Lecture Slides

AUTOMATION,
INSTRUMENTATION AND
PROCESS CONTROL DURING
PLANT DESIGN AND START-UP,
PI-DIAGRAMS
20.5.2019
SUBJECTS
• Process automation design and specifications
• Instrumentation design and specifications
• Process control philosophy
• PI-diagrams
• Instrumentation tasks
PROCESS AUTOMATION DESIGN
Co-operation between process design and automation

experts
Process design Automation design Automation

engineering
• PI-diagrams • Design of
automation • Programming of
• Instrumentation/
environment control system
equipment lists and
specifications • Specs of • Supply and
technical control installation of
• Overall and unit
system (tech. automation system
process control
requirements)
philosophy • Testing and
start-up
• Equipment signalling
(I/O, digital bus…)
Instrumentation design
Equip unit processes with measurement instruments, take into account:
• Permitting and treatment requirements
• Risk assessment
• Control philosophy
• Operational personnel è automation degree
• Goals for energy and resource efficiency
• Reporting needs
• Available budget
• Maintenance issues and opex

Instrumentation design Mechanical equipment
Specify instruments Specify control
• Number of units • Number of units, rotation of stand-by

units
• Placement, installation/mounting
methods • Reserve power connection
• Measuring principle • Control room monitory display

specifications (alerts, state, control)
• Measurement range
• Emergency shut-down specs
• Alert limits
• Local control cabinets and
• Dimensioning of flow measurements
panels/connected to plant level
(size)
automation
• Local display specification
• Reserve power connection

Control concept -design
• 2 design levels: 1) unit process level, 2) single equipment/instrument control loop in
automatic mode
• Normal running/start-up/shut-down/emergency shutdown
• Rotation of stand-by units
• Power shut down situations è start-up description under emergency power
• Alerts, process locking specifications
• Start-up of unit processes in sequence
• Calculations: running times, calculated values (circulation %, chemical dosages…)
• Process reporting specifications

Construction period and Start up -tasks
• FAT-tests
• Simulation of process unit arrangements under construction period
• “Dry and wet tests”, SAT-tests
• Training
• Process control simulations

PID- PIPING AND
INSTRUMENTATION DIAGRAM
• Overall picture of unit process combination and plant
structure
• Incl. all equipment, piping, valves, fittings,

measurements, control-loops
• Specified symbols for different equipment
• Draining, cleaning and ventilation valves 50-UW-5304-10CS

V02
• Item numbers (positions) 100-UW-5305-10CS
100-UW-5302-10CS
• Pipe codes and classes V01
5304-
V01
100-UW-5301-
10CS
• Delivery limits 5303-

V01
UR. TIL.
V02
50-UW-5303-10CS
PID-SYMBOLS
STANDARD SYMBOL REPLACED WITH A SPECIFIC ONE
FLOW DIAGRAM PI-DIAGRAM
COMPRESSOR OR PISTON COMPRESSOR

BLOWER IN
GENERAL
HEAT EXCHANGER PIPE HEAT

IN GENERAL EXCHANGER
PID-SYMBOLS
PID-SYMBOLS
PID-DIAGRAM
FIELD INSTRUMENTS:
LOCAL INSTRUMENT
INSTRUMENT, REMOTE CONTROL ROOM
INSTRUMENT, LOCAL CONTROL BOARD
HH
H
TA ALERTS AND LOCKING LIMITS
12 L
LL
PI-DIAGRAM
MEASUREMENTS:
• First letter: what is measured or controlled
• The following letters: Supplementing measurement and specifying operational

principle
• Letters in the following order I, R, C, T, Q, S, Z, A

PI-DIAGRAM
MEASUREMENT CODING (SFS4103):
1. kirjain 2. kirjain seuraavat kirjaimet

Mittaussuure Lisämäärite Näyttö- tai lähtötoiminta
A --- Hälytys
B --- Audiovisuaalinen toiminta
C --- Säätö
D Tiheys Ero ---
E Kaikki sähkösuureet Anturitoiminta
F Virtaus Suhde ---
G Pituus tai asento ---
H Käsiohjaus ---
I --- Osoitus
J --- Jaksottainen toiminta ---
K Aika tai aikaohjelma ---
L Pinnan korkeus ---
M Kosteus Viestin muunto
N Käyttäjän valittavissa Käyttäjän valittavissa
O Käyttäjän valittavissa ---
P Paine Testaus, näytteenotto
Q Laatu Yhdistäminen, summaaminen
R Ydinsäteily Tallennus
S Nopeus tai taajuus Kytkentätoiminta
T Lämpötila Lähetintoiminta
U Monimuuttuja Monitoiminta
V Viskositeetti Venttiili, toimiyksikkö
W Paino tai voima ---
X Määrittelemättömät suureet Määrittelemättömät toiminnat
Y Käyttäjän valittavissa Laskentatoiminta
Z --- Hätä- ja turvatoiminta (lukitus)
PI-DIAGRAM
MEASUREMENT CODING EXAMPLES:
QJP
1. Sampling, clock timered, local contr. panel 1
PI
2. Pressure measurement, 2
local device
PC
3
3. Pressure measurement + control in process contr. system FIRQ
4
4. Flow measurement, indication, recording, counter
HH
H
5. Ammonia measurement, indication, control, alarm/locking QICZA
5
NH4-N
PSA
6. Pressure switch, alarm in pr. Control system
6
LCZA
7. Level measurement, control, alarm/lower, locking/lower 7 L
LL
8. Moment switch, alarm in pr. Control system WSA

8
PI-DIAGRAM
DESIGN TOOLS:
• basic-AutoCAD
• “intelligent” database structured software
• Cadmill Process, Vertex, AutoCAD Plant 3D PID
• è symbol libraries (drag and drop)
• è automated lists of piping, equipment, instruments
• è common database with mechanical design (2-way updates)

STANDARDIZATION
INSTRUMENTATION EXAMPLES
AERATION SEC. SEDIMENTATION
Fe/Al
Qr
BOD 90 %
P 90 %
Fe/Al Ca NH4-N è NO3-N

NO3-N èN2
QW
Qr
BOD 90 %
P 90 %, N 50 %
Ca
NO3-N èN2NH4-N è NO3-N
QNO3-N QW
Qr
BOD 95 %
P 95 %, N 70 %
THANKS!

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AUTOMATION,

• Process automation design and specifications

• Instrumentation design and specifications

• Process control philosophy

Co-operation between process design and automation

Process design Automation design Automation

• Permitting and treatment requirements

• Operational personnel è automation degree

• Goals for energy and resource efficiency

• Maintenance issues and opex

• Number of units • Number of units, rotation of stand-by

• Measuring principle • Control room monitory display

• Local display specification

• Reserve power connection

• Normal running/start-up/shut-down/emergency shutdown

• Rotation of stand-by units

• Power shut down situations è start-up description under emergency power

• Alerts, process locking specifications

• Start-up of unit processes in sequence

• Calculations: running times, calculated values (circulation %, chemical dosages…)

• Process reporting specifications

• Simulation of process unit arrangements under construction period

• “Dry and wet tests”, SAT-tests

• Process control simulations

• Incl. all equipment, piping, valves, fittings,

• Specified symbols for different equipment

• Draining, cleaning and ventilation valves 50-UW-5304-10CS

• Item numbers (positions) 100-UW-5305-10CS

• Delivery limits 5303-

FLOW DIAGRAM PI-DIAGRAM

COMPRESSOR OR PISTON COMPRESSOR

HEAT EXCHANGER PIPE HEAT

INSTRUMENT, REMOTE CONTROL ROOM

INSTRUMENT, LOCAL CONTROL BOARD

• First letter: what is measured or controlled

• The following letters: Supplementing measurement and specifying operational

• Letters in the following order I, R, C, T, Q, S, Z, A

MEASUREMENT CODING (SFS4103):

1. kirjain 2. kirjain seuraavat kirjaimet

8. Moment switch, alarm in pr. Control system WSA

• “intelligent” database structured software

• Cadmill Process, Vertex, AutoCAD Plant 3D PID

• è symbol libraries (drag and drop)

• è automated lists of piping, equipment, instruments

• è common database with mechanical design (2-way updates)

AERATION SEC. SEDIMENTATION

AERATION SEC. SEDIMENTATION

Fe/Al Ca NH4-N è NO3-N

AERATION SEC. SEDIMENTATION

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