1

SUMMER TRAINING REPORT

PLANT: HIGH DENSITY POLY ETHYLENE (HDPE)

DEPARTMENT: INSTRUMENTATION

SUBMITTED BY:
DEBARCHANA TRIPATHI

GALGOTIAS COLLEGE OF ENGINEERING & TECHNOLOGY

DURATION: 26th JUNE to 17th JULY ,2008

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ACKNOWLEDGEMENT

Riding the wings of change is a technical skill that professionals in industries have to
learn and perfect. To ensure progress for industries in today’s cutthroat industrial arena,
engineers need to constantly update themselves from an industrial perspective. To learn from
this approach we the students have to avail of the industrial training that is included in our
curriculum.
I consider myself very lucky that I could gather the required technical skills from
HALDIA PETROCHEMICALS LIMITED a pioneer in the petrochemical arena. I thank Mr.
P. K. Kundu (Sr. G. M Instrumentation) for making the arrangements so that I can undergo
this training in an organized fashion. I am grateful to Ms. Debashree mukherjee(Plant HR
and A) Mr. Prahlad Saha (DGM Instrumentation) for assigning me to such an important part
of the plant and periodically checking on my performance and enquiring about my problems,
if any, despite having a very busy schedule. I also thank Mr. Shantanu Konar (Chief Mgr
Instrumentation) ,Mr. Aparesh Jana ( Deputy Mgr Instrumentation) , Mr. Indranil Hatua
(Deputy Mgr Instrumentation),Mr. Arghya sengupta (Asst Mgr instrumentation),Mr.
Shyamal Bibar (Asst. Mgr) for sharing there knowledge and experiences with me. I also
thank the entire loving and caring HPL family who has shared their valuable industrial
experiences with me.
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Introduction
I have come from GALGOTIAS COLLEGE OF ENGINEERING & TECHNOLOGY
to Haldia Petrochemicals Limited (HPL) for summer training during 26th JUNE to 17th
JULY.I have undergone a vocational training at HDPE (High Density Polyethylene Plant)
for last one month. One month long training starts with being familiar with the process of
HDPE plant. Especially I have studied on different types of instruments used in HDPE
plant.
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A few words about HPL

Haldia Petrochemicals Ltd, one of the largest petrochemicals complexes in India and the only one of its
kind in the eastern region was commissioned on April 2, 2000. A producer of polymers and chemicals,
Haldia Petrochemicals is ushering in an industrial era of plastic processing and ancillary industry that has
not been traditionally at hand in this part of the country. The complex produces ethylene, propylene and
associated liquid stream products for downstream processing into polymers & chemicals.
HPL has a number of plants for the production of world class petrochemical products. The plants are
operational and commercial production has already started.
The integration process of the plant complex started in October, 2000 and the operations reached the stage of
commercial production with effect from August 01, 2001.
In the intervening period till date, the company has been able to successfully operate the entire complex,
establish several polymer grades as industry benchmarks secure an all India market share of 22% and put in
place a sophisticated end-to-end IT enabled supply management system.
These achievements recorded over a period of 10 months since commissioning of the Haldia complex, gives
Haldia Petrochemicals the confidence to face the challenges ahead. The global over-supply position in
polymers, the consequent squeeze on margins for producers, the high debt burden of the Company and a
difficult liquidity position are real issues, which are being addressed by the management.
While these are indeed challenging times, the Company is fully convinced of the intrinsic strengths of its
plants, processes and people, to see it through to its goal of becoming a total petrochemicals solutions
provider.

Plants & Units: -HPL has a number of plants for the production of world class petrochemical products. The
plants are operational and commercial production has already started. In the intervening period till date, the
company has been able to successfully operate the entire complex, establish several polymer grades as
industry benchmarks secure an all India market share of 22% and put in place a sophisticated end-to-end IT
enabled supply management system. HPL has total six units. They are:-

1.Naphtha Cracking Unit (N.C.U)

2. Naphtha cracking associated unit (N.C.A.U)

3. High Density Polyethylene (H.D.P.E)

4. Linear Low Density Polyethylene (L.L.D.P.E)

5. Polypropylene (P.P.E)

6. Integrated Offset Plant (I.O.P).

Units:-

. Capacity (TPA) Process License

Naphtha Cracker Unit 466,000 ABB Lummus Global
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Associated Units :
Butadiene Extraction Unit 82,000 BASF
PGH Plant 330,000 IFP
Benzene Extraction Unit 85,000 Lurgi
C4 Hydrogenation Unit 120,000 IFP
Polypropylene Plant 230,000 Montell
LLDPE / HDPE Plant 250,000 Montell
HDPE Plant 220,000 Mitsui
BOO Units :
Captive Power Plant 116 MW L&T
Nitrogen Plant 9000 NM3 /Hr Praxair

High Density polyethylene Plant

About Halene H HDPE: The Halene H HDPE Technology is a new generation Bi modal slurry
process. Most Halene H HDPE and HMHDPE products are exceptionally tough and impart high
mechanicals. The Halene H Grades from Shoreline offer very good Impact stiffness balance.
The Halene H HDPE offers a wide range of conventional HDPE as well as HMHDPE Grades. This
encompasses Extrusion Grades like Films, Raffia, Pipes, Cable insulation and a wide array of Moulding
grades.
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Halene H HMHDPE film Grades have excellent tensile properties and high Whiteness Index. This is a
unique USP as converters could substantially save on the cost of process additives. The other HDPE
extrusion grades have a wide band of applications like Raffia, Films and could well be used in Moulding
applications.
The Halene H HMHDPE and HDPE Blow Moulding grades have exceptional Impact/Stiffness balance, high
Whiteness Index -–an USP unmatched by most Domestic Producers of Polymers in India, and the Injection
Moulding grades exhibit very good Impact Stiffness balance.

Process ability of Halene H Resins: - The Halene H HMHDPE and HDPE Grades exhibit
exceptional process ability on most Film and specialty Extruders. This is possible due to an unique Bi modal
Technology adopted. The exceptional balances of properties are possible with precise control of Molecular
Weight Distribution (MWD) in the Resin.

Future Products Planned from Halene H Stable: - Stand Alone Insulation Grade for wire &
cable industry.

Extrusion Grades - HDPE & HMHDPE: -

.
Grade Melt index HLMI Density Special Features Applications
Code 12

E 5201 0.40 . 0.952 Multi application Grade, High ESCR Blow Mould, Films, Compounds
BMWD

F 5400 0.07 10-13 0.954 High Mechanicals, BMWD Thin High Strength Films

F 5600 0.04 7-9 0.956 High Mechanicals, BMWD Thin High Strength Films

R 5801/T6 0.64 . 0.958 Multi application Grade Blow Mould, GP Films, GP Pipes

Y 5401 0.80 . 0.954 High Tenacity, High Monofilament, GP Films

process ability
P 5200 0.06 . 0.952 Compliance to PE 80 Pipes

Moulding Grades - HDPE & HMHDPE Blow Moulding & Injection

Moulding:-
Grade Melt HLMI Density Special Applications
Code index Features
12
B 6401 0.4 . 0.964 High Impact, Blow Moulding up to 20L
High Stiffness
B 5600 0.04 7-9 0.956 High Impact, Blow Moulding up to 150
High Stiffness
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B 6000 . 2.8- 0.960 High Impact, Blow Moulding up to 240L

3.2 High Stiffness
HD 18 . 0.948 Good Impact GP In. Molding unto 100 L capacity
LX2 Stiffness
Balance
M 7 . 0.960 Good Impact GP In. Moulding, Crates
6007L Stiffness
Balance

Process Overview
The HDPE plant consists of seven sections. They are
1. Catalyst Feeding.
2. Polymerization.
3. Separation and drawing.
4. Palletizing and storage.
5. Hexane recovery.
6. Process auxiliary.
7. Bagging and Palletizing.

Catalyst Feeding Section

Total five catalysts are fed at the catalyst feeding section. They are PZ, TE, AT, AI, OG. Different
procedures are followed for different catalyst preparation.
PZ catalyst preparation:- PZ catalyst is dissolved In Hexane by means of feed drum agitator.
TE catalyst preparation: - To catalyst is dissolved In Hexane by means of drum agitator.
AT catalyst preparation:- AT catalyst is transferred by nitrogen pressure from AT container to AT feed
drum. It dissolves in Hexane by nitrogen bubbling method. Meanwhile gas coming from AT catalyst
container and feed system is charged into flare system.
AI catalyst preparation:- AI catalyst is transferred by nitrogen pressure from AI container to AI feed drum.
It dissolves in Hexane by nitrogen bubbling method. Meanwhile gas coming from AI catalyst container and
feed system is charged into flare system.
OG catalyst preparation: - It is transferred by own pressure from a cylinder. Catalyst concentration is
made constant with the help of FQ.
Catalyst feed:- The prepared catalysts are fed into reactor with the help of feed pumps.

Polymerization Section
Raw Material and hexane feed to Polymerizes:-
1. Ethylene
2. Hydrogen gas
3. Propylene
4. Butene1
5. Hexane
Polymerize recycled gas: -
All the gases along with polymerizer recycle gas are fed to reactor through the injection pipes.
Reactors: -
At the reactor 80 o C and 3 kg/cm2 pressure is maintained. There the polymerization occurs. Slurry of
polyethylene and hexane produced. Then the slurry is passed thorough condenser from where hexane is
separated.
Slurry Cooler: -
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Produced slurry of polyethylene is then sent to slurry cooler. Slurry cooler pump is used to remove the
polymerization heat together with recycled gas system and reactor jacket cooling system.
Overflow slurry handling: -
Since the over flow slurry contains bubbles of mixed gas in the polymerizes, the slurry is separated in the
dilution drum into liquid and gas phase. The polymer slurry is flashed into he flash drums.

Separation and drying section

Separation: -
The slurry is continuously fed to the slurry transfer pump to the horizontal type Centrifuge revolving at
high rpm, which polymer is separated by the centrifugal force. The polymer is discharged from the
centrifuge by the screw conveyor provide in the bowl in the form of wet cake containing hexane by approx.
30% wt and fed to he dryer via the wet cake screw feeder.
Drying: -
A) Steam tube rotary drier: -
Mixed gas consisting of nitrogen and hexane vapor flows through the dryer concurrently with the product.
Dryer has 30 minutes of holding time; it contains 0.2% volatile matter (hexane) n its temperature is approx
100 o C. Low pressure steam is supplied to the steam is supplied to the steam tube.
B) Dryer gas circulation system: -
The mixed recycled gas containing a small amount of polymer particles goes into dryer. The fine polymer
entrained with mixed gas is collected by the circulation liquid. The noncondensible gas which leaves the out
let of the purge gas condenser is pressurized to 3kg/cm2 G by the of gas compressor and part of it is supplied
to the gland for flushing, while surplus is discharged to he flare system.
Pelletizing, Storage and packaging section
Powder Hopper: -
The product powder is transferred to the N2 gas pneumatic powder conveying system through the powder
rotary valve. The product which is forwarded by the powder transfer blower is continuously separate in the
powder cyclone from n2 & dropped into the powder hopper. N2 gas is filter through the bag filter to be
recalculated very fine powder entered with N2 gas continuously recovered.
Powder bulk loading:-
From the powder hopper the polymer powder can be transferred by means of pneumatic transport, to the
powder bulk loading silo. Belo this silo a truck bulk loading station is provided only for LINE1.
Stabilizer Measuring System: -
Every kind of solid stabilizer(AB,AE,AJ,AK,AL,HA,HD,HF,SF,UC & UD) and nine kind of liquid
stabilizers(AA,AD,AF,AH,EB,ED,EJ,HB & W)
Are automatically weighed and discharged in accordance with the blending ratio for individual product
types.
Powder and stabilizer feeding system: -
The powder system which has left the outlet is measured by powder measuring feeder and is fed to feeder.
The solid stabilizer mixture in accordance with the stabilizer recipe predetermined for product type is
prepared and discharged Bach wise by gravity. Stabilizer mixture is metered and fed to the feeder. Liquid
stabilizers and W stabilizers fed into feeder y liquid stabilizer feed pump respectively.
Pelletizing System: -
The palletizer is twin screw type continuous mixer with gear pump where PE powder and stabilizers are
mixed and kneaded. Molten polymer is pushed towards the die gear pump system then the molten polymer is
extruded the die-hole into the cutter box through which pellet cooling water is circulated. The extruded is cut
into pellet by revolving cutter. The resin in the pellet from is transferred to the pellet separator. For
protection a grid PW strainer is provided to remove any fused blocks of pellet. The pellet which passed the
grid is send, after they are drained to the perforated plate screen. The pellet cooling water flows into PW
drum, for which it is reticulated to the cutter box.. After pressurized PW circulation pump then cooler to 70o
C by PW cooler. Powdery matter sustained in the pellet cooling water is discharged out of the system trough
the overflow outlet by continuously feeding DM water through the FC. Since the waste water contains the
solid particle & stabilizers are suspended or dissolved in it, it is transferred to the powder separator. Solids
are separated so the ate itself can be disposed off as “oily water” . Products pellets are classified by pellet
vibrating screen into undersize, normal, oversize product. Normal size pellet which flows into the pellet
separator hopper are pneumatically conveyed specified silo through the pellet rotary valve by the pellet
transfer blower.
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Pellet blending and transferring system: pellet silo of capacity of 500 m3 each one. In order to rectify the
fluctuation of quality due to possible variance in operating condition at process control, the pellet blending is
carried out through transferring the pellet to the bagging hopper.
Repelleting system: -
The off-spec material is handled by this system.

Hexane recovery section

Caustic soda washing:-
Mother liquor which has been separated by separator is washed with caustic soda and process water to
decrease ash and chloride contained before being sent to low polymer separation system. Mother liquor
(crude Hexane is transferred to HE and NaOH separator through HE & NaOH contactor together with DM
water and LP steam which is fed into system to maintain to 60o C temperature. West water is continuously
discharge from vessel. Then caustic soda washed crude Hexane is transferred to HE water separator vessel.
Hexane striping:-
Hexane containing low polymer and crude Hexane from fed drum is feed by the crude Hexane fed
pump .Hexane vapor is generated by depressurized to 0.2kg/cm2G .Then it is condensed and cooled in
Hexane overhead condenser . Molten low polymer in Hexane concentrated container is pressurized to
22kg/cm2G and heated up to 120 to 220oC.The low polymer solution, after removing Hexane is transferred
to LP holding drum.
Low polymer flaking:-
LP is transferred to the drum flakers where it is cooled with circulating cooled water system. Vent gas is
exhausted to atmosphere with ventilator.
Hexane purification:-
Hexane vapor is condensed and cooled in exchanger and flows into stripper receiver gravity. Now the
hexane layer is saturated with 250ppm water. Then it is sent to Hexane dehydrator.
Pure Hexane distribution:-
Purified Hexane with water content of 10ppm or less is pressurized to 12kg/cm2G or higher by the H.P
Hexane pump dehydrated to 5ppm or less by Hexane dryer. Then Hexane is distributed as per process
requirement.

Control valve
The most general type of final control element is control valve. This device is designed for used in process
control applications involving liquid gas or vapor Flow rate. Control valve controls the process variable
directly (as flow, pressure etc.) or indirectly (as temperature, level).
Principal of control valve: -
Flow rate in process control is usually expressed in volume/unit time. If a mass Flowrate is decided it
can be calculated from particular fluid density. If a given fluid is delivered through a pipe then the volume
Flow rate is:
Q=A x V
Q = Flowrate (m3/sec)
A =pipe area (m2)
V =Flow velocity (m/s)
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A control valve regulates the Flowrate in a fluid delivery system. In general, a close relation exists between
the pressure along a pipe and the Flowrate so that if the pressure is changed then the Flowrate is also
changed. A control valve change Flowrate by changing the pressure in a flow system because it introduces a
constriction in the delivery system. In the figure below, the placement of a construction in pipe introduces a
pressure difference across the pipe. We can show the Flowrate through the constriction is given by
Q=K x ( p1-p2) 1/2
K= proportional constant
P1-p2=pressure difference.
The constant K depends on the size of the valve, the geometrical structure of the delivery system, and to
some extent, on the material flowing through the valve. Now the actual pressure of the entire fluid delivery
(and sink) system in which valve is used (and, hence, the flow rate) is not a predictable function of the valve
opening only. But because the valve opening does change the Flowrate, it provides a mechanism of flow
control.
Types of control valve
A different type of control valve is classified by a relationship between the valve stem position and the flow
rate through the valve. The control valve characteristics are assigned with the assumption that the stem
position indicates the extent of the valve opening and the pressure difference is determined by the valve
alone. There are three basic types of control valve those relation ship between position (as percentage of full
range) and flow rate (as percentage of maximum) is given by
1. Quick opening:-
This type of valve is predominately for fully on / full off control application. Such a valve for example
may allow 90% of flow rate with only a 30% of travel of stem.
2. Linear:-
This type of valve has a flow rate varies linearly with the stem position. It represents the ideal situation
where the valve control determine the pressure drop .the relationship expressed as
Q/ Q max= S/S max
Where
Q= Flowrate
Q max = maximum Flowrate
S=stem position and S max = maximum stem position
3. Equal percentage valve:
A very important type of valve employed in he flow control has characteristics such that a given
percentage change In the stem position produce an equivalent change in flow, that is, an equal
percentage. Generally, this type of valve not shut off the flow completely in its limit of stem level. This
Q min represents the minimum flow that one limits of its travel. At the other extreme, the valve allow a
flow Q max its maximum, open valve, flow rate . for this type, we define the range ability R as the ratio
R= Q max/Q min

Control valve accessories:-

Positioner:-

Positioners are instruments which, help improve control by accurately positioning a control valve
actuator in response to control signal. Positioner receives an input signal either pneumatically or
electrically and provide output power, generally pneumatically, to on actuator to assure valve
positioning. A feed back linkage between valve stem and Positioner is established so that stem position
can be noted by the instrument and compared with the position dieted by the control signal. Use of the
Positioner is generally desirable to liberalize the control valve plug position with the control signal. The
Positioner will improve the performances control valve systems. There are situations; however, where
process dynamic eliminates the use of Positioner.
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Pneumatic Amplifier:-

A pneumatic amplifier is also called a relay, rise the pressure and ./ or air flow volume by some
linearly proportional amount from input signal. Thus if the booster has a pressure gain 10, the o/p world
be 30-150 psi. for i/p of 3-15 psi. This is accomplished via a regulator i.e. activate a control signal. As
the signal pressure varies, the diaphragm motion will move the plug in the body block of the booster. If
the motion is down, the gas leak is reduced and the pressure in o/p line increased. This device is shown
the reverse acting because a high signal pressure will cause o/p pressure to decrease.

I to P converter:-

The current to pressure converter is a very important element in process control . often when we
want to use the flow level electric current to do work , its The most general type of final control element
is control valve. This device is designed for used in process control applications involving liquid gas or
vapor Flowrate. Control valve controls the process variable directly (as flow, pressure etc.) or indirectly
(as temperature, level).

Pneumatic actuator :-

If a valve is used to control to fluid flow, some mechanism must be physically open or closed the
valve. It based on forced-area relationship
F=(p1-p2)xA
Where p1-p2 = pressure difference, A =diaphragm area, F= forced
Many type of pneumatic actuator are available but control valve is the most common. Increasing the
control pressure applied on the diaphragm scenes the stem position

Air filter pressure regulator:-

The purpose of air pressure regulator is to control air pressure. Generally the instrument air supply is
4-7kg/cm2 output of input converter 0.2-1kg/cm2. It has a metallic filter that absorbs moisture and dust
and cleans the air.

Trip valve:-

It is a special type of valve where a specific actuator action is required when supply pressure fails or
goes bellow a specific value. When the pressure goes bellow the specific value the trip valve causes the
valve to trip. Auxiliary power is provided for actuator action by pneumatic volume tank.

Solenoid valve:-

It is used for switching application of control valve it provides the over ride equipment and fail safe
interlock. Upon loss in the electrical power the solenoid valve is closed the port of valve Positioner and
build the pressure from the diaphragm.

Limit switch: -

Electrical power switch are used to provide the operation of alarm signal light relays etc. the switch
can be fully integrated or fully adjustable unit with multiple switches or stand alone switch and trip
equipments.

Volume booster:-
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The volume booster is normally used in control valve actuator to increase the stocking speed. The
devices incorporates a dead band features to adjust their response and eliminates instabilities.

Manual hand wheel: -

For override control a manual hand wheel is provided for emergency or mal functioning. Nearly all
actuator are equipped with gear style or screw style hand wheel..

General classifications of valve

Valve are generally classified as
1. Gate valve
2. Globe valve
3. Ball valve
4. Butterfly valve
5. Plug valve

Gate valve:-

In this valve the diameter of the opening through which the fluid passes is nearly same as that of the
pipe and direction of the flow does not change as a results wide open gate valve is not used for
controlling flow and usually left as fully open or closed.

Globe valve:-

Globe valve is widely used for controlling flow. The opening increases almost linearly with stem
position and wear is evenly distributed around the disk. The fluid passes to restricted opening and
change direction several times. As a result pressure drop is large the glob valve.

Plug valve:-

It is operated by moving a tapered plug their by varying the gap between the plug and the valve shift.
The flow is control by the linear movement of the valve stem.

Ball valve:-

The ball valve consist of a spherical ball as sealing element it is an on off valve. It has occasional
application in flow control. Ball valve also capable of higher flow rate capacity of glob valve.

Measurement

Pressure Measurement

Pressure gauge:-

In case of process measurement system most commonly use for indicating instruments is pressure
gauge. In this gauge the primary sensing element bourdon tube element. Bourdon tubes are the most favored
mechanical element for measurement of pressure and constitute an important group of primary transducer
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for converting pressure into linear and angular displacement. One end of the tube is attached to a rigid base,
enabling communication with the source of pressure while the other end is closed an sealed, having freedom
of movement. Due the pressure difference between the inside and outside of he tube, the cross-section of the
tube is deform and the tube bends to acquire a circular cross-section this resulting effect being the
displacement of the free tip.

c-bourdon

Diaphragm

The most typical diaphragm-type manometer used for measuring a vacuum is a variable-capacitance
transducer with a metal diaphragm deflected by the measured pressure. The diaphragm is positioned close to
stationary plates. The pressure is measured by sensing the capacitances formed by the diaphragm and plates.
There is no significant difference between this transducer and the conventional capacitive pressure gage,
which is used for measuring absolute or differential pressure. The specific conditions for measuring a
vacuum require using filters to keep the sensing chamber free of contamination. Incorporating a getter
stabilizes the operation of the transducer by absorbing gas molecules in the reference cavities. Some
transducer designs require a high-temperature bake-out of the elements to drive gas molecules out of the
surfaces that are in contact with the fluid. This out gassing is performed prior to measurements.

Pv = vacuum, 1 = gas filter, 2 = diaphragm, 3 and 4 = electrodes, 5 = evacuated and sealed chamber.

Pressure switch
It consist of two parts
1. mechanical part
2. electronics part
1. Mechanical part senses the pressure of line by diaphragm. There is an actuator after the diaphragm
which moves the liver. So according the movement of the lever a micro switch is made closed or
open.
2. In the electronic part three type of terminal are there
1. common
2. normally closed
3. Normally opened.
There is also provisions to adjust the set point manually according to the desired pressured by a nut.
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Pressure switch low: - In PSL generally common and NO is taken the circuit is made by application
pressure that is at normal condition. When the pressured goes down to the set point the actuator
comes down and the circuit is open and trips an alarm.
Pressured switch high: - In PSH common and NC is taken. When the pressure goes to up to set
point the actuator goes up and make the circuit close and give rise to the alarm.

Temperature measurement

RTD - Abbreviation for Resistance Temperature Detector. It is a sensor which operates on the principle that
the resistance increases with an increase in temperature at a specific rate.

The relation ship between resistance of RTD and temperature change is expressed by this series

Rt= Ro(1+∑j(∆t)j )

j=1

In narrow range of operation Rt= Ro(1+(∆t) )

Commonly manufacturers are using a platinum resistance element. More accurate and more linear than most
thermocouples and generally much more costly and slower responding.

Material Range(oC) 1 Ω/Ω/oC ℓ µΩ-cm Minimum wire

dia. cm
Platinum -250 to 700 0.00385(std.) 9.83 0.002

0.00392(ref.
grade )
Copper -200 to 250 0.0042 1.56 0.002
Nickel -100 to 350 0.0063 to 6.28 0.002
0.0067

In case of platinum’s resistance temperature relation ship is more linear than other.

The metal used must have the following g properties:-

• Extremely stable resistance temperature relationship, so that neither of Rt, 1, 2 drift with
repeated heating & cooling within the specified range of operation.
• Specific resistance in Ω/cc must be within limits that will allow fabrication of practical size
of element.
• Small resistance change due to non-temperature effect(strain, contamination)
• Large resistance large with temperature higher sensitivity
• Material must not undergo change in phase or state within responsible temperature range.
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• Must be commercially available.

• RTD may be used be 2,3,4 wired for different sensitivity.

Thermocouple - A temperature sensor based on the principle that a voltage is produced when two dissimilar
metals. The junction produces a voltage in proportion to the difference in temperature between the
measuring junction and the reference junction. This principle is called Sea beck Effect

E Chromel (+) Constantan (-) 95-900C

J Iron (+) Constantan (-) 95-760C
K Chromel (+) Alumel (-) 95-1260C
N Nicrosil (+) Nisil (-) 650-1260C
T Copper (+) Constantan (-) -200-350C

• Temperature range must be measured

• evaluation of operation
• physically space limitation
• method of insulation
• response time

Temperature gauge &switch:-In this type of instrument the thermal expansion property is used. When
temperature increased the free end bends this displacement is transferred to angular displacement which is
calibrated. In case of switch in a given span it on/off the switch (bimetallic element is most used).

Level Measurement
Introduction:-
Level measurement is an integral part of process control, and may be used in a wide variety of
industries. Level measurement may be divided into two categories, point level measurement and continuous
level measurement. Point level sensors are used to mark a single discrete liquid height, a preset level
condition. Generally, this type of sensor is used as a high alarm, to signal the existence of an overfill
condition, or as a marker for a low alarm condition. The more sophisticated continuous level sensors can
provide complete level monitoring of a system. A continuous level sensor, as the name implies, measures
the fluid level within a measurement range, rather than at a specific, single point. The continuous level
sensor provides an analog output that directly correlates to the level within the containing vessel. This
analog signal from the sensor may be directly linked to a visual indicator or to a process control loop,
forming a level management system.
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Capacitive-Level Sensors:
Capacitive level sensors serve as continuous and point-level sensors by measuring the capacitance
between two electrodes immersed in the liquid and the electro conductive tank's wall. At level increased,
change in capacitance is happened due to change in dielectric media . So we can measure the capacitance at
zero level and at 100% level and calibrate the transmitter. In case of non-conducting liquid the immersed
electrode does not need to insulate but case of conducting liquid must be insulated the electrode.

C = (ε l l1 + ε l ) / [2 ln (r1 / r2)]
v 2

Ultrasonic Level Measurement

Oscillations of quartz, ceramic or magnetostrictive elements at an ultrasound frequency have greater

amplitude in gas than in liquid. Wetting the elements causes a decrease in the amplitude, providing the
detection of the liquid level . Point-level or continuous-level sensing is provided by measuring the time lapse
between the transmission and reception of the ultrasound pulses generated by ceramic crystals at the
bottom/top of the tank. Usually one crystal acts, alternately transmitting and receiving pulses that pass along
the liquid height and are reflected from the surface back to the tank bottom. Some constructions contain
separate elements for generating and receiving the pulse. In this type of case the liquid level must not
below(case of bottom position of sensor)or above( in case of top position of sensor)
Point-level detection is also performed by two piezoceramic crystals oriented
toward each other across the inside of a tank. One of the crystals transmits ultrasonic waves and the other
one receives them. The transmission is intensified when the liquid wets the crystals. The increase in the
output voltage of the receiving crystal indicates that the level has reached the specific point.

• Case of powder silo level measurement the sensor position must be at top of vessel.
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• Must be maintain a suitable distance of sensor and the powder don’t cross the maximum level .

Differential pressure type level measurement

The most commonly used in industry for measuring level of liquid is differential pressure type level
measurement. In differential pressure type level measurement take two pressure from top of vessel/tank and
bottom of the vessel/tank. In which the atmospheric pressure is eliminated.

p2-p1=∆p=hℓg
h=∆p/(ℓg)
Where p1=pressure at the top, p2=pressure at bottom, h= height of liquid, ∆p= differential pressure , ℓ=
density of liquid , g= acceleration due to gravity.
• In case of DP type level measurement in slurry material their must be purging in both two pipe & no
difference in DP.
Float Type Level measurement:-
In Float type or displacer type measurement Archimedes principle is used .In a float-type level sensor the
buoyancy force holds the float on the surface of the liquid. The float carries a member having a can be
actuated by the proximity of the float. In the float mechanically links the switching mechanism through the
sealing in the wall (e.g., bellows). The switching system can respond to the restraining force developed by a
spring element connected to the float or by an actuator of a force-balance servo system.
 18

Bubbler type level measurement

The operation of a air bubbler is similar to blowing air into a glass of water with straw. The more
water is in the glass the harder one needs to blow. Bubbler type level sensor has been used for as long as
compressed air has. If the air pressure entering the dipper pipe is greater than the hydrostatic head of the
process fluid in the tank, the air will bubble out at the bottom of the pipe. The dipped pipe is large in
diameter (2 inch or 50 inch ) in order to minimize to the pressure drop as the air flows through it. Two
separate should be made to this pipe, one for the regulated air supply, and the other for the level indicating
pressure gauge. The pipe tip should be kept about 3 inch(75mm)from the bottom of the tank to kept it from
clogging by sediment. As liquid level changes, the air pressure in the dipped pipe also changes. Pressure
gauge or manometer is used for level indication measure the pressure in the dipped pipe, by pressure switch
for alarming and transmitter for remote display or monitoring. The dipped pipe or tube material must be
selected to match the corrosive nature of the process fluid.

Bubbler type level Measurement

Vibration type level switch

There is a number of level switch designs which keeping to a probe or other element in oscillation or
in natural frequency vibration and triggering a relay when the process material in the tank reaches the
vibrating element and damped out the vibration. The read probe, and the tuning fork vibration are
distinguished only in their frequencies of oscillation (reed, 120Hz; probe, 200 to 400 Hz ; tuning fork,85Hz).

Applications:- Soliphant is a ragged limit switch for silos containing powder or fine grained solid including
those which with very low bulk density. The various version ensures it can be used in wide range of
application including zone 10 dust explosion area and food stubs.
Typical applications: - grain, powder, chalk, plaster cement, plastics granules.

Features and benefices:-

• No calibration
• In sensitive to build up
• No moving part
• Various electronics inserts
• Plastic housing cover
 19

Flow Measurement

The most common principals for fluid flow metering are:

1 Differential Pressure Flow meters
2. Mass Flow meters
Differential Pressure Flow meters:
In a differential pressure drop device the flow is calculated by measuring the pressure drop over an
obstructions inserted in the flow. The differential pressure flow meter is based on the Bernoulli’s Equation,
where the pressure drop and the further measured signal is a function of the square flow speed.

Figure 1 Bernoulli Theorem

The most common types of differential pressure flow meters are:
1.Orifice Plates
2. Venturi Tubes
3. Variable Area - Rota meters
1. Orifice Plate
With an orifice plate, the fluid flow is measured through the difference in pressure from the upstream side to
the downstream side of a partially obstructed pipe. The plate obstructing the flow offers a precisely
measured obstruction that narrows the pipe and forces the flowing fluid to constrict.

Figure: Orifice Plate

The orifice plates are simple, cheap and can be delivered for almost any application in any material.
The Turndown Rate for orifice plates is less than 5:1. Their accuracy are poor at low flow rates. A high
accuracy depends on an orifice plate in good shape, with a sharp edge to the upstream side. Wear reduces
the accuracy.
Orifice, Nozzle and Venturi Meters

Venturi Tube
 20

Due to simplicity and dependability, the Venturi tube flow meter is often used in applications where it's
necessary with higher Turndown Rates, or lower pressure drops, than the orifice plate can provide.
In the Venturi Tube the fluid flow rate is measured by reducing the cross sectional flow area in the flow
path, generating a pressure difference. After the constricted area, the fluid is passes through a pressure
recovery exit section, where up to 80% of the differential pressure generated at the constricted area, is
recovered.

Figure Venturi Tube

With proper instrumentation and flow calibrating, the Venturi Tube flow rate can be reduced to about 10%
of its full scale range with proper accuracy. This provides a Turndown Rate 10:1.
Orifice, Nozzle and Venturi Meters
Flow Nozzles
Flow nozzles are often used as measuring elements for air and gas flow in industrial applications.

Flow Nozzle
The flow nozzle is relative simple and cheap, and available for many applications in many materials.
The Turndown Rate and accuracy can be compared with the orifice plate.
Orifice, Nozzle and Venturi Meters
The Sonic Nozzle - Critical Flow Nozzle
When a gas accelerate through a nozzle, the velocity increase and the pressure and the gas density decrease.
The maximum velocity is achieved at the throat, the minimum area, where it breaks Mach 1 or sonic. At this
point it's not possible to increase the flow by lowering the downstream pressure.
This situation is used in many control systems to maintain fixed, accurate, repeatable gas flow rates
unaffected by the downstream pressure.
Recovery of Pressure Drop in Orifices, Nozzles and Venturi Meters
After the pressure difference has been generated in the differential pressure flow meter, the fluid pass
through the pressure recovery exit section, where the differential pressure generated at the constricted area is
partly recovered.
 21

As we can see, the pressure drop in orifice plates are significant higher than in the Venturi tubes.
Variable Area Flow meter or Rota meter
The Rota meter consists of a vertically oriented glass (or plastic) tube with a larger end at the top, and a
metering float which is free to move within the tube. Fluid flow uses the float to rise in the tube as the
upward pressure differential and buoyancy of the fluid overcome the effect of gravity.

The float rises until the annular area between the float and tube increases sufficiently to allow a state of
dynamic equilibrium between the upward differential pressure and buoyancy factors, and downward gravity
factors.
The height of the float is an indication of the flow rate. The tube can be calibrated and graduated in
appropriate flow units.
The Rota meters typically have a Turn down Ratio up to 12:1. The accuracy may be as good as 1% of full
scale rating.
Magnetic floats can be used for alarm and signal transmission functions.
Coriolis Flow meter
Direct mass measurement sets Coriolis flow meters apart from other technologies. Mass measurement is not
sensible to changes in pressure, temperature, viscosity and density. With the ability to measure liquids,
slurries and gases, Coriolis flow meters are universal meters.
 22

Coriolis Mass Flow meter uses the Coriolis Effect to measure the amount of mass moving through the
element. The fluid to be measured runs through a U-shaped tube that is caused to vibrate in an angular
harmonic oscillation. Due to the Coriolis forces, the tubes will deform and an additional vibration
component will be added to the oscillation. This additional component causes a phase shift on some places
of the tubes which can be measured with sensors.
The Coriolis flow meters are in general very accurate, better than +/-0,1% with an turndown rate more than
100:1. The Coriolis meter can also be used to measure the fluids density.

Weight Measurement
Load Cell:-
One important direct application of Strain Gauge is for the measurement of force or weight. These
transducer devices, called load cells, measure deformations produced by the force or weight. In general, a
beam or yoke assembly is used that has several strain gauges mounted so that the application of a force
causes a strain in the assembly that is measured by the gauges. A common application uses one of these
devices in support of a hopper or feed of dry or liquid materials. A measure of the weight through a load cell
yields a measure of the quantity of material in the hopper, by measuring the change in the resistance by
Bridge circuit. Generally, these devices are calibrated so that the force (weight) is directly related to the
resistance change. Forces as high as 5 MN (approximately 106 Ibo) can be measured with an appropriate
load cell.

The form of load cell considered Figure is fine for illustrating principles, but real load cells cannot be
made in this simple way. The problem is that forces applied to the top of the load cell may cause it to lean or
bend, instead of simply compressing. In such a case, one side surface of the beam may experience
compression while the other side undergoes tension. Obviously, this will alter the correct interpretation of
the result.
Practical load cells are made with yoke assemblies designed so that mounted strain gauges cannot be
exposed to stresses other than those caused by the compress ional force applied to the cell.
 23

Digital load cell:-

The deflection less Intelligent Digital Load Cell Type IDL-F with “vibrating wire” issued as a weighing
module for dynamic weighing in continuous and batch wise gravimetric Brabender metering feeders.
Function: Electric exciters excite a pretensioned wire resulting in resonance
Vibration of the wire, which is read in by an integrated microprocessor. The wire frequency is almost a
parabolic function of the load exerted on the load cell. To optimize the linearity, corrective coefficients are

stored in an EEPROM, which is also integrated in the load cell. These coefficients are taken into
consideration when the microprocessor computes the weight value. The only further interferences that
require compensation are temperature changes. These are also considered by the microprocessor to

correct the weighing result. The weight value thus determined is dynamically updated and serially
transmitted to a microcomputer controller.
The particular feature of the load cell is an additionally integrated filtering system for dynamic electronic
vibration attenuation eliminating the influence of ambient vibrations. Three interactive software filters
attenuate low frequency vibrations filtering the weight value via several (24 at maximum) eight-stage filters.
The filters can be operated as a statically or dynamically controlled filtering system. The Intelligent Digital
Load Cell IDL-F is available as a load cell for installation in weighing systems or as platform scale modules,
featuring an internal resolution
Of 1:1,000,000.Load Cell Type IDL-F.
 24

Analyzers
Oxygen Analyzer
The oxygen content of the electrolyte is brought into equilibrium with that of the sample . No
external voltage, spontaneous Reaction.

Cathode: O2 + 2H2O + 4 electrons 4(OH)-

Anode : 2Pb (2Pb++) + 4electrons

These electrons cause a current flow through the electrolyte, the magnitude of which is in proportion to the
O2 concentration of the electrolyte.

The sample gas diffuse through a diffusion barrier to the cathode of the electrochemical cell where it
is reduced to hydroxyl ins. Due to the conductivity of KOH electrolyte the
Ions migrate to the anode where they are oxidized back to O2 .An external voltage drives
This reaction, which results in the cell current that, is proportional to the oxygen concentration in the sample
gas.
MFI analyzer
It is a standard of grading different polymer families. By virtue of melt flow index (MFI) we can
know about the property of the polymer properly.
Melt flow index is define by the weight of the polymer discharged trough a capillary at 190o C ,43.2 psig
pressure. The L/D ratio of capillary is made constant where L is the length of the capillary and D be the
diameter of the capillary.
In case of polymer plant it is mandatory to supervise the grade of polymer always. To analyze the polymer
grade continuously MFI analyzer is used.
 25

schematic diagram of MFI analyzer

Introduction
MFI analyzer is connected to polymer melt to be tested through the transfer line. The
measurement head receives the polymer melt then pumps it through capillary orifice measuring both
Flowrate and pressure drop across capillary. With this measurement the shear rate / shear stress relationship
of a polymer can be determine and converted into melt flow index of apparent viscosity.
General operation
Pressure measurement system : The pressure transducer are located in the measurement rate converted
cavity pressure into electrical signal. The transducers are bounded strain gauge which makes direct contact
with polymer. Change in the cavity pressure produce a stress change in the transducer bridge resistance
which result in the electrical signal proportional to the pressure change.
Speed measurement system: the metering pump motor and the tachometer are directly coupled together so
tachometer signal is calibrated to read out to the pump.
Motor speed control system pressure loop : in the analysis mode of operation (closed loop) , the require
pressure droop[ across the capillary is developed by the control by the polymer Flowrate (pump speed ). The
Flowrate is necessary to produce this pressure droop through capillary depends on the polymer viscosity and
capillary geometry.
Consequently pump speed will be increased if the polymer viscosity decrease. A large diameter capillary is
used to the capillary L/D ratio is decreased. capillary pressure is sensing by the pressure transducer just
above the capillary entrance. In the signal conditioning module the pressure(mV signal, is converted into a
+/- 10v dc signal are send to the CPU analog to digital converter. In normal operate mode the remote control
unit pressure PID loop compare the pressure signal with the loop set point signal and in the motor speed
control signal(0-10v D.C.) is send too the motor speed controller to drive the D.C. motor. There is an
acceleration circuit in motor speed controller tip, protect the transducer on starter. The motor speed control
converts the high-level controller signal to a full wave phase control D.C. signal to drive the motor. The
MSC has a minimum or maximum adjustment.
Motor speed control system- speed control loop: - In the analysis mode of operation (closed loop system) the
required shear rate is developed by control of the pump speed. Pump speed is sensed by the digital
tachometer located in front of motor. The tachometer signal is converted from a pulse strain into a pump
shaft frequency. In the normal operate mode the remote control unit speed PID loop compares the speed
signal with the loop set point signal and motor speed control signal 0-10v D.C. is sent to the motor speed
controller to drive the D.C. motor. There is an acceleration circuit in the motor speed controller to protect
the transducer. The motor speed control converts the high-level controller signal to a full wave phase control
D.C. signal to drive the motor.
The temperature control system: - the temperature control system maintain the polymer melt at precise test
temperature. In the flow passage barrel (measurement head) the melt temperature is regulated by 2 zone of
 26

closed loop temperature control. The polymer resident time, thermal mass, proper insulation. The first
control zone is around the metering pump. The largely account between the polymer feed and test
temperature. The second temperature control, zone regulates the test zone itself.(capillary transducer area).
The processor temperature is read by grade "A" three wire RTD. In the signal conditioning module the
temperature signal ids converted into +/- 10v D.C. signal and send to the CPU A/D converter. In the remote
control unit the appropriate temperature control
Loop compares the temperature signal with a loop set point and time proportional pulse is developed. This
pulse is used to control a solid-state relay, which controls the ac voltage to the associated heater. The
polymer melt temperature is read by melt thermocouple located opposite the pressure transducer due to the
characteristics of the thermocouple RTD probes will e provide more accurate reading to the test temperature.

Annubar

Basic principle:-
The annubar works upon the basic principal of Pitot tube. When a solid body is held centrally and
stationary in a pipe line with a fluid streaming down due to the presence of the body, the fluid while
approaching the object start losing its velocity till directly in front of the body where the velocity is zero.
This point is known as stagnation point. As the kinematics head is loosed by the fluid it gains a static head.
By measuring the difference of the pressure between that at normal flow line and at the stagnation point, the
velocity is found out

The stagnation pressure on a body immersed in a moving liquid is the sum of the static pressure and
dynamic pressured. Thus, Pt = P + Pv
Where Pt = total pressure which can be sensed by fixed probe provided the fluid stagnates at the
sensing point in an isentropic manner.
P = the static pressured of the fluid whether in motion or at rest
Pv = the dynamic pressured equal to the kinetic energy of fluid.
With respect to the static state, the energy relation at the isentropic stagnation point of an ideal probe is :
Pt VP
∫ dp/ρ =∫ (Vp)dV/(gc)
P 0
Vp = the approach velocity at the probe location.
ρ = fluid density
gc=constant
For a liquid of constant density, the integration yields at a point
Pt – P = Pv = P. (Vp)2 /(2gc)
For a compressible perfect gas for which P/( ργ) remains constant during an isentropic change a similar
relation emerges
Pt – P = Pv = ρ.(( γ-1)/ γ).(Vp) 2 /(2gc)
Where γ = ratio of specific heats
Assuming isentropic stagnation at the sensing point at the probe
Pt VP
∫ dp/ρ =∫ (Vp)dV/(gc)
P 0
Where using English unit.
Vp=velocity of approach (ft/s)
P= pressure (lb/ft2)
Ρ= fluid density (lbm/ft3)
 27

gc= 32.2(lbm/lbf)(ft/s2)
if density is constant the integration yields
Pt – P = Pv = ρ.(Vp)2 /(2gc)
For a compressible perfect gas for which P/( ργ) remains constant during an isentropic
Change a similar relation is obtain
Pt – P = Pv = ρ.(( γ-1)/ γ).(Vp) 2 /(2gc)
γ is the ratio of specific heat
in order to compute the point velocities it is necessary to measure both point value of static pressure(P) and
total pressure(Pt), whence
(Pt-P) 0.5
Vp=C----------------
ρ
Principle Of Operation:-
The Pitot tube are one the most used (and cheapest) ways to measure fluid flow, especially in air
applications as ventilation and HVAC systems, even used in airplanes for the speed measurement.

The Pitot tube measures the fluid flow velocity by converting the kinetic energy of the flow into potential
energy.
The use of the Pitot tube is restricted to point measuring. With the "annubar", or multi-orifice pitot probe,
the dynamic pressure can be measured across the velocity profile, and the annubar obtains an averaging
effect.
of 70:1 or more.

How Annubar Works:-

Diamond II Annubar flow sensor are patent primary flow sensing element. They are inserted into the flow
stream across the pipe diameter. The pressure drop across the sensor is minimal because of its very low
restriction to flow. Sensing ports are located are both located in both upstream & down stream side of
Annubar primary flow element. These port are connected to dual averaging plenums. The number of port is
proportional to pipe diameter. The upstream & down stream ports & plenum produce an average reference
pressure. The difference is an accurate & stable DP signal i.e proportional to Flow rate .
 28

The Annubar primary flow element sensor technology is key to increase performance of the ProBar and
mass proBar flow meter.

The diamond II shape is the key to accuracy the repeatability. The patent shape provides a smooth
and stable point of fluid separation between the high and the low side. The design of the sensor ensure that
plumage of the sensing ports does not occur in particular laden fluid
Annubar Calculation
Model:-DHF-35,HA2,CA2S,GV8SA,FA8C,VA8SV,FA8C,IHDS,QI1,QS1,QE8.
Fluid:- Water.
Pipe Size:- 36SCH10.
---------------------------------------------------------------------------------
D.P equation Liquid volume Rate of flow:
C'= Fna x K x D x Fra x Fm x Faa x Fl x √ (1/ Gf)
2

Hw = (qa/c’) 2 Qa = C' x √(hw)

---------------------------------------------------------------------------------
Description Term value units
---------------------------------------------------------------------------------
Units Conversion Factor .0003958
ANNUBAR Flow Coefficient K .6416
Internal Pipe Diameter D 898.55 mm
Manometer Factor Fm 1
Gauge location Factor Fl 1
---------------------------------------------------------------------------------
 29

Measuring Max Nor. Units

Range
--------------------------------------------------------------------------------------------
Flowrate Qa 7000 6538 5548 m3/H
Calculation Constant C' 205.033 205.033 205.033
Pipe Reynolds Number Rd 3441200 3236200 2727400
Reynolds Number factor Fra 1 1 1
Flowing Viscosity uf 0.8 Centipoise
Flowing Temperature Tf 33 C
Thermal Expansion Factor Faa 1
Flowing Density pf 999.1 Kg/m3
Flowing Spec Gravity Gf 1
Flowing Pressure Pf 4.7 kg/cm2 G
Differential Pressure hw 1165.6 1030.9 732.19 mm H20
--------------------------------------------------------------------------------------------

LIMITS

Customer Design P & T: 4.7 kg/cm2 G & 33 C

Max Allowable DP: 1400 mm H20 @33 C
Flow at maximum allowable DP:7671.6 m3/H
Do Not Insert Flo-tap above 350 mm H2O
Flow al maximum Insert DP 3840 m3/H
Natural frequency 73.9 CPS
Maximum allowable Pressure 99.3 kg/cm2 G @33 C
And Temperature 204 C
--------------------------------------------------------------------------------------------

This ANNUBAR provides annual saving upto 17,060 $ in comparison to Orifice Plate.

Annular setup
step1:Liquid Service in a Horizontal Pipe:-
 30

Install the flow meter within 40 degrees of the vertical axis to prevent air from becoming entrapped within
the probe. Do not position the Annubar within 50 degrees of the horizontal axis unless full bleeding of
air from the probe is possible. Figure below illustrates the recommended location for the Annubar when
used with liquid service.

STEP 2:DRILL THE HOLE IN THE PIPE

Follow the steps below to drill the hole in the pipe.
1. Depressurize and drain the pipe.
2. Select the location for the hole you are about to drill. Select a location anywhere around the circumference
of the pipe for vertical pipes.For horizontal pipes, the hole location depends upon the service for which the
Annubar is to be used:
• Liquid service: drill the hole along the bottom of the pipe
• Gas service: drill the hole along the top of the pipe
• Steam service: drill the hole along the bottom of the pipe
3. Determine the diameter of the hole to be drilled. Use the chart
in Figure 3-7.
4. After the hole is drilled, deburr the hole on the inside of the pipe.
Drill a Hole for Opposite-Side Support
A second hole must be drilled for the opposite-side support weld coupling if opposite-side support is
supplied. This hole must be the same diameter as the first hole; place it directly opposite the first hole so that
the sensor can pass completely through the pipe. Use the following steps to find the location for the second
hole:
1. Wrap a piece of soft wire or string around the pipe to measure the pipe’s circumference.
2. Remove the wire or string and measure half of the circumference length.
3. Re-wrap the half-length around the pipe from the center of the first hole.
4. Mark the center of what will become the second hole, as shown in Figure.
5. Deburr the drill hole inside of the pipe.
Note: Drille the hole 180degree from the first hole from opposite side support module.

sensor Diameter
15/16 7/18
25/26 7/8
35/36 1-5/16
45/46 2-1/8
 31

STEP 3: TACK WELD THE FITTINGS TO THE PIPE

Follow these steps to tack weld the fittings to the pipe:
1. Insert the Annubar assembly into the factory-supplied weld fitting (with integral support ring), then into
the hole.
2. Align the head and transmitter so they are parallel with the ground.
3. Tack weld the fitting(s) to the pipe and remove the Annubar.

tack welding fitting to the pipe

To protect the weld fitting threads from weld splatter, wrap the factory-supplied heavy aluminum foil around
the threads before welding, or use a thread protector cap, as shown in Figure Be sure to allow the mounting
to cool or serious burns may occur.

STEP 4: INSERT THE ANNUBAR INTO THE PIPE

After the mounting hardware has cooled, install the adapter body and
support plug (if required), as shown in Figure in above . Use a sealant
compound rated for use at the process temperature on the threads.

1. Mark the tip of the Annubar sensor with a marker.

2. Insert the flowmeter into the adapter body until the sensor tip contacts the pipe wall (or support plug).
3. Remove the flowmeter.
4. Verify that the sensor tip touched the pipe wall. If the tip did not
touch the wall, adjust the adapter body until sensor tip touches the
wall, and re-install the Annubar.
5. Install the first packing ring on the Annubar between the lock ring and the packing follower; take care not
to damage the split packing rings.
6. Push the packing ring into the adapter body and against the weld-lock ring. Repeat this process for the
two remaining rings, alternating the location of the packing ring split by 180 degrees. Figure 3-11 illustrates
the Annubar insertion process described here.
 32

packing ring insulation

Annubar Averaging Pitot Tube

NOTE

If the Annubar appears to be too long, go back to step 3. Verify that the adapter body was installed
into the weld fitting before the Annubar was installed.
7. With the flow arrow on the Annubar head pointed in the direction of the pipe flow, thread the Pak-Lok nut
onto the adapter fitting until it is hand tight only.
8. Use a wrench to tighten the Pak-Lok nut in ¼ turn increments until it has been tightened one full turn. The
Pak-Lok nut should be tightened only enough to prevent leakage. Do not overtighten the Pak-Lok nut;
damage to the sensor will result.

NOTE

Use a maximum of 1-¼ turns when installing the sensor. This is critical
when installing Annubar models with a sensor size of 15 or 16.
 33

Moisture Analyzer
About Al2O3 Analyzer:-
The aluminum oxide sensor consists of an aluminum strip anodized to provide a porous oxide layer. A very
thin coating of gold is evaporated over this structure. The aluminum base and the gold layer from the two
electrodes of what is essentially an aluminum ode capacitor. Water vapor is rapidly transported through the
gold layer and absorbed by the pore walls of the sensor. The number of water molecules absorbed is
proportional to the fugacity (in thermodynamics, fugacity is means of the tendency of a substance to escape
by some chemical process from the phase in which it exists) of the water in the liquid. T equilibrium
conditions, the fugacity of the water in the liquid are equivalent to the water vapor pressure above the liquid.
In most cases it is directly proportional o the concentration of dissolve water in the organic liquid.

Since the pore opening are small in relation of the size of most organic molecule, admission into the pore
cavity is limited to the small molecule such as water. The number of water molecule absolved determines
the probe wall conductivity which influence the value of the sensor’s electrical impedance. The surface of
aluminum oxide sensor can then be viewed as a semi permeable structure allowing the measurement of
water vapor pressure in liquid organic in the some manner as is accomplished in gaseous medium. In
general, The aluminum oxide transducer identical values of electrical output, whether immersed directly in
the fluid or pleased in gas space immediately above, that is the measure vapor pressure is identical in both
phase.
The measured vapor pressured can be used to determine the weight content of dissolved water with in an
organic liquid by Henry’s law which states that the mass of gas dissolved by a given volume of solvent, at
constant temperature , is directly proportional to the pressure of the gas with which it is in equilibrium. The
concentration of water in the organic liquid , expressed in part per million by weight of milligram per liter,
equals the partial pressure of water vapor times constant
Cw=KPw
The Panametrics aluminum oxide hygrometer has been designed to measure reliably the moisture
content of gases and liquid. The water vapor pressure at the measurement location is the result of not only
 34

the moisture content of the fluid entering into the system but also due to deception of the moisture from
associated piping, leaks in the piping system.
One advantage of this hygrometer is that it can be used for measurement i.e. the element is designed
for directly with in the region to be measured
The most frequent question associated with the moisture measurement system occurs when:-
1. The parts per million value changes as the total gas pressure changes.
2. Response time is very slow.
3. The point changes as the temperature changes
4. The dew point changes as the flow rate changes.
The Panametrics hygrometer is very rapid , is insensitive to temperature and flow rate and measure the vapor
pressure of water only . If the above effects are noted then they are almost always the result of a system ,
A. Pressure:- The Panametrics Hygrometer will measure the dew point of a system at all pressure from a
few micron of Hg vacuum pressure to 5000 psig .The sensor is expose to pressure changes the measured
dew point will be related to the vapor pressure of water .
It is generally advantageous to operate at the highest pressure especially at very low moisture concentration .
This minimizes wall effects and will result in higher dew point with subsequent increased sensitivity .
B. Response Time:- The response time of the Panametrics standard M-series is very rapid .An increasing
flow rate and temperature can decrease response time of whole system .The preferred material of
construction especially for any sampling system are SS. Material which should be avoided are rubber
elastomers and related compound .
C. Temperature: - The hygrometer is insensitive to temperature. The only precaution should be observed is
that it is recommended that the ambient temperature should be +10oC.
D. Flowrate: - The Panametrics hygrometer is insensitive to Flowrate changes. The maximum velocity
limitation is 5000 cm/sec is limitation of mechanical stability rather than the Flowrate sensitivity.
Effects of contaminants
Industrial gases and liquid often contain particulate matter such as carbon particles , salt , rust
particles , polymerized substances ,chemical liquid droplets , dust molecular sieve for alumina dust ,can be
present .Their effect on the operation of the Panametrics sensor is given bellow
A. Nonconductive particulate: - In general non conductive liquid particulate condensing is not seriously
hindering the performance of the sensor. On rare occasion it may become logged under the contact arm
of the sensor.
B. Conductive particulate: - Since the hygrometer reading is inversely proportional to the impedance, a
decrease in resistance decrease will cause an increasing in meter reading . Thus conductive particulate
across the sensor leads or on the sensor surface can leave to reduce the impedance with an erroneous
high dew point.
C. Corrosive particulate: - The material that will corrode the Al deleteriously affect the operation of the
sensor.
Corrosive gases and liquids
M-series sensor have been designed to minimize the affect of corrosive gases and liquids.
No copper solder or epoxy is used in the construction of the sensor. The moisture content of the gases as
H2O, SO2, cyanide containing gases acetic acid vapor, and other is directly measured.
These precautions and condition are follows:-
1. The moisture content of the corrosive gases must be 10ppm or less @1 atmosphere or concentration of
the corrosive species must be 10ppm or less @1 atms.
2. The sampling system containing the sensor must be pre dried with an inert gas prior to passage of the
corrosive steam
3. The system must be purged with dry inert gases prior to the removal of sensor
4. Employ the lowest possible pressure.
These condition and precautions have led to successful application in such cases as HCl
,SO2, Cl2 ,Br2
Solid applications
A. Inline measurement
The sensor can be used in line continuously monitor in drying process. When two sensor read the
same or almost same dew point then drying process is complete. This technique has been
successfully for example, in drying photographic film
Under a particular set of operating condition the sensor meter reading can be calibrated
versus solids with more moisture contain (Flowrate temperature and pressure ). Assuming the
 35

condition are relatively constant the sensor meter reading can be curve over the desired range has
been developed. Once is done sensor can be used to monitor the moisture contain of solid
continuously
B. Laboratory procedure
1. A small amount of sample can be dissolve in a suitable hydrocarbon. The increase in a moisture content
of hydrocarbon can then be used to calculate directly the moisture content of the sample
The lower limit of sensitivity of sensor is -110oC dew point this dew point can correspond to 10-6 in a
liquid or a less depending on the saturation value .The maximum concentration of one can measure
depends to on the liquid itself. Generally it becomes insensitive in excess of 1% of weight .
2. Evolved moisture is passed through a chamber of known volume containing calibrated sensor. From
the volume and the measured vapor pressure of water , the number of moles of water can be calculated
and related to the %/weight in volume
Aluminum Oxide Probe Maintenance
Little or no probe maintenance is required. Check probe calibration from time to time. If for some
unexplainable reason, an electrically conductive liquid or any other temporary contaminants is on the Al2O3
sensor; the ambient moisture measurement will be incorrect. Panametrics recommends return of the flow or
the factor for analysis and re calibration. If time does not allow this the cleaning of the probe can be attend
by a qualified technician or chemist in a laboratory.
Preliminary:-
Probe must be treated gently and can not be cleaned in anything which will attack the components.
The material of constructors are Al , Al2O3, nichrome, gold SS, glass , and viton A..
The Al steel is fragile and can be easily bent or destroyed so do not permit anything to touch it.
Probe Cleaning Procedure
Before bringing the probe cleaning procedures you will need following item:-
• Approx. 300ml of reagent hexane toluene
• Approx. 300ml of distilled water(not DM)
• Two glass container to hold above contaminants (do not use a metal container.).
To clean the Al2O3 probe:-
1. Take a dew point measurement in ambient atmosphere and record it.
2. Carefully unscrew the protective shield covering the sensor, taking care not to touch the sensor inside,
3. Soak the sensor in distilled water for 10 minutes.
4. Remove sensor from the distilled water and let soak in hexane o toluene for 10 minutes.
5. Remove sensor from the hexane or toluene and place in low temp. oven .set at 48oC to 52 oC for 24 hrs.
6. Repeat step 3,4,5 for protective shield.
7. Care fully replace the probe's protective shield; make sure you do not to touch the probe sensor.
8. Connect the probe to the probe cable.
9. Take a dew point measurement in same ambient atmosphere as in step 1.
10. Compare this dew point reading and check to see that the reading after cleaning is amore accurate value
for a dew point of the ambient atmosphere.
11. If the probe is determined to be in proper calibration( 2 oC accuracy) reinstall the probe in the sample
cell and proceed with normal operation if the probe is determined not be in the proper calibration repeat
step 1 through 8 using the time interval of 5 times the length of previous cleaning.

Empirical Calibration
For those liquid =s in which a henry's law type analysis is not applicable., the absolute moisture content is
based determined by empirical calibration. A Henry law type calibration is not applicable for those liquids
for which with exhibit a high saturation value (2% by wt. Of water), are completely miscible with water (e.g.
,dioxane) or the conductive (isopropyl alcohol) . for such liquid a calibration of due point of hygrometer
reading versus solution of water contents is most satisfactory.
Such calibration can be conducted with the aid of Karl-Fischer analysis, or by adding known amount
of water to a known amount of the dry organic liquid. (equilibrium must be established).
A. Instructions for used apparatus H-2 used for with Karl-Fischer Analysis.
1. Fill glasses bottle with sample liquid.
2. Close Valve.
3. Turn on stirrer.
 36

4. Permit time for sample liquid ,glass bottle and remainder of system to come to equilibrium to
come with Room temperature
5. Turn on hygrometer and monitor reading of probe.
6. When equilibrium is reached and meter indication is stable record the meter reading .
7. Using a syringe withdraw sample for Karl-Fischer Analysis through the rubber system
8. Open exhaust valve.
9. Wet up to dry the liquid by bubbling wet N2 or dry N2 respectively through the liquid.
10. When meter indicates approx. level of wetness or dryness turn off N2 inlet by exhaust valve.
11. Repeat steps 4 through 7 to obtain the measurement.
B. Instructions for use apparatus H2 for adding known amount of H2O.
1. Construct typical apparatus H2
2. Weigh the apparatus
3. Fill the glass bottle with liquid sample
4. Bubble dry N2 gas through SS tube while magnetic stirrer is operating
5. Monitor liquid sample with probe and continue drying until dew point become some minimum
value
6. Turn off supply of dry N2
7. Weigh the apparatus including the liquid to determine the weigh of liquid
8. Add a known weight of H2O and continue stirring until completely dissolved in the liquid .
9. Weight of H2O
----------------------- x 106 = PPMw
Total weight of Liquid
10. Repeat step 8 & 9 until several point have been plotted.

Smart transmitter
The smart transmitter is an intelligence transmitter.
Smart transmitter features:-
1. Configuration:-

Smart transmitters can be configured to meet the demands of the process in which they are used. For
example, the same transmitter can be set up to read almost any range or type of thermocouple, RTD,
or Thermistor. Because of this, they reduce the need for a large number of specific replacement
devices.

2. Re-ranging:-

The range that the smart transmitter functions under can be easily changed from a remote location,
for example by the technician in a control room. The technician or the operator has access to any
smart device in the loop and does not even have to be at the transmitter to perform the change. The
operator does need to use a communicator, however. A communicator allows the operator to
interface with the smart transmitter. The communicator could be a PC, a programmable logic
controller (PLC), or a hand-held device. Re-ranging is simple with the smart transmitter. For
instance, using a communicator, the operator can change from a 100 ohm RTD to a type-J
thermocouple just by reprogramming the transmitter. The transmitter responds immediately and
changes from measuring resistance to measuring millivoltage. There is a wide range of inputs that a
smart transmitter will accept. For instance, with pressure units, the operator can determine ahead of
time whether to use inches of water, inches of mercury, psi, bars, millibars, pascals, or kilopascals.

3. Characteristics:-

Another characteristic of a smart transmitter is its ability to act as a stand-alone transmitter. In such a
capacity, it sends the output signal to a or a PLC

4. Signal conditioning:-
 37

Smart transmitters can also perform signal conditioning, scanning the average signal and eliminating
any "noise" spikes. Signals can also be delayed (dampened) so that the response does not fluctuate.
This is especially useful with a rapidly changing process.

5. Self diagnosis:-

Finally, a smart transmitter can diagnose itself and report on any problems in the process. For
example, it can report on a circuit board which is not working properly.

vendors
Level measurement
DP type TATA Honeywell
Capacitance type Endress Houser
Displeasure type Tokyokeiso
Ultra sonic type Endress Houser
Bubblier type TATA Honeywell

Level switch
vibration type Endress Houser
Temperature measurement
Gauge Goa industries, Gauge India
Thermocouple Pyroelectric
RTD Pyroelectric
Pressure measurement
Pressure transmitter TATA Honeywell
Pressure gauge G-gauge, Borden India
Flow measurement
Orifice TATA Honeywell
Venturi TATA Honeywell
Rotameters Tokyokisko
Mass flow meter Rosemound ( micromotion )
Annubar Dietrich standard
Weight
Load cell Yama Qta
Vibration Brabander
Load cell
I/P converter ABB
ON/OFF valve Choil
Control valve
V ball Masoline
Excantric rotary
Globe valve
Mmicroflow valve
Analyzer
Oxygen Panametric
Moisture Panametric
MFI Dynsco
 38

DCS
ARCHITECTURE
SUPERVISOR NETWORK
GUS HM EPLCG
AM
HG

LCN A
LCNB

NIM

HPM

LCN =LOCAL COMMUCATION NETWORK

SM

PRO
CESS NETWORK
UCN A UCN B

* UCN = UNIVERSAL COMMUNICATION

NETWORK
• GUS = GLOBLE UNIVERSAL STATION

• HM = HISTORY MODULE

• EPLC= ENHANCED PROGRAMMABLE LOGIC

CONTROL
• NIM= NETWORK INTERFACE MODULE

• HPM = HIGH PERFORMANCE PROCESS

MANAGER
• SM = SAFETY MANAGER

GUS IS TWO CONSOLE .

1. ENGINEERING STATION (9,10)
2. OPERATING STATION (1TO 8)
 39

Overview: -

Total plant solution is a data acquisition and control system that can be tailored to
meet your specific requirement. It can be small system with just handful of device
or it may be highly complex system with several devices and several kinds of
communication.

LCN:-
The back bone of every TPS system is a communication network known as
local control network (LCN) the LCN directly links those devices to provide the
following function.
• Human interface.
• Interface to UNIX/X window system.
• File server history storage and analysis.
• Extensive advanced control.
• Interface between multiple LCN.
• Interface to computers.
• Interface to process network.
• Interface to UCN distributed control.
GUS:-
The TPS system provides and integrated the process and the operator .
standard hardware and software contributes to the interface to satisfy variety of
interface a number of hardware station are available. In control room
environment several station are typically combined into process operator control.
HM :-
The HM(history module) is available with redundant drives and different
storage capacity makes possible storage of, and quick assesses to large quantities
of data:
• History of process alarm, operator changes, operator massage system
status change system error and system maintenance.
• System file of all type, load images and other data require any time
modules are reloaded or personalities are changed.
• On process information of maintenance and analysis.
AM:-
Application module is used for special type of complex system. There is a
programmable interface to configure as per process requirement.
HG:-
Hiway gateway interconnects Honeywell data hiway with the LCN, making
the transition from the transmission technique and protocol of the LCN
transmission technique and protocol to the hiway. It also provides the function
such as polling alarm scanning and time synchronization for the hiway based
devices

EPLC:-
Enhanced PLC gateway provide efficient interface for non Honeywell
programmable controller they do so by supporting the defecate industry sub
system protocol of Allen Bradley and Mod Bus.

NIM:-
The NIM interconnects the LCN with the UCN network. The UCN
interrogates Honeywell's most advanced process connected device into TPS.

UCN:-
 40

It is design to be compatible with IEEE and ISO standards. The UCN is a high
speed ,high security process network. It is peer to peer communication capability
allows for easy sharing of process data, making it convenient to implement
sophisticated control scheme.
Process manager:
PM is highly flexible data acquisition and control device that provided a
complete range of capabilities. It consists of a powerful control processor that
performs regulatory logic and sequencing function coupled with up to 40
selectable intelligent I/O processor.
In addition separate communication and I/O interface processor assure high speed
flow of information both internal and external to the PM. The number and type of
control functions to be implemented along with the smart transmitter and supports
bi-directional digital communications.
A process oriented programming language is available for implementation of
batch and hybrid applications as well as computational capability needed to some
continuous control task.
Advanced process manager:-
The APM adds new functions and capacity to those available with the process
manager it offers increased integration of discrete control with the device control
point. It also supports flexible subsystem integration with the array point and
serial I/O processor and new types of control point.

High performance process manager:-

The HPM represent an evolution of PM and APM its duel 68040 platform
offers a wide range of capabilities for present feature process requirement. The
HPM performance is significantly 5 times better than the PM and APM. A tool
box function can be configure and programmed to needs the data acquisition and
advanced process requirement.
Logic manager:-
The LM integrates the high speed logic function into the architecture of UCN.
Its control processor is programmed using ladder logic and which continuously
and rapidly exacted as long as the control processor is in the RUN mode. It
provides the interface for the rest of the TPS system to access a variety of data
point types.
Safety manager:-
SM provides a family of nodes on the UCN that consist of a SM interface card
and SM that provides the safety functions. There are two safety manager is
available. The R500 safety manager is for the Triconex Tricon version 8.
For R510 offers safety manager for the fail safe control (FSC) system.

The PLC system

Introduction:-
The PLC system is used for emergency purpose. When the process is going out of the track then an override
control is used to save the system from several damage. As DCS system is little bit slow system so PLC is
used for ESD (Emergency shutdown) or other override systems.
Connection with the DCS system:-
The PLC system is connected to the DCS system through the EPLC module of the LCN network of DCS.

The PLC system:-

In this system PLC system Single Chassis Version 9 TRICON Systems is used. For this particular
system.The TRICON is a state-of-the-art programmable logic and process controller that provides a high
level of system fault tolerance. This section describes Fault tolerance and lists the main features offered by
the TRICON system.

THEORY OF OPERATION:-
 41

Triple-Modular Redundant (TMR) architecture (shown in Figure 1–2) ensures Fault tolerance and provides
error-free, uninterrupted control in the presence of either hard failures of components or transient faults from
internal or External sources. Every I/O module houses the circuitry for three independent legs. Each leg on
the input modules reads the process data and passes that information to its Respective Main Processor. The
three Main Processors communicate with Each other using a proprietary high-speed bus system called the
TRIBUS.

Triplicated Architecture of the TRICON Controller Once per scan, the Main Processors synchronize and
communicate with their Neighbors over the 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 send outputs generated by The control program to the output modules. In addition to
voting the input data, The TRICON votes the output data. This is done on the output modules as close
to the field as possible to detect and compensate for any errors that could occur
Between the TRIBUS voting and the final output driven to the field. For each I/O module, the system can
support an optional hot-spare module. If Present, the hot-spare takes control if a fault is detected on the
primary module During operation. The hot-spare position is also used for on-line system repairs.

Main Processor Modules:-

A TRICON system contains three Main Processor modules. Each controls a Separate leg of the system and
operates in parallel with the other two Main Processors A dedicated I/O communication processor on each
Main Processor manages The data exchanged between the Main Processor and the I/O modules. A
Triplicated I/O bus, located on the chassis backplane, extends from chassis to Chassis by means of I/O bus
cables. As each input module is polled, the appropriate leg of the I/O bus transmits new input data to the
Main Processor. The input data is assembled into a table in the Main Processor and is stored in memory for
use in the hardware voting process. The individual input table in each Main Processor is transferred to its
neighboring Main Processors over the TRIBUS. During this transfer, Hardware voting takes place. The
TRIBUS uses a direct memory access Programmable device to synchronize, transmit, vote and compare data
among the three Main Processors. If a disagreement occurs, the signal value found in two out of three tables
prevails, and the third table is corrected accordingly. One-time differences Which result from sample timing
variations are distinguished from a pattern of differing data. Each Main Processor maintains data about
necessary corrections in local memory. Any disparity is flagged and used at the end of the scan by the
TRICON’s built-in fault analyzer routines to determine whether a fault exists on a particular module.
The Main Processors put corrected data into the control program. The 32-bit main microprocessor and a
math coprocessor execute the control program in parallel with the neighboring Main Processor modules. The
control program generates a table of output values which are based on the table of input values according to
customer-defined rules built into the application. The I/O communication processor on each Main Processor
Manages the transmission of output data to the output modules by means of
the I/O bus.
 42

Architecture of a Main Processor

Using the table of output values, the I/O communication processor generates smaller tables, each
corresponding to an individual output module in the system. Each small table is transmitted to the
appropriate leg of the corresponding output module over the I/O bus. For example, Main Processor A
transmits the appropriate table to Leg A of each output module over I/O Bus A. The transmittal of output
data has priority over the routine scanning of all I/O modules. The I/O communication processor manages
the data exchanged between the Main Processors and the communication modules using the communication
bus which supports a broadcast mechanism.
The model #3006 Main Processors provide 2 Megabytes SRAM each for fully expandable V9 TRICON
Systems, while model #3007 Main Processors Provide 1 Megabyte SRAM each for Single Chassis V9
TRICON Systems only. The SRAM is used for the user-written control program, SOE1 data,
data, diagnostics and communication buffers.In the event of an external power failure, the SRAM is
protected by batteries which reside on the backplane of the Main Chassis. In the absence of power
to the TRICON, the batteries maintain the integrity of the program and the retentive variables for a
minimum of six months. The Main Processor modules receive power from the dual Power Modules and
power rails in the Main Chassis. A failure on one Power Module or power rail does not affect system
performance.

Bus Systems & Power Distribution:-

Three triplicated bus systems are etched on the chassis backplane: the TRIBUS, the I/O bus, and the
communication bus. The TRIBUS consists of three independent serial links operating at 4 Mbaud.
It synchronizes the Main Processors at the beginning of a scan. Then each Main Processor sends its data to
its upstream and downstream neighbors. The TRIBUS takes the following actions:
– Transfers analog, diagnostic and communication data – Transfers and votes digital input data
– Compares data and flags disagreements for the previous scan’s output Data and control program memory
An important feature of TRICON architecture is the use of a single transmitter to send data to both the
upstream and downstream Main Processors. This ensures the same data is received by the upstream
processor and downstream Processor. Each I/O module transfers signals to or from the field through its
associated field termination assembly. Two positions in the chassis tie together as one logical slot. The first
position holds the active I/O module and the second position holds the hot-spare I/O module. Termination
cables are tied to panel connectors at the top of the backplane. Each connection extends from the
termination module to both active and hot-spare I/O modules. Therefore, both the active module and the hot-
spare module receive the same information from the field termination wiring. The 375 Kbaud triplicated I/O
bus transfers data between the I/O modules and the Main Processors. The I/O bus is carried along the bottom
of the backplane. Each leg of the I/O bus runs between one Main Processor and the corresponding legs on
the I/O module. The I/O bus extends between chassis using set of three I/O control. The 2 Mbaud
 43

communication bus runs between the Main Processors and the communication modules. Power for the
chassis is distributed across two independent power rails and down the center of the backplane. Each module
in the chassis draws power from both power rails through dual power regulators. There are four sets of
power regulators on each input and output board: one set for each leg (A, B, and C) and one set for the status
indicators.

Digital Input Modules:-

The TRICON supports two basic types of digital input modules: TMR and single. On TMR modules, all
critical signal paths are 100% triplicated for guaranteed safety and maximum availability. On single
modules, only those portions of the signal path which are required to ensure safe operation are triplicated.
Single modules are optimized for those safety-critical applications where low cost is more important than
maximum availability. 1.3.3.1 TMR Digital Input Modules Each digital input module houses the circuitry
for three identical legs (A, B and C). Although the legs reside on the same module, they are completely
isolated from each other and operate independently. Each leg conditions signals independently and provides
optical isolation between the field and the TRICON. (The model #3504E High-Density Digital Input
Module with 64 points is an exception—it has no isolation.) A fault on one leg cannot pass to another. In
addition, each leg contains an 8-bit microprocessor called the input/output (I/O) communication processor
which handles communication with its corresponding Main Processor. Each of the three input legs
asynchronously measures the input signals from each point on the input termination module, determines the
respective states of the input signals, and places the values into input tables A, B and C Respectively. Each
input table is regularly interrogated over the I/O bus by the I/O communication processor located on the
corresponding Main Processor module. For example, Main Processor A interrogates Input Table A over I/O
Bus A. DC models of the digital input modules can self-test to detect “stuck ON” conditions where the
circuitry cannot tell whether a point has gone to the OFF state. Since most safety systems are set up with a
“de-energize-to-trip” capability, the ability to detect OFF points is an important feature. To test for
“stuck ON” inputs, a switch within the input circuitry is closed to allow a zero input (OFF) to be read by the
optical isolation circuitry. The last data reading is frozen in the I/O communication processor while the test
is running.

Single Digital Input Modules

Each digital input module houses the intelligent control circuitry for three identical legs (A, B and C).
Although the legs reside on the same module, they are completely isolated from each other and operate
independently. A fault on one leg cannot pass to another. The intelligent control circuitry consists of an
8-bit microprocessor called the I/O communication processor which handles communication with its
corresponding Main Processor. Each of the three input legs independently measures the input signals by
means of a non-triplicated set of signal conditioners. This is done for each point on the input termination
module. Each leg determines the states of the points and places their values into input tables A, B and C
respectively. Each input table is regularly interrogated over the I/O bus by the I/O communication
microprocessor located on the corresponding Main Processor module. For example, Main Processor A
interrogates Input Table A over I/O Bus A. Special self-test circuitry is provided to detect all stuck-ON and
stuck-OFF fault conditions within the non-triplicated signal conditioners in less than 500 milliseconds. This
is a mandatory feature of a fail-safe system, which must detect all faults in a timely manner and upon
detection of an input fault, force the measured input value to the safe state. Because the TRICON is
optimized for de-energize-to-trip applications, detection of a fault in the input circuitry forces to OFF (the
de-energized state) the value reported to the Main Processors by each leg.

Digital Output Modules

There are four basic types of digital output modules:
– Supervised digital output modules
– DC voltage digital output modules
– AC voltage digital output modules
– Dual DC digital output modules
Every digital output module houses the circuitry for three identical, isolated legs. Each leg includes an I/O
microprocessor which receives its output table from the I/O communication processor on its corresponding
Main Processor. All of the digital output modules, except the dual DC modules, use special quadruplicated
output circuitry which votes on the individual output signals just before they are applied to the load. This
voter circuitry is based on parallel-series paths which pass power if the drivers for Legs A and B, or Legs
 44

B and C, or Legs A and C command them to close—in other words, 2-out-of-3 drivers voted ON. Dual
digital output modules provide a single parallel or series path, with the 2-out-of-3 voting process applied
individually to each switch. The quadruplicated output circuitry provides multiple redundancy for all
critical signal paths, guaranteeing safety and maximum availability. The dual output module provides just
enough redundancy to ensure safe operation. Dual modules are optimized for those safety-critical
applications where low cost is more important than maximum availability. Each type of digital output
module executes a particular type of Output Voter Diagnostic (OVD) for every point. In general, during
OVD execution the commanded state of each point is momentarily reversed on one of the output
drivers, one after another. Loop-back on the module allows each microprocessor to read the output value for
the point to determine whether a latent fault exists within the output circuit. (For devices that cannot tolerate
a signal transition of any length, OVD on both AC and DC voltage digital output modules can be disabled.)
A supervised digital output module provides both voltage and current loop back, allowing complete fault
coverage for both energized-to-trip and de-energized-to-trip conditions. In addition, a supervised digital
output module verifies the presence of the field load by doing continuous circuit-continuity checks. Any loss
of field load is annunciated by the module. A DC voltage digital output module is specifically designed to
control devices which hold points in one state for long periods of time. The OVD strategy for a DC voltage
digital output module ensures full fault coverage even if the commanded state of the points never changes.
On this type of module, the output signal transition normally occurs during OVD execution, but is
guaranteed to be less than 2.0 milliseconds (500 microseconds is typical) and is transparent to most field
devices. On an AC voltage digital output module, a faulty switch identified by the OVD process will cause
the output signal to transition to the opposite state for a maximum of half an AC cycle. This transition may
not be transparent to all field devices. Once a fault is detected, the module discontinues further iterations of
OVD. Each point on an AC voltage digital output module requires periodic cycling to both the ON and OFF
states to ensure 100% fault coverage.

Analog Input Modules

On an analog input module, each of the three legs asynchronously measures the input signals and places the
results into a table of values. Each of the three input tables is passed to its associated Main Processor module
using the corresponding I/O bus. The input table in each Main Processor module is transferred to its
neighbors across the TRIBUS. The middle value is selected by each Main Processor, and the input table in
each Main Processor is corrected accordingly. In TMR mode, the mid-value data is used by the control
program; in duplex mode, the average is used. Each analog input module is automatically calibrated using
multiple reference voltages read through the multiplexer. These voltages determine the gain and bias
required to adjust readings of the analog-to-digital converter. Analog input modules and termination
modules are available to support a wide variety of analog inputs, in both isolated and non-isolated versions:
0-5 VDC, 0-10 VDC, 4-20 mA, thermocouples (types K, J, T and E), and resistive thermal devices (RTDs).

Analog Output Modules

The analog output module receives three tables of output values, one for each leg from the corresponding
Main Processor. Each leg has its own digital-to-analog converter (DAC). One of the three legs is selected to
drive the analog outputs. The output is continuously checked for correctness by “loop-back” inputs on each
point which are read by all three microprocessors. If a fault occurs in the driving leg, that leg is declared
faulty, and a new leg is selected to drive the field device. The designation of “driving leg” is rotated among
the legs so that all three legs are tested.

Termination Modules
For field wiring of the V9 TRICON chassis, you can use either Triconex-supplied termination assemblies or
provide your own termination cables that match the TRICON’s panel connectors. A field termination
module is an electrically passive circuit board to which field wiring is easily attached. A termination module
merely passes input signals from the field to an input module or passes signals generated by an output
module directly to field wiring, thereby permitting removal or replacement of the input or output module
without disturbing field wiring.
 45

Communication Modules:-
By means of the communication modules described in this section, the TRICON can interface with Modbus
masters and slaves, other TRICONs in Peer-to-Peer networks, external hosts running applications over 802.3
networks, and Honeywell and Foxboro Distributed Control Systems (DCS). The Main Processors broadcast
data to the communication modules across the communication bus. Data is typically refreshed every scan; it
is never more than two scan-times old. Enhanced Intelligent Communication Module (EICM) — Supports
RS-232 and RS-422 serial communication with external devices at speeds up to 19.2 Kbaud. This EICM
provides four serial ports which can interface with Modbus masters, slaves, or both; or a TriStation. The
module also provides a Centronics-compatible parallel port. Network Communication Module (NCM) —
This module allows the TRICON to communicate with other TRICONs and with external hosts over
802.3 networks using a high-speed 10 Megabit/second data link. The NCM supports a number of Triconex
protocols and applications as well as user-written applications, including those that use TCP-IP/UDP-IP
protocol, as shown in Table 1–3. Safety Manager Module (SMM) — This module acts as an interface
between a TRICON controller and Honeywell’s Universal Control Network (UCN), one of three principal
networks of the TDC-3000 DCS. The SMM appears to the TDC-3000 as a safety node on the Universal
Control Network (UCN), allowing the TRICON to manage process-critical points within the overall TDC-
3000 environment. The SMM transmits all TRICON aliased data and diagnostic information to TDC-3000
operator workstations in display formats that are familiar to Honeywell operators. Availability of the SMM
depends on Honeywell’s schedule for Release 500 and future releases. Hiway Interface Module (HIM) —
This module acts as an interface between a TRICON controller and Honeywell’s TDC-3000 control system
by means of the Hiway Gateway and Local Control Network (LCN). The HIM can also interface with
Honeywell’s older TDC-2000 control system by means of the Data Hiway. The HIM enables higher-order
devices on the LCN or Data Hiway, such as computers and operator workstations, to communicate with
the TRICON. The HIM allows redundant BNC connections directly to the Data Hiway and has the same
functional capacity as up to four extended Data Hiway Port (DHP) addresses. Advanced Communication
Module (ACM) — This module acts as an interface between a TRICON controller and Foxboro’s Intelligent
Automation (I/A) Series DCS. The ACM appears to the Foxboro system as a safety node on the I/A Series
Nodebus, allowing the TRICON to manage process-critical points within the overall I/A DCS environment.
The ACM transmits all TRICON aliased data and diagnostic information to I/A operator workstations
in display formats that are familiar to Foxboro operators. Availability of the ACM depends on Foxboro’s
schedule for Version 4.2.2 of the I/A Series Software.

Power Modules
Each TRICON chassis houses two Power Modules arranged in a dual-redundant configuration. Each module
derives power from the backplane and has independent power regulators for each leg. Each can support the
power requirements for all the modules in the chassis in which it resides, and each feeds a separate power
rail on the chassis backplane. The Power Modules have built-in diagnostic circuitry which checks for out-of-
range voltages and over-temperature conditions. A short on a leg disables the power regulator rather than
affecting the power bus .

System Diagnostics & Status Indicators

The TRICON incorporates integral on-line diagnostics. Probable failure modes are anticipated and made
detectable by specialized circuitry. Fault-monitoring circuitry in each module helps fulfill this requirement.
The circuitry includes but is not limited to I/O loop back, dead man timers, loss-of-power sensors, and so on.
This aspect of the system design enables the TRICON to reconfigure itself and perform limited self-repair
according to the health of each module and leg.