Industrial training report

ON
Control and Automation at Larsen and Turbo

Submitted in partial fulfillment of the requirements for the award of
degree of
Bachelor of technology
In
Instrumentation and control Engineering

Guide: Submitted by:
Mr. Sunil More Manish Gupta
(07810403011)



Department of Instrumentation and Control Engineering
Amity School of Engineering and Technology
GGS Indraprastha University, New Delhi
(2011-2015)

ACKNOWLEDGEMENT

I sincerely and honestly thank my college for giving me opportunity for 6
weeks industrial in Larsen and Turbo .I am highly indebted to my teachers
for their guidance and constant supervision as well as for providing
necessary information regarding the project and also for their support in
completing project.
I am indebted to Mr.Sunil More project leader, for sparing his most special
time in providing guidance to me in training. Without his wise counsel,
inestimable encouragement it would have been difficult for me to have
knowledge of the functioning of various types of equipments. Gratitude is
also due to him for his constant guidance and direction in writing this
piece of work.
I would also like to thank all the staff members at Larsen and Turbo, who
have been very co-operative and patient with me and contributed towards
my summer training a success and a wonderful learning experience.
CONTENTS

1. Terminal Automation System
2. Main Features
3. System involved in TAS
4. Working of TAS
5. Safety interlocks in TAS
6. TAS network diagram
7. Conclusion
8. References

Terminal Automation Systems
Terminal Automation System (TAS) provides monitoring, control and management of the
entire product handling process from receiving to storage to distribution. Our terminal and
tank farm experience includes products such as crude oil, refined oil, liquefied natural gas,
petroleum gas and chemical tank farms, utilizing loading systems for ships, trains, trucks and
pipelines. With data integration as the systems core, TAS combines automatic control and
business management functions. It is an integrated, modular, open and scalable solution that
helps ensure the safe and stable operation, optimal management and profit maximization of
the terminal, as well as lowering production costs.
Terminal Automation Control
Process control
Safety control
Fire & Gas control
Terminal Business Management
Material transfer (truck loading/unloading, vessel loading/unloading, tanking,
pipelining etc.)
Material tracking
Storage tanks and inventory management
Material sorting/classification management
Customer management
Vehicles and vessels management
Equipment and assets management
Order and contract management
Distribution statements
Supervisor query
ERP interface
Main features
Terminal Management System (TMS)
TMS is an integrated terminal management system at MES level. It can send
commands to the control system via the interface with the process control system, and
also transmit necessary data to the ERP system.

TMS is mainly responsible for the operations and management of the entire
production and business processes at the terminal. It includes operations of material
receiving and distribution, stock tracking, tank farm condition monitoring, stock
material change, stock calculation, metrical information collection of volume and
quality data, water separation, tank cleaning, data management of operation records,
receipt preparation, log books distribution, at the same time analyzing operation and
business data, while performing position operation guidance and management. With
integrated management throughout all business processes, besides being able to
enhance the operation efficiency at the terminal, it is also able to standardize and
improve terminal companies management effectiveness.

As a TMS network usually adopts the B/S
(browser/ server) structure, the terminal
management may perform data entry, editing,
management, query, statistics and summary,
statements review and printing, and online
release through the Web server using a browser
with appropriate authority. Additionally, special
software does not need to be installed in the
system to perform this task.

With a standard database as its core, TMS
provides data display and output in various
forms of data sheets and graphs.

Process Control System
Process Control system is a unified platform for
sequential control, process control, electrical
control and safety control. It provides a
powerful, flexible, low-cost and all-in one
solution for process monitoring and safety at
tank farms.

PlantPAx performs data acquisition, control and
management of production control, and
transmits and receives process variables from
the control center. Authorized staff at the plant may perform monitoring, control,
scheduling and management over the entire plant through the control center. Its main
features include:

o Data acquisition: to collect, display, record and provide alarms on process
parameters, fi re control, electrics, cathodic protection and equipment
condition (failure and analysis of oil pumps and instruments) as well as other
related data
o Control: real-time control of equipment (valves/ pumps)
o Display: running status, operating instructions, dynamic trends, historical
trends, simulative process flow diagrams
o Authorization and user management
o Alarm report processing: display of alarms and events and printing of reports
o Database: real-time data collection and establishment of historical and real-
time databases of the control system
o Programming and configuration: programming, configuration and data editing
of the control system
o Communication: communication among the measuring system, automation
system and other subsystems
Systems and Working involved in TAS
Pipeline Strainers

Smith Meter

Pipeline Strainers provide protection for 4 or larger turbine and

positive displacement metering systems against dirt and foreign materials.

Features
1. 304 stainless steel perforated plate basket
2. Blind flange-type cover with lifting lug
3. NPT differential pressure taps
4. NPT vent and drain taps
5. Basket seal

Options
1. 304 Stainless Steel basket liners
2. Air Release Kit
3. Basket Differential Pressure Gauge Kit
4. Quick closure style covers
5. NACE compliance

Liquid Measurement

We offer the right solution for your liquid measurement application. Working in
partnership with our customers, FMC Technologies assists with application know-
how and process and system design expertise through equipment specification,
installation and start-up. Regardless of the application, we provide highly reliable
products with repeatable accuracy. And for those unique special-purpose
applications, we find solutions through our innovative, industry-leading measurement
technologies.

What sets FMC Technologies Measurement Solutions apart from our competitors?

1. Technically superior design
2. A wide range of proprietary technologies
3. Unsurpassed knowledge of liquid petroleum custody transfer and control
4. Supply of individual meters and accessories
5. Supply of complete, automated and fully integrated measurement and product
analysis systems

AccuPlus

Currently available in European countries only.

The AccuPlus product line represents high precision injector units for typical
downstream additive and product marker injection applications.
1. Utilizes an advanced positive displacement metering technology and new
electronic encoder technology offering 10,000 pulses per liter for more
accurate injection of expensive additives
2. Provides dependable injection over a wide range of ppm rates with no need for
different devices
3. The pressure drop is lower than comparable gear meters in the same
application to reduce wear and pumping cost
4. High-End Injection Solenoid Valve Technology for more accurate and trouble
free operations.
5. Easily connects directly with Smith Meter

AccuLoad III electronic preset

controller to eliminate the need for separate, unreliable and expensive
Additive Controller Electronic
6. Easily replaces existing aged injectors and non-reliable separate controllers

Conventional Turbine Meters

The Smith Meter

Turbine Meters, with their multi-bladed rotor and rugged design,

provide a consistently higher accuracy and dependability. This design also ensures a
longer service life paired with a low cost of maintenance. Unsurpassed accuracy and
industry leading design make Smith Meter Conventional Turbine Meters the right
choice for all petroleum measurement needs from loading racks to pipelines,
inventory control and line balancing.

Positive Displacement Meters
As the centerpiece of FMC Technologies Measurement Solutions vast liquid
measurement product line, the Smith Meter

Positive Displacement (PD) Meter has

long been the standard for unsurpassed reliability and superior custody transfer
accuracy. Boasting high measurement stability, superior accuracy and a low pressure
drop, our PD Meters offer unmatched service life and ease of maintenance. From
petroleum production to marketing or transportation, Measurement Solutions is the
most trusted supplier of accurate and reliable Positive Displacement metering
equipment in the petroleum industry.

Benefits of Positive Displace Meters:

1. Superior accuracy and measurement stability
2. Low pressure drop
3. Low operating cost
4. Long service life
5. Tolerance to entrained solids
6. Ease of maintenance

Smith Meter Valves and Line Accessories

FMC Technologies Measurement Solutions offers a complete line of valves and line
accessories that can be used with Smith Meter

products.

From the Smith 200 Series Control Valves featuring hydraulic operation, to the Set-
Stop Valve Packages featuring both electrohydraulic and digital electrohydraulic
operation, FMC Technologies has the solution for your valve application needs.

Smith Meter Strainers protect the metering system from dirt and other foreign
materials for optimum metering accuracy.

Air Release and Purger Systems

Smith Meter

Air Eliminators and Deaerators separate and release air or gas from
petroleum or other liquids before they are passed through the meter. Complete
elimination of air or gas is essential for accurate metering. Therefore, the Smith Meter
Air Eliminators, Deaerators and Air Purging Systems are a necessary part of an
efficient metering system when there is a possibility of air or gas being present in the
flowstream.

AccuLoad III Preset Controller

With the latest configurations, including the Split Architecture System and the
AccuLoad II-to-III Upgrade package, operators choose the Smith
Meter

AccuLoad

III family of products for maximum load control and flexibility.

The AccuLoad III product line provides the power and flexibility required for todays
highly efficient and regulated terminals. By offering a wide variety of loading arm
configurations- mixing blending arms with straight product- AccuLoad III maximizes
efficiency and product throughput like never before. Up to six products can be
blended together either sequentially or with ratio methods. Enhanced additive controls
include piston, standard metered or smart, as well as high-volume additive with flow
control.

Standard Loading Systems Modules

FMC Technologies loading system modules are based on the experience and quality
of the Smith Meter

brand.

Smith Meter is the only supplier worldwide who can provide all the required state-of-
the-art technology components from its own product line. The basic system module
includes the entire measuring section from the supply line inlet connection to the air
purger systems required by Weights & Measures regulations and ends at the control
valve exit or, optionally, at the top or bottom loading arm coupling.

These systems are designed for the European Market that require regulations such
as the Pressure Equipment Directive 97/23/EC (PED), the Directive 94/9/EC for
Equipment and Protective Systems intended for use in potentially explosive
atmospheres (ATEX), national Weights & Measures directives and especially the new
European Measurement Instrumentation Directive 2004/22/EG (MID) now statutory
in the European Community.

Biofuel Blending Systems

FMC Technologies Measurement Solutions is the most qualified company in the
world to supply a customized pre-packaged blending or unloading skid. Offering all
components including: meters, valves, strainers, presets, manual isolation valves,
proving valves, air eliminators, pumps, loading arms, safety equipment,
instrumentation, pre-wired and tested. FMC Technologies' skid packages also include:
sizing and specifying equipment, mechanical and electrical drawings, field
commissioning and local spare parts globally.

For 70 years, FMC Technologies has been the world leader in loading rack
measurement equipment.
1. Supplying more blending systems than anyone in the world
2. Offering more varieties of blending methods
3. Offering all metering technologies
4. Market leader in packaged systems

Proximity Card Reader

The Smith Meter

Proximity Card Reader offers terminal operators an alternative for

maintaining control and security by providing a reliable method of identifying drivers
and other users by communicating directly with the AccuLoad III or the terminal's
automation system.

Configured to operate as either a gate reader or an island reader, the card reader can
be supplied in a General-Purpose Enclosure or in an Explosion-Proof Enclosure that is
designed and approved for Class I, Division I, Groups C and D locations. The cards
for the reader have also been approved to be used in Class I, Division I, Groups C and
D locations and may be the only cards on the market approved for use in this
environment.

Bottom Loading Equipment

Sening

offers a complete range of proven mechanical products and systems for

bottom loading applications which can be combined with state-of-the-art electronic
technology.

Benefits

Higher flow rates
Increased efficiency
Vapor recovery
Increased driver and operator safety

Sening components are in accordance with international standards for bottom loading
of light petroleum products.

Overfill Protection:
- Optic overfill sensors (e.g. EN 13922)
- Pneumatic overfill sensors (on-board operation)

Vapor Recovery:
- Compartment vent valves
- Flame arrestor and vapor hood
- Vapor recovery adaptors and valves

Pneumatic Control Equipment:
- From individually designed switches and control components to fully integrated
factory assembled pneumatic control systems

Valves, Sight Glasses, Flanges, Couplings and Fittings:
- Foot valves (emergency valves), line valves and discharge valves
- API couplings
- Bottom loading manifolds
- Other line accessories and fittings

Manlids
- 20" (according to EN 13314, 13317)
- 16" (according to AS2809.2-1999)

Safety Interlocks in TAS
Safety control at the terminal involves equipment safety, personal safety and environmental
safety, and thus is the top priority in the terminal operation. TAS provides solutions which
comply to SIL2 or SIL3 standard, which can effectively realize safety control of the entire
plant including the tank farm, pump area and loading area.
Fire & Gas System includes:
Fire-area control philosophy
Automatic control, interlocking control and monitoring of the fire pumps, electric
valves and fire-fighting control
Automatic water replenishment of the fire water tank
High-pressure stability automation system
Heat, smoke and flame detectors, on-site manual fire call point, combustible gas
signal detection acquisition, monitoring and alarm system
Alarm signal to the industrial CCTV system
Signals interlock to the emergency evacuation system
Terminal Loading System
The terminal loading system is applied in the storage and transportation operations at the
terminal to improve the accuracy of product receipt or delivery, and lowers costs and
improves efficiency by automating shipping/trucking/barreling. At the same time, it helps to
avoid accidents caused by static electricity, manual measurement, and abnormal loss of
product. Meanwhile, it also provides accurate data to the upper ERP management system to
significantly improve the management and macro-control capability of the tank farm.
Operator authorization management
Driver and vehicle authorization management
Fill in, submit and process bills of materials
Crane position allocation and condition monitoring
Loading preparation, execution and completion of the entire management process
Acquisition and use of flow and weight signals
Intelligent control and interlocking protection of pumps and valves
Dynamic screen display of loading process,
Safety protection systems, static electric grounding as well as recovery systems
Reports, billing and invoice printing
Data archiving and database management
Communication
By adopting a completely open architecture and supporting standard communication
interfaces and protocols, TAS allows easy and convenient data sharing within an enterprise.
The system can communicate with third-party equipment and ERP system by means of serial
communication, DeviceNet, ControlNet, EtherNet/IP, OPC, etc.


Terminal Automation System Network Diagram

CONCLUSION
With a view to utilize summer vacations through the activities of academic pursuits an
industrial training at LARSEN AND TURBO was undergone
The project is all about study of various departments, workshops, onsite practical knowledge
of various instruments and instrumentation mechanisms. The training also covers the concept
of controlling instruments .its building block and calibration.
The training was quite fruitful as it helped in sharpening the operational skills of
instrumentation and working in technically excellent and advanced instrumentation equiped
particularly in company having international reputation and engaged in international projects
REFERNCES
1. http://www.l&t.c&a.in/
2. Manual on calibration