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Feature | February 2016

Measured engineering

Instrumentation and control automation is designed at realising the competitive advantages for a power plant or company, through design, maintainance and management of control systems.

Instrumentation is defined as the art and science of measurement and control of process variables within a production or manufacturing area. The process variables used in industries are Level, Pressure, Temperature, Humidity, Flow, pH, Force, Speed etc.

Control engineering or control systems engineering is the engineering discipline that applies control theory to design systems with desired behaviors. Control engineers are responsible for the research, design, development and control devices/systems, typically in manufacturing facilities and plants. The practice uses sensors to measure the output performance of the device being controlled and those measurements can be used to give feedback to the input actuators that can make corrections toward desired performance.

When a device is designed to perform without the need of human inputs for correction it is called automatic control (such as cruise control for regulating a car´s speed). Multi-disciplinary in nature, control systems engineering activities focus on implementation of control systems mainly derived by mathematical modeling of systems of a diverse range.

Instrumentation and Control Engineering
Instrumentation and control automation is designed at realising the competitive advantages for a power plant or company. Holistic solution approaches for the critical infrastructure ¨behind the scenes¨ boost availability, flexibility and profitability of power generation - over the entire lifecycle, with the lowest possible operating and maintenance costs.

For decades now, the crucial lever for achieving the most profitable power plants and plants with the highest performance in the world, is due to the ability to control power plants with precision, and to activate hidden performance reserves and maximising useful service life.

It also plays a significant role in both gathering information from the field and changing the field parameters, and as such are a key part of control loops. Instrumentation Technology, being an inter-disciplinary branch of engineering, is heading towards development of new and intelligent sensors, smart transducers, MEMS Technology, Bluetooth Technology.

In short, it deals with measurement, automation and control processes. Almost all process and manufacturing industry such as steel, oil, petrochemical, power and defiance production have separate instrumentation and control departments, manned and managed by instrumentation and control engineers. Automation is the buzz word in process industry, and automation is the core job of instrumentation and control engineers. Hence, the demand for instrumentation will always be there.

Case Studies: Honeywell
Honeywell to boost output and efficiency for Russian refinery giant Honeywell Process Solutions (HPS) in December 2015 announced it has implemented its Experion® PKS R.410 distributed control system (DCS) at Angarsk Petrochemical Company, the largest oil refining and petrochemical complex in the Irkutsk region of Eastern Siberia, Russia.

The advanced DCS will simplify operations and improve the process efficiency of the refinery´s delayed coking unit, which extracts valuable fuels from heavy oil residues of the refining processes. The investment forms part of the plant´s continual efforts to match world-class standards in process automation, and is part of a company-wide modernization between 2012 and 2020 by Rosneft, Angarsk´s owners and the largest publicly traded oil company in Russia. The modernisation will help the plant´s products reach the Euro 5 emissions standard, as well as bring a range of improvements to process management, operational safety, downtime risk management, steam and fuel consumption.

Commissioned in 1955, Angarsk is among Russia´s largest refineries. It has a capacity of 80.5 million barrels per year, with products sold domestically as well as exported. The plant has now produced its first shipment of premium fuel compliant with Euro-5, and is continuing its strategy to increase refining volume and processing depth while minimizing operational costs.

The DCS integrates with Safety Manager, Honeywell´s safety instrumented system platform that safeguards assets and shares critical safety information with the process control system. The platform helps prevent incidents and minimise impacts by protecting equipment, monitoring for fire and gas leaks, and supporting critical control functions.

Case Studies: Siemens
Instrumentation services enhance the reliability and availability of plants Siemens is offering a new service for the calibration of measuring devices in process instrumentation. This enhances the reliability, availability and lifespan of field devices, thereby ensuring a high quality product. As part of the Process Instrumentation Services - Calibration and Verification, Siemens experts provide calibration and verification services for field devices such as the Sitrans flowmeters, pressure transmitters, temperature measuring devices and belt scales.

The service can be provided at the plant (on-site) or in the laboratory (off-site). It is geared in particular for companies involved in water and waste water treatment as well as companies involved in the chemical, food and pharmaceutical industry. It is also suitable for the mining, cement, oil and gas and energy production industries. The calibration and verification services fulfill the highest standards in terms of quality, reliability and traceability. The calibration equipment used for on-site calibration and calibration in the laboratory is certified in accordance with national and international standards; factory calibration is ISO/IEC 17025 certified. Users are subsequently furnished with a calibration and verification certificate. Exact calibration prevents unplanned downtime which in turn reduces total operating costs, safeguarding the quality of the end products.

These services include:

  • Calibration and verification of measuring instruments by Siemens experts
  • On-site calibrations or laboratory calibrations
  • Measuring instruments certified to national and international standards
  • Suitable for all companies involved in the process industry Siemens is offering a new service for the calibration of measuring devices in process instrumentation.

This enhances the reliability, availability and lifespan of field devices, thereby ensuring a high quality product.

Case Studies: AVEVA
Russian O&G cluster of Bashkortostan Republic implements AVEVA´s Integrated Engineering & Design solution AVEVA in December 2015 announced that the leading Russian oil & gas cluster of Bashkortostan Republic has standardised on AVEVA´s Integrated Engineering & Design software solution. The cluster required a proven multi-discipline engineering and design solution for capital projects globally that would increase productivity and improve efficiency. The cluster is a group of companies that specialise in oil & gas including, energy-efficient technologies and precision engineering. All members of the cluster will use AVEVA software on all projects.

The main goal of the initiative is to develop and support oil & gas activities in this region, an important territory for the Russian oil industry. A significant number of powerful engineering and design institutes as well as operators are located here. The cluster itself unites over 100 companies. ¨Institute of Petroleum Refining and Petrochemistry of the Republic of Bashkortostan¨ (INHP RB) was chosen to manage and coordinate all the activities of the cluster, as well as its development, research, expertise, administration and IT.

INITEC Energfa integrates engineering & design with AVEVA
AVEVA in November 2015 announced that INITEC Energia, one of the largest engineering companies in Spain within the electricity generation sector, has extended its Integrated Engineering & Design (IE&D) strategy through the addition of AVEVA Instrumentation software.

An existing AVEVA customer, INITEC Energia replaced a competitive product, with the latest release of AVEVA Instrumentation to improve engineering and design efficiency, due to concerns over lack of integration between its old software and the larger design process, which required the use of awkward Excel spreadsheets to export data. Using the expanded AVEVA IE&D solution, INITEC Energia has now eliminated the need for manual intervention, ensuring information is visible between disciplines and across the entire project, improving design accuracy and avoiding costly reworking.

AVEVA Instrumentation is feature-rich software for instrumentation engineering and design in plant and marine projects. It´s advanced graphical user interfaces, advanced cable routing integration capabilities, use of design rules and catalogues for data creation; offer maximum workflow flexibility, improving project productivity and design quality.

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