1. I & E ENG Department
Summer Intern 2016
August 5, 2016
I & E intern
Phillip Arteaga
2. Agenda
2
About Me
Purdue University EE
Overview of selected activities
Reconciliation of DCS & SIS cabinet IO
Thermowell study
Wrap Up
3. Programmed Motor Protection Relays in BU-521 (Propak)
This Relay monitors the performance of the motor control starter,
determines if it goes outside acceptable parameters, and trips it
Wrote a procedure for the relays, which is now in the validation process
Worked with Rockwell and Eaton
Work with my supervisor on the instrument air compressor to troubleshoot
the problems using special equipment such as the Fluke 1736 Power Logger ,
and read and learn about this device
Assisted in use of the Fluke 1736 as it was used to measure voltage and
current of the 3 phases at the same time when energized and tracks it
The electrical contactor needed to be replaced
3
Overview
4. Cataloged the DCS and SIS cabinets: these are the control systems that run the plant and
keep it safe
Loop sheet is a drafted drawing of the IO module, which show how
the plant was originally designed and modified over time
DOC 4000 is a recently added software utility that surveys the control
systems to tell what channels are used
A third resource is the actual field termination strip in the IO cabinet
4
DCS (Distributed Control Systems) & SIS (Safety
Instrument Systems) reconciliation
5. 5
Loop Sheet (ENG) Doc 4000 (Controls) Field (I &E)
Spare
Spare
Example 1: Loop diagram revision not yet complete
6. Example 2: Spare IO not yet documented with a loop diagram
template
6
Loop Sheet (ENG) Doc 4000 (Controls) Field (I &E)
7. Example 3: IO point documented, but pending installation
Spare
7
Loop Sheet (ENG) Doc 4000 (Controls) Field (I &E)
8. Area 100, 239 spares
Area 200, 168 spares
Area 300, 202 spares
Area 500, 115 spares
Area 900, 100 spares
Over 400+ IO modules in the plant checked as well as terminal strips
Hire a contractor to update and redline loopsheets due to high
percentage of inconsistencies found when comparing loopsheets with
the field and DOC4000
8
Findings & Recommendations
9. A thermowell is made for holding a temperature element within the pipe; it is
exposed to the process flow and has to withstand process conditions
Calculate whether a thermowell needs to be replaced, or passes per the most
recent standards
Many Dimensional and Process data are input to thermowell design
calculation
9
Thermowell Study
10. New ASME PTC 19.3 standard (2010) requires more conservative design
Why are we doing this study? To confirm the thermowells meet new
standard
Process data for some wells needs to be collected to perform further
calculations, but so far those completed look good
10
Findings & Recommendations
outside the pipe inside the pipe
typical break point
11. What I enjoyed
“if your not learning something new everyday your doing
something wrong” John Brubaker
What I didn’t enjoy
The 3 hours round trip drive which has been some days up
to 5 hrs
Suggestions
Improve set up with designated engineer and technician as
a mentors
Fall
Back to school at Purdue
Wrap Up
12. Thank you For giving me this opportunity to work here.
12
Thank you & Questions
Editor's Notes
MOTOR protection RELAY ( A RELAY IN THIS CASE IS A DEVICE THAT MONITOR THE PERFORMANCE OF A MOTOR STARTER )If the motor was going outside of the parameters programed it could cause it to trip ( you don’t want to work on anything that powerful)
The device we used checked the current and voltage at the same time on all three phases once we got the data off the device we realized everything was good on our end, we had other issue like we smelled burning we didn’t know what it came from… the fan inside the bus was the issue for that smell it had burned out, the electrical contactor needed to be replaced and then we were good, but some other issues that occurred coupling between the motor and compressor the metal coupling was twisted and thwarted
This is an example of some of my results (loop sheet is a drafted drawing out the IO module that is how the plant was originally designed) DOC 4000( was a recently added software utility that survey the control systems to tell what chancels are used) Last this a terminal strip which is the field DOC 4000 GOES INTO THE CONTROL SYSTEMS AND COLLECTS THE INFO IN A CONVIENT FORM AND DIPLACES IT FOR NON PROGRAMMERS…. EXPLAIN SOFT POINT AND HOW IT HAS TO BE CHANGE BY THE CONTROLS SYSTEM
The doc4000 shows spare (no loop sheet so you actually have to go in the field to see the module has been wired out to a terminal strip so from doc 4000, we don’t know if those things exist )
The reason this is important is because the engineers designing additional new instruments need to know if there are spare channels
Also the tech and operators need to know what there pulling out since some documents terminals do not have loop sheets
Also if there was a problem and it was an emergency situation and you couldn’t even access that area you would have no way except for going out in the field to figure out what is on the terminal strip and where it goes
The reason this is important is because the engineers designing additional new instruments need to know if there are spare channels
Also the tech and operators need to know what there pulling out since some documents terminals do not have loop sheets
Also if there was a problem and it was an emergency situation and you couldn’t even access that area you would have no way except for going out in the field to figure out what is on the terminal strip and where it goes
2010 new standard with new design guidance , themorwell is only made for holding a temperature element, it is expose to the process flow and has to withstand, one of the ways a thermowell can fail is by shedding vortez ( the flow is affected by thermowell causing the tornados or vortex shedding off the thermowell bounding off the thermowell causing it to vibrate) from fatigue over the years the standard for designing has change such as the new standard in 2010, the reason we go thru this is because we have had thermowell break the reason this is important we don’t want a hole in the pipe or hitting downstream machinery TEST WELLS NEED FOR START UP EXPERIMENT VS WHAT NEED TO CONTROL ON A DAILY BASIS