plc based annunciation system

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Fasih Ahmed University of Engineering And Technology, Taxila PLC Based Annunciation System

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Page 1: PLC Based Annunciation System

Fasih Ahmed

University of Engineering And Technology, Taxila

PLC Based Annunciation System

Page 2: PLC Based Annunciation System

Objective

Replacement of Obsolete Annunciation System with Programmable Logic

Controller(PLC) based annunciation system for Ammonia Compressors 101-J, 103-J and

105-J.

Page 3: PLC Based Annunciation System

Agenda of Presentation• Overview of Ammonia plant.• Basics of Annunciation system.• Problems with the current Annunciation system.• Variants for the current system.• Overview of the assigned project.

Page 4: PLC Based Annunciation System

Overview of Ammonia plant and manufacture.

• Ammonia Plant was installed in 1976.• Present plant production capacity is 960 tons

per day.• The designer of ammonia plant is Kellogg

International Corporation (KIC).• Haber’s Process.

Page 5: PLC Based Annunciation System

Basics of Annunciation System.

“A signal designed to alert, inform, guide or confirm deviations from acceptable system status.”

Page 6: PLC Based Annunciation System

Graphical Overview of Annunciation System

Page 7: PLC Based Annunciation System

Parts of an Annunciation System.1- Annunciation Panels.

2- Recorders

Page 8: PLC Based Annunciation System

3- Annunciation Modules

Page 9: PLC Based Annunciation System

Problems with the current installed annunciation system.

• No spares are there for annunciation modules.• Annunciation modules are not reliable as they have passed

their lifetime. • The probability of fault is more in annunciation modules.• Large number of annunciation modules are required in an

annunciation system.• Maintenance of current installed annunciation modules is not

very easy.• Cannot accommodate changing system environment.

Page 10: PLC Based Annunciation System

Implementation of PLC Based Annunciation Systemon 101-J, 103-J 105-J.

Project Implementatio

n I/O Listing

Select the vendor

and type of PLC

Logic And Graphics Developm

ent

Listing of BOMTesting Training

Page 11: PLC Based Annunciation System

I/O Listing.

• On the basis of project I/Os the type of PLC is selected.• For this particular project there are total 80

inputs and 76 outputs.• Number of Analog and Digital I/Os are selected

on the basis of requirement of the project.

Page 12: PLC Based Annunciation System

Hardware Selection.

• For this particular project ALLEN BRADLEY PLC is selected for installation based on inventory optimization.• The suitable type or model of PLC selected is

named as MicroLogix 1100.• The MicroLogix 1100 has 10 Digital Inputs and 2

Analog Inputs.

Page 13: PLC Based Annunciation System

Continued

Page 14: PLC Based Annunciation System

Logic Implementation Software.

• RSLogix 500, Revision 7.0 or later.• Factory Talk Gateway.• Two communications ports

RS-232/485 communication port (Channel 0)

Ethernet port (Channel 1).

Page 15: PLC Based Annunciation System

Listing of Project BOM

• Bill of material for the required hardware should be made in order to make a purchase request (PR) from the industry.• The budget required for installation of the

desired project is approximately 4 million rupees.

Page 16: PLC Based Annunciation System

Testing and Training

• Test Run.• Training

Operation

Instrument

Page 17: PLC Based Annunciation System

Legend:

T1

T3

PROJECT TIMELINE

T4

T1

T2

T3

T4

T5

T6

T7

T8

Procurement

Logic development

Graphics development

Integration of graphics with logic

Field Execution

Simulation and verification

T9

Test Run

Training

Procurement

MOC Approval

Logic development

Graphics development

T5

Integration of graphics with logic

T6

Simulation and verification

T7 T8 T9

Field execution

Test Run

Training

T2

MOC Approval

Page 18: PLC Based Annunciation System

Substitutes for Annunciation modules.

• Experion HS by Honey Well .• SIMATIC PCS 7 by Siemens • Bulletin 1756 ControlLogix® I/O modules.• HART(Highway Addressable Remote Transducer)

Protocol.• FOUNDATION Fieldbus.

Page 19: PLC Based Annunciation System

HART ProtocolHighway Addressable Remote Transducer ( HART ) is a bidirectional communication on analogue wires

for sending and receiving digital data .

Page 20: PLC Based Annunciation System
Page 21: PLC Based Annunciation System
Page 22: PLC Based Annunciation System

Benefits of HART.• Quickly verify and validate control loop and device configuration.• Use remote diagnostics to reduce unnecessary field checks.• Avoid the high cost of unscheduled shutdowns or process

disruptions.• Minimize the impact of deviations by gaining new, early warnings.• Enable automated record keeping of compliance data.• Facilitates automated safety shutdown testing.• Can communicate with DCS.

Page 23: PLC Based Annunciation System

Fieldbus Foundation H1.

• FOUNDATION H1 fieldbus designed primarily for process industries is a real-time digital communication network designed specifically for process control applications.

• No need of 4-20mA analog signal. • All control decisions take place inside the field devices.• High speed Network ( H2 ), later replaced by Ethernet

technology (HSE) .• Low speed Network ( H1) .

Page 24: PLC Based Annunciation System
Page 25: PLC Based Annunciation System

Benefits of Foundation H1

• Reduced Hardware Requirements.

Page 26: PLC Based Annunciation System

• Reduces signal distortion.• High Signal Integrity.

• Greater Signal Fidelity.• Elimination of I/O cards.• Reduced Device Count.• Elimination of Virtual Marshalling.

Page 27: PLC Based Annunciation System

Any Questions ?

Page 28: PLC Based Annunciation System

Thank You