation of Instruments Location Lists (Areas Wise) from Instruments location drawings using MS Access/Excel
10. Segregation of Protection and Normal Process instruments on their IO type wise using MS Access/Excel
11. Equivalent division of all instruments on all three Process networks using MS Access/Excel
12. Preparation of wiring diagrams and Cabling Schedule from field Instruments to JBs, JBs to Marshaling Cabinets, Marshaling Cabinets to Controllers, Marshaling and Controller cabinets to SER and Instrument Loop Diagrams (ILDs) using Bentley AutoPLANT Instrumentation and Wiring (P&IW) with MS Access and AutoCAD.
13. Assignment of IO points to all Signals
14. Preparation of Power supply drawing for the Control System Cabinets using AutoCAD.
15. Installation of Mosaic Panels, Marshaling cabinets, Control Cabinets, SER and Power Cabinet in MCR
16. Preparation of System wise Commissioning Lists of Control System using MS Access/Excel
17. Preparation of as built drawings
18. Printing of Cable Markers and different size Cable Sleeves using Tyco TE3124 printer
19. Printing of A0, A1 and A2 size drawings using HP DesignJet T1300 Postscript Plotter
20. Printing of A3 size drawings using HP Color LaserJet 5500 printer
At this Project DCS (Honeywell Experion PKS C200) and PLC (ML100R Honeywell) were used for monitoring of all plant parameters, with parallel monitoring Protection System. Integrated with DCS, PLCs were used to operate various plant equipment such as Electrical systems (SIEMENS), motors, control valves (Flow Serve) and dampers (Balemo)
The Main Control Room was consist of Distributed Control System (DCS), Hardwired Mosaic Panels, Consoles, Protection System and SER (Sequential Event Recorder)
DCS philosophy was based on specific requirements having four separate and independent process networks.
• Process Network I
This process network includes two PLCs, one HLIU, one LC, one SLC and one FSC.
• Process Network II
This process network includes two PLCs, one HLIU, one SLC and one FSC.
• Process Network III
This process network includes two PLCs, one HLIU, one SLC and one FSC.
• Process Network IV
This process network is dedicated for electrical system and it will have one redundant PLC
The first three process networks were used to monitor triplicated redundant signals for safety systems as well as non-redundant signals from other systems.
As per layout the Operator and engineering stations were installed in front of hardwired mosaic panel. Protection consoles were placed adjacent to stations
One of the major design goals of DCS was to ensure a high level of system availability: first by increasing the meantime between failure (MTBF - 20 years) and secondly by lowering the meantime to repair by using redundant power supplies, networks and Controllers
My key responsibility was to understand the whole system Design Philosophy and Architecture
I was involved in the following activities
1. Understanding of all Process systems, P&IDs and their importance
2. Understanding of PFDs of all Process Systems
3. Understanding of all Process instruments in the process systems and their type
4. Preparation of MCR Control Cabinets, Marshaling Cabinets, Mosaic Panels, Server Station, Engineering Station, SOE Consoles, Operators Consoles Layouts using AutoCAD
5. Preparation of MCR Cable Trays, Electrical Grounding, Instruments Grounding, Lighting Layouts using AutoCAD
6. Preparation of MCR False Ceiling, Wall Paneling, Aluminum Partitioning and False Ceiling Layouts using AutoCAD
7. Preparation of Mosaic Panels and Safety Consoles MIMICs using AutoCAD
8. Preparation of Instruments Lists from each system using MS Access/Excel
9. Preparation of Signals Lists of Electrical Systems, MOSAIC and SER using MS Access/Excel
10. Preparation of Instruments Location Lists (Areas Wise) from Instruments location drawings using MS Access/Excel
11. Segregation of Protection and Normal Process instruments on their IO type wise using MS Access/Excel
12. Segregation of instruments on their IO type basis using MS Access/Excel
13. Equivalent division of all instruments on all three Process networks using MS Access/Excel
14. Preparation of wiring diagrams and Cabling Schedule from field Instruments to JBs, JBs to Marshaling Cabinets, Marshaling Cabinets to Controllers, Marshaling and Controller cabinets to SER and Instrument Loop Diagrams (ILDs) using Bentley AutoPLANT Instrumentation and Wiring (P&IW) with MS Access and AutoCAD.
15. Assignment of IO points to all Signals
16. Preparation of Power supply drawing for the Control System Cabinets using AutoCAD.
17. Installation of Mosaic Panels, Marshaling cabinets, Control Cabinets, SER and Power Cabinet in MCR
18. Preparation of Commissioning Lists of Control System
19. Preparation of Spare Lists of all for control system cards and other items
20. Printing of Cable Markers and different size Cable Sleeves using Tyco TE3124 printer
21. Printing of A0, A1 and A2 size drawings using HP DesignJet T1300 Postscript PlotterPrinting of A3 size drawings using HP Color LaserJet 5500 printer
At this Project DCS (Honeywell Experion PKS C200) and PLC (ML100R Honeywell) were used for monitoring of all plant parameters, with parallel monitoring Protection System. Integrated with DCS, PLCs were used to operate various plant equipment such as Electrical systems (SIEMENS), motors, control valves (Flow Serve) and dampers (Balemo)
The Main Control Room was consist of Distributed Control System (DCS), Hardwired Mosaic Panels, Consoles, Protection System and SER (Sequential Event Recorder)
DCS philosophy was based on specific requirements having four separate and independent process networks.
• Process Network I
This process network includes two PLCs, one HLIU, one LC, one SLC and one FSC.
• Process Network II
This process network includes two PLCs, one HLIU, one SLC and one FSC.
• Process Network III
This process network includes two PLCs, one HLIU, one SLC and one FSC.
• Process Network IV
This process network is dedicated for electrical system and it will have one redundant PLC
The first three process networks were used to monitor triplicated redundant signals for safety systems as well as non-redundant signals from other systems.
As per layout the Operator and engineering stations were installed in front of hardwired mosaic panel. Protection consoles were placed adjacent to stations
One of the major design goals of DCS was to ensure a high level of system availability: first by increasing the meantime between failure (MTBF - 20 years) and secondly by lowering the meantime to repair by using redundant power supplies, networks and Controllers
My key responsibility was to understand the whole system Design Philosophy and Architecture
I was involved in the following activities
1. Understanding of all Process systems, P&IDs and their importance
2. Understanding of PFDs of all Process Systems
3. Understanding of all Process instruments in the process systems and their type
4. Preparation of MCR Control Cabinets, Marshaling Cabinets, Mosaic Panels, Server Station, Engineering Station, SOE Consoles, Operators Consoles Layouts using AutoCAD
5. Preparation of MCR Cable Trays, Electrical Grounding, Instruments Grounding, Lighting Layouts using AutoCAD
6. Preparation of MCR False Ceiling, Wall Paneling, Aluminum Partitioning and False Ceiling Layouts using AutoCAD
7. Preparation of Mosaic Panels and Safety Consoles MIMICs using AutoCAD
8. Preparation of Instruments Lists from each system using MS Access/Excel
9. Preparation of Signals Lists of Electrical Systems, MOSAIC and SER using MS Access/Excel
10. Preparation of Instruments Location Lists (Areas Wise) from Instruments location drawings using MS Access/Excel
11. Segregation of Protection and Normal Process instruments on their IO type wise using MS Access/Excel
12. Segregation of instruments on their IO type basis using MS Access/Excel
13. Equivalent division of all instruments on all three Process networks using MS Access/Excel
14. Preparation of wiring diagrams and Cabling Schedule from field Instruments to JBs, JBs to Marshaling Cabinets, Marshaling Cabinets to Controllers, Marshaling and Controller cabinets to SER and Instrument Loop Diagrams (ILDs) using Bentley AutoPLANT Instrumentation and Wiring (P&IW) with MS Access and AutoCAD.
15. Assignment of IO points to all Signals
16. Preparation of Power supply drawing for the Control System Cabinets using AutoCAD.
17. Installation of Mosaic Panels, Marshaling cabinets, Control Cabinets, SER and Power Cabinet in MCR
18. Preparation of Commissioning Lists of Control System
19. Preparation of Spare Lists of all for control system cards and other items
20. Printing of Cable Markers and different size Cable Sleeves using Tyco TE3124 printer
21. Printing of A0, A1 and A2 size drawings using HP DesignJet T1300 Postscript PlotterPrinting of A3 size drawings using HP Color LaserJet 5500 printer
I posted there for more than a year. it was the state of the are education with the infield training.
Major courses covered here are
1. Mechanical
2. Fluid Mechanics
3. Thermodynamics
4. Electronics
5. Electricity
6. Industrial Safety
7. Chemistry
8. Turbine, Generator And Auxiliary
9. Electrical Equipment
10. Mechanical Equipment
11. Instrumentation And Computer Control
12. Instrument
13. Boiler And Auxiliary
At the end of the formal training i was involved in I&C Design (Control Specially) studies about 2 months.
It was four months training covering AutoCAD 2D+3D features in detail