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MISR FERTILIZERS PRODUCTION COMPANY

INSTRUMENTATION TRAINING COURSE

FIELD INSTRUMENT TRAINING COURSES


FOR

PREPARED BY : ENG / EHAB AMAN


ENG / Ibrahim Elsaid

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CONTENTS

INSTRUMENT OVERVIEW
Tag Number classifications
TEMPERATURE MEASURMENTS
OVERVIEW…………………………………………………………………………………………..
THERMOMETER…………………………………………………………………………………..
THERMOCOUPLE………………………………………………………………………………….
RESISTANCE TEMPERATURE DETECTORS (RTD‘S)………………………………….
TEMPERATURE TRANSMITTERS ……………………………………………………………
PRESSURE MEASUREMENT
OVERVIEW…………………………………………………………………………………………..
LOCAL PRESSURE INDICATOR………………………………………………………………
PRESSURE TRANSMITTER……………………………………………………………………

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INSTRUMENT OVERVIEW

FLOW MEASUREMENT
OVERVIEW……………………………………………………………………………………………..
FLOW ORIFICE………………………………………………………………………………………..
VENTURI…………………………………………………………………………………………………

LEVEL MEASUREMENT
OVERVIEW………………………………………………………………………………………………
PRESSURE OR DIFFERENTIAL PRESSURE………………………………………………..
FLOAT OR DISPLACER……………………………………………………………………………..
SIGHT GLASSES………………………………………………………………………………………
SIGHT GLASS CHECKING………………………………………………………………………….

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MOPCO FIELD INSTRUMENTS OVERVIEW

VALVES HOOKUP AND ACCESSORIES


POSITIONER IDEA OF OPERATION AND MODELS…………………………………
BOOSTER IDEA OF OPERATION AND MODELS……………………………………..
PNEUMATIC LOCKUP RELAY IDEA OF OPERATION AND MODELS…………...
ELECTRICAL SOLENOID IDEA OF OPERATION AND MODELS………………….
QUICK EXHAUST IDEA OF OPERATION AND MODELS…………………………….

TURBINES Control
BENTLY NEVADA AXIAL DISPLACEMENT MEASURMENTS……………………….
BENTLY NEVADA RADIAL VIBRATION MEASURMENTS…………………………….
BENTLY NEVADA OVER SPEED SYSTEM………………………………………………….
TURBINE SPEED GOVERNER , CURRENT TO PRESSSURE CONVERTER ,

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MOPCO FIELD INSTRUMENTS OVERVIEW

‫ِمذِـخ‬
‫‪MISR FERTILIZERS PRODUCTION COMPANY‬‬

‫‪MOPCO FIELD INSTRUMENTS OVERVIEW‬‬

‫‪ٔٚ‬ظشا ٌض‪٠‬بدح أػذاد د‪ٚ‬ائش اٌج‪١‬بْ ‪ٚ‬اٌزؾىُ ف‪ ٝ‬اٌّظبٔغ ‪ٚ‬رجب‪ٚ ٓ٠‬ظبئف‪ٙ‬ب وبْ ٌضاِب اٌز‪ٛ‬طً إٌ‪ ٝ‬طش‪٠‬مخ رشل‪ ُ١‬خبطخ ثىً دائشح ػٍ‪ ٝ‬ؽذح‬
‫ػٍ‪ ٝ‬إٌؾ‪ ٛ‬اٌزبٌ‪-:ٝ‬‬

‫‪3‬‬ ‫‪03‬‬ ‫‪409‬‬

‫رقم انذائزة أَ انجٍاس‬


‫رقم انمصىع‬ ‫رقم انُحذة‬
‫‪٠ٚ‬أخز االسلبَ ِٓ ‪ 1‬اٌ‪3 ٝ‬‬ ‫‪ٚ‬رأخز االسلبَ ِٓ ‪ 1‬ؽز‪ٝ‬‬
‫ؽغت رشر‪١‬ت اٌّظٕغ ف‪ٝ‬‬ ‫‪ 99‬ؽغت اٌؾبعخ‬
‫ٔفظ اٌّىبْ‬
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MOPCO FIELD INSTRUMENTS OVERVIEW

ٟ‫ُ وبألر‬ّٙ١‫زُ رمغ‬٠ ٚ ‫بص‬ٙ‫ اٌغ‬ٚ‫سلُ اٌذائشٖ ا‬

1- 000 – 199: Temperature Measurements


2- 201 - 299: Pressure Measurements
3- 301 - 499: Flow Measurements
4- 501 - 599: Level Measurements
5- 601 - 699: Hand Valve , Hand switch
6- 701 - 799: Analyzers
7- 801 - 899: Scanners , Burners , weights ,
8- 901 - 999: Vibration , Axial Displacement , Speed Sensors , On / Off Valves
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Temperature Measurements

Temperature Measurements
‫قٕاص انحــــــــــــــــــــــزارة‬

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Temperature Measurements

Overview
Measuring the temperature in any plant is one of the parameters required to keep the process in certain
conditions by the operators or by automatic control loop.
‫ب‬١‫ِبرى‬ٛ‫ ار‬ٚ ً١‫ اٌزشغ‬ٟٕ‫ك ف‬٠‫زُ ٘زا اِب ػٓ طش‬٠ ٚ ‫خ‬١‫خ األٔزبع‬١ٍّ‫اًِ اٌؾغبعٗ ٌضجظ اٌؼ‬ٛ‫ اٌّظبٔغ ِٓ اٌؼ‬ٟ‫بط اٌؾشاسٖ ف‬١‫ل‬
ُ‫ائش اٌزؾى‬ٚ‫ك د‬٠‫ػٓ طش‬

Temperature measurements are divided in to .ٌٟ‫بط اٌؾشاسٖ ا‬١‫ُ طشق ل‬١‫ّىٓ رمغ‬٠

1 -Local Reading ( Temperature Indicator ) ‫لغ‬ٌّٛ‫ٓ اٌؾشاساد ثب‬١‫ِج‬

Operators in the field depend on local temperature indicator reading to record


there data in logging sheets
.‫ ٘زح اٌمشاءد‬ٍٟ‫زُ اٌزؾىُ ثٕبء ػ‬٠ ٚ ‫ساق‬ٚ‫ ا‬ٟ‫ً اٌمشاءد ف‬١‫ً ثزغغ‬١‫ اٌزشغ‬ٟٕ‫َ ف‬ٛ‫م‬٠ ‫ ٘زٖ اٌؾبٌخ‬ٟ‫ف‬

2- Remote Reading ( Thermocouple , RTD , … )


Operators in control room depend on remote temperature measurement to
observe temperature and DCS system record it in trends.
The main benefit for remote temperature measurement is in temperature control
loops
ُ‫ائش اٌزؾى‬ٚ‫ د‬ٟ‫ رغزؼًّ ف‬ٚ‫ْ ِغشد لشاءٖ أ‬ٛ‫ اِب رى‬ٚ ‫ اٌشبشبد‬ٍٟ‫مشاء لشأد اٌؾشاسح ػ‬٠ ً١‫ اٌزشغ‬ٟٕ‫ف‬

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Temperature Measurements

1- Local Reading ( Temperature Indicator )


1.1 - Thermometer

‫لغ‬ٌّٛ‫ٗ ثب‬١‫ضؼ‬ٌّٛ‫بط اٌؾشاسٖ ا‬١‫ش طشق ل‬ٙ‫اؽذ ِٓ اش‬ٚ ‫ؼزجش‬٠

Thermometer is one of the common instrument used to


measure the temperature locally and can be mounted on

Process Pipe line


Vessel
Compressor , Turbine , …

The theory of operation can be one of the following

Local Temperature Indicator

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Temperature Measurements

1.1.1 - Bimetal Thermometer ْ‫ اٌّؼذ‬ٟ‫ٓ اٌؾشاسح صٕبئ‬١‫ِج‬

Two different metal strip with different expansion coefficient are connected so
when temperature change a deformation in the strip happened which can be
converted to mechanical movement and reading

‫ؾذس‬٠ ٖ‫ش اٌؾشاس‬١‫ ػٕذ رغ‬ٚ ‫ّب ِؼبِالد رّذد ِخزٍفخ‬ٌٙ ٓ١‫ٓ ِخزٍف‬١ٔ‫د ِؼذ‬ٛ‫ع‬ٚ ٍٟ‫خ اٌّؼذْ ػ‬١‫ٕبد اٌؾشاسٖ صٕبئ‬١‫رؼزّذ ِج‬
‫ظ‬٠‫ اٌزذس‬ٍٟ‫خ ػ‬١‫ لشاءٖ خط‬ٌٟ‫ٍخ ا‬٠ٛ‫ّىٓ رؾ‬٠ ‫د‬ٚ‫رّذد ثزفب‬

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Temperature Measurements

1.1.2 - FILLED SYSTEM THERMOMETERS

These instruments operate on the principle that as the temperature increases, so too does the pressure as the
molecules in the fluid become more active. A spiral bourdon tube, similar to that used for pressure measurement, can
be used for temperature. The tube may contain either liquid or gas and as the temperature increases, so too does the
pressure causing the tube to uncoil and move the pointer to indicate the temperature.

‫زّذد‬٠ ‫ دسعخاٌؾشاسح‬ٟ‫ أخفبع ف‬ٚ‫س اسرفبع ا‬ٚ‫خ فؼٕذ ؽذ‬٠ٛ‫ثخ ٍِز‬ٛ‫ عبئً لبثً ٌٍزّذد داخً أج‬ٚ‫د غبص ا‬ٛ‫ع‬ٚ ٍٟ‫ع ػ‬ٌٕٛ‫رؼزّذ فىشح ػًّ ٘زا ا‬
.‫ اٌضغظ‬ٟ‫ ٔمض ف‬ٚ‫بدح ا‬٠‫ ر‬ٌٟ‫ب ا‬٠‫ اٌغبئً ِؤد‬ٚ‫ٕىّش اٌغبص ا‬٠ ٚ‫ا‬
ْ‫ إٌمظب‬ٚ‫بدح ا‬٠‫اء ثبٌز‬ٛ‫ش اٌمشاءح ع‬١١‫ رغ‬ٌٟ‫ ثبٌزب‬ٚ ْ‫ إٌمظب‬ٚ‫بدح ا‬٠‫اء ثبٌز‬ٛ‫خ ع‬٠ٛ‫ثخ اٌٍّز‬ٛ‫ رؾشن األٔج‬ٌٟ‫ ا‬ٞ‫ؤد‬٠ ْ‫ إٌمظب‬ٚ‫بدٖ ا‬٠‫ش اٌضغظ ثبٌز‬١١‫رغ‬

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Temperature Measurements
2- Remote Reading ( Thermocouple , RTD , … )
2.1 Thermocouple
A second, widely used, temperature indicating system is the thermocouple.
Two different metal welded . As temperature change on the junction mV generated
between two sides
ٓ١‫ٓ اٌطشف‬١‫ٌذ ث‬ٛ‫ٌذ ف‬ٛ‫ز‬٠ ‫خ‬١ٍ‫ ػ‬ٚ ‫ُ ِؼب‬ِٙ‫زُ ٌؾب‬٠ ٓ١‫ٓ ِخزٍف‬١١ٔ‫ٓ ِٓ ِؼذ‬١‫عٍى‬
.‫ دسعخ ؽشاسح ِمبثٍخ‬ٌٟ‫ٍخ ا‬٠ٛ‫ رؾ‬ٚ ‫بعخ‬١‫ّىٓ ل‬٠ ‫ٌذ‬ٛ‫ٌذ اٌّز‬ٛ‫ اٌف‬ٟ‫ش ف‬١‫ؾذس رغ‬٠ َ‫ش اٌؾشاسح ػٕذ ٔمطخ اٌٍؾب‬١‫ػٕذ رغ‬

Theory Of Operation

Thermo couple most commonly used in plant


ٟ‫بط اٌؾشاسد ف‬١‫ ل‬ٟ‫غزؼًّ ف‬٠ ٚ ‫ اٌّظٕغ‬ٟ‫ األوضش أزشبسا ف‬ٛ٘ ‫ع‬ٌٕٛ‫٘زا ا‬
...... ٚ ‫ط‬ٛ‫ اٌخط‬ٚ ‫اٌّؼذاد‬

Thermo couple used in synthesis , CO2 Compressor

ٟٔ‫خ داخً ضبغظ صب‬١‫ىبٔى‬١ٌّ‫بط ؽشاساد األعضاء ا‬١‫ ل‬ٟ‫ع ف‬ٌٕٛ‫غزؼًّ ٘زا ا‬٠
.‫ً اٌمشاءد‬١‫ ٌزغغ‬ٚ‫خ ا‬٠‫ رٌه ٌٍؾّب‬ٚ ْٛ‫ذ اٌىشث‬١‫اوغ‬
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Temperature Measurements

Thermo couple used in process air


compressor , Ammonia compressor

‫خ داخً ضبغظ‬١‫ىبٔى‬١ٌّ‫بط ؽشاساد األعضاء ا‬١‫ ل‬ٟ‫ع ف‬ٌٕٛ‫غزؼًّ ٘زا ا‬٠


.‫ً اٌمشاءد‬١‫ ٌزغغ‬ٚ‫خ ا‬٠‫ رٌه ٌٍؾّب‬ٚ ‫ب‬١ِٔٛ‫األ‬

Thermo couple used in All the turbines

ٚ ‫ٕبد‬١‫خ داخً اٌزشث‬١‫ىبٔى‬١ٌّ‫بط ؽشاساد األعضاء ا‬١‫ ل‬ٟ‫ع ف‬ٌٕٛ‫غزؼًّ ٘زا ا‬٠
.‫ً اٌمشاءد‬١‫ ٌزغغ‬ٚ‫خ ا‬٠‫رٌه ٌٍؾّب‬

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Temperature Measurements

2.2 RTD Resistance Temperature Detector

R = R0 ( 1 + α delta T )

This sensor depend on resistance which is function in temperature variation


3 wires to compensate length effect.

‫ش دسعخ اٌؾشاسح ؽغت اٌؼاللخ اػالح‬١١‫ش ِغ رغ‬١‫ب رزغ‬ٙ‫ّز‬١‫ِخ ل‬ٚ‫ِمب‬


‫ي اٌغٍه‬ٛ‫ش ط‬١‫ رٌه ٌّالشخ رأص‬ٚ ‫غزؼًّ صالس اعالن‬٠ ُ‫بص ػٓ غشفخ اٌزؾى‬ٙ‫ب اٌغ‬ٙ١‫جؼذ ف‬٠ ٟ‫ األِبوٓ اٌز‬ٟ‫ف‬

RDCS = Rm - RL RTD 3 Wires

R Rm DCS
RDCS
RL

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Temperature Measurements

2.3 Temperature Transmitter

ٚ‫ٌذ ا‬ٛ‫ ف‬ٛ٘ ً‫ْ اٌذخ‬ٛ‫ى‬٠ ‫خ‬١ٍ‫ ػ‬ٚ ‫ِبد اٌخبطخ ثخ‬ٍٛ‫ وً اٌّؼ‬ٚ ‫ظ‬٠‫ّخ اٌزذس‬١‫ ل‬ٚ ‫بص اٌؾشاسح‬ٙ‫ع ع‬ٕٛ‫ب ث‬ٙ‫زُ ثشِغز‬٠ ‫خ‬١ٔٚ‫ػجبسح ػٓ وبسرخ اٌىزش‬
ُ‫ ٔظبَ اٌزؾى‬ٌٟ‫بس ا‬١‫ْ خشط اٌز‬ٛ‫ى‬٠ ‫ ؽغت اٌؾشاسح‬ٚ ‫صع‬ٌّٛ‫ٌذ صبثذ ِٓ ٔظبَ اٌزؾىُ ا‬ٛ‫ ف‬24 ‫خ‬٠‫ اٌزغز‬ٚ ‫ع اٌؾغبط‬ٛٔ ‫ِخ ؽغت‬ٚ‫ِمب‬

Temperature Transmitters used in compressor House , NG Compressor

1- 24 Vdc from DCS


2- 4 – 20 mA

DCS
4-20 mA

24 Vdc

Temperature
Transmitter

Thermocouple / RTD

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Pressure Measurment

Pressure Measurements
‫قٕاص انضغـــــــــــــــــــــــــــــط‬

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Pressure Measurements

Overview

Measuring the pressure in any plant is one of the parameters required to keep the process in
certain conditions by the operators or by automatic control loop.

Pressure measurements are divided in to

Local Reading ( Pressure Indicator ) ‫لغ‬ٌّٛ‫ٓ اٌضغظ ثب‬١‫ِج‬

Operators in the field depend on local pressure indicator reading to record there
data in logging sheets
.‫ ٘زح اٌمشاءد‬ٍٟ‫زُ اٌزؾىُ ثٕبء ػ‬٠ ٚ ‫ساق‬ٚ‫ ا‬ٟ‫ً اٌمشاءد ف‬١‫ً ثزغغ‬١‫ اٌزشغ‬ٟٕ‫َ ف‬ٛ‫م‬٠ ‫ ٘زٖ اٌؾبٌخ‬ٟ‫ف‬

Remote Reading ( Pressure Transmitters )

Operators in control room depend on remote pressure measurement to


observe pressure and DCS system record it in trends.
The main benefit for remote pressure measurement is in pressure control loops
ُ‫ائش اٌزؾى‬ٚ‫ د‬ٟ‫ رغزؼًّ ف‬ٚ‫ْ ِغشد لشاءٖ أ‬ٛ‫ اِب رى‬ٚ ‫ اٌشبشبد‬ٍٟ‫مشاء لشأد اٌؾشاسح ػ‬٠ ً١‫ اٌزشغ‬ٟٕ‫ف‬

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Pressure Measurements

Local Reading ( Pressure Indicator )

The operator use the pressure indicator to record the


pressure in many items like

1- line pressure,………………..

2- vessel pressure ,……………

3- Tank pressure , ……………..

Theory of operation

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Pressure Measurements

Remote Reading ( Pressure Transmitter )

Used as remote reading to indicate on DCS or control the pressure on certain item or shutdown
plant, ….
ُ‫ز‬٠ ٟٔٚ‫ عضء اٌىزش‬ٚ ‫ٌذ‬ٛ‫ٌذ ف‬ٛ‫ز‬٠ ‫ب‬ٙ١ٍ‫ب ِبدح ػٕذ اٌضغظ ػ‬ٍٙ‫بط ثذاخ‬١‫ْ ِٓ غشفخ ل‬ٛ‫زى‬٠ ٚ ‫بص ٌمشاءح اٌضغظ‬ٙ‫غزؼًّ ٘زا اٌغ‬٠
...... ٚ ‫ظ‬٠‫ اٌزذس‬ٚ ‫ اٌؾشاسح‬ٚ ‫ش اٌضغظ‬١‫ً ِٓ ؽ‬١‫ثشِغزخ ثبٌّذخالد اٌخبطخ ثبٌزشغ‬
.,‫ّخ اٌضغظ‬١‫مبثً ل‬٠ ‫ش‬١‫ اِج‬ٍٍِٟ ‫َ اٌىبسرخ ثأخشاط‬ٛ‫ب رم‬ٙ١ٍ‫ِبد اٌّخضٔخ ػ‬ٍٛ‫ اٌّؼ‬ٚ ‫ٌذ‬ٛ‫َ اٌىبسرخ ثمشاءح اٌف‬ٛ‫خ رم‬١ٍ‫ ػ‬ٚ
.‫ اٌخشط‬ٚ ‫ٓ اٌضغظ‬١‫خ ث‬١‫اٌؼاللخ خط‬

1- Needs Input power 24 vdc

2- Two wires technique

EMERSON pressure transmitter 20


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Flow Measurements

Flow Measurements
‫قٕاص معذل‬
‫انســـــــــــــــــــــزٔان‬

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Flow Measurements

1- Local Reading

Local reading is used to give flow indication for the operator locally.

1.1- Variable Area Flow Meter

Type : KROHNE

‫ضؼ اػالح‬ٌّٛ‫بْ ؽغت اٌشىً ا‬٠‫خ اٌغش‬١ّ‫ثخ اٌشىً ِظّّخ ؽغت و‬ٍٛ‫خ ِغ‬١ٍ‫اِخ داخ‬ٛ‫ك ػ‬٠‫خ ػٓ طش‬١ّ‫بص ثمشاءح اٌى‬ٙ‫َ ٘زا اٌغ‬ٛ‫م‬٠
ْ‫ب‬٠‫خ اٌغش‬١ّ‫ رؼبدي و‬ٟ‫ اٌمشاءح اٌز‬ٌٟ‫زؾشن اٌّؤشش ا‬٠ ٌٟ‫ ثبٌزب‬ٚ ‫اِخ‬ٛ‫زأصش ثؾشوخ اٌؼ‬٠ ‫ظ‬١‫ٓ اٌمشاءح ثٗ ِغٕبط‬١‫ِج‬
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Flow Measurements

1.2- Target Flow Meter

ٚ ‫اثخ‬ٛ‫زؾشن ؽغت اٌج‬٠ ‫ اٌّؤشش‬ٌٟ‫ ثبٌزب‬ٚ ْ‫ب‬٠‫خ اٌغش‬١ّ‫اثخ رزؾشن ؽغت و‬ٛ‫ ٘زح اٌج‬ٚ ‫ظ‬١‫ب ِغٕبط‬ٙ‫اثخ ث‬ٛ‫َ اٌغبئً ثذفغ ث‬ٛ‫م‬٠
ْ‫ب‬٠‫مشاء ِؼذي اٌغش‬٠ ‫ اٌّؤشش‬ٌٟ‫ثبٌزب‬

Heinrich

Theory Of Operation

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Flow Measurements

Remote Reading

Remote reading is used to give flow reading to control system either as indication or control principle

There are several methods for flow measurements

1- Delta P Flow Mater.


2- Magnetic Inductive Flow Mater.
3- Vortex Flow Meter.

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Flow Measurements

Remote Reading
2.1- Delta P Flow Meter.

F α K SQR ( Delta P )
There are several elements are used to create delta P to measure the flow some of them are

. Flow Element
1. Orifice Plate
This operates on the principle that there is a difference in pressure created across an
orifice plate when flow is present.

ٟ‫ فمذاْ ف‬ٌٟ‫ ا‬ٞ‫ؤد‬٠ ْ‫ب‬٠‫ اٌغش‬ٟ‫ش ف‬١‫بص ثؼًّ اخزٕبق طغ‬ٙ‫َ ٘زا اٌغ‬ٛ‫م‬٠
ْ‫ب‬٠‫ ِؼذي اٌغش‬ٍٟ‫ؤصش ػ‬٠ ‫ش ال‬١‫بْ ثؾ‬٠‫خ اٌغش‬١ّ‫اٌضغظ ِظُّ ؽغت و‬

‫ش‬١‫ اِج‬ٍٍِٟ ‫ٍخ اي‬٠ٛ‫َ ثزؾ‬ٛ‫م‬٠ ٚ ٟٔٚ‫بص اٌىزش‬ٙ‫ك ع‬٠‫ٌذ ػٓ طش‬ٛ‫بط فشق اٌضغظ اٌّز‬١‫زُ ل‬٠

25
MISR FERTILIZERS PRODUCTION COMPANY

Flow Measurements

Remote Reading

Flow Element

Orifice Plate

Isolation Valves

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MISR FERTILIZERS PRODUCTION COMPANY

Flow Measurements

Remote Reading

Flow Element

2. VENTURI

The venturi also operates on the pressure differential principle where there is a flow restriction. It
gives a low pressure loss for the measurement of all kinds of fluids.

VENTURI

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‫‪MISR FERTILIZERS PRODUCTION COMPANY‬‬

‫‪Flow Measurements‬‬

‫‪Remote Reading‬‬
‫‪٠‬غزؼًّ ٘زا اٌغ‪ٙ‬بص ٌمشاءح ِؼذي اٌغش‪٠‬بْ ‪٠ ٚ‬زى‪ ِٓ ْٛ‬غشفخ ل‪١‬بط ثذاخٍ‪ٙ‬ب ِبدح ػٕذ ؽذ‪ٚ‬س فشق ضغظ ػٍ‪ٙ١‬ب ‪٠‬ز‪ٌٛ‬ذ ف‪ٌٛ‬ذ ‪ ٚ‬عضء اٌىزش‪ٟٔٚ‬‬
‫‪٠‬زُ ثشِغزخ ثبٌّذخالد اٌخبطخ ثبٌزشغ‪ ِٓ ً١‬ؽ‪١‬ش اٌضغظ ‪ ٚ‬اٌؾشاسح ‪ ٚ‬اٌزذس‪٠‬ظ ‪...... ٚ‬‬
‫‪ ٚ‬ػٍ‪١‬خ رم‪ َٛ‬اٌىبسرخ ثمشاءح اٌف‪ٌٛ‬ذ ‪ ٚ‬اٌّؼٍ‪ِٛ‬بد اٌّخضٔخ ػٍ‪ٙ١‬ب رم‪ َٛ‬اٌىبسرخ ثأخشاط ٍٍِ‪ ٟ‬اِج‪١‬ش ‪٠‬مبثً ل‪ّ١‬خ ِؼذي اٌغش‪٠‬بْ‪ ,‬اٌؼاللخ غٕز‬
‫خطٕت ث‪ ٓ١‬فشق اٌضغظ ‪ِ ٚ‬ؼذي اٌغش‪٠‬بْ‪.‬‬

‫) ‪F α K SQR ( Delta P‬‬


‫‪Type : EMERSON‬‬
‫‪Delta P Flow Transmitter.‬‬

‫‪1-‬‬ ‫‪24 Vdc power‬‬

‫‪2-‬‬ ‫‪4 – 20 mA‬‬

‫‪3- Non linear Flow measurement‬‬

‫‪High Pressure Sample Line‬‬

‫‪Low Pressure Sample Line‬‬


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‫‪MISR FERTILIZERS PRODUCTION COMPANY‬‬

‫‪Flow Measurements‬‬

‫‪2.2- Magnetic Inductive Flow Meter .‬‬

‫‪Type : KROHNE‬‬

‫رؼزّذ فىشح ػًّ اٌغ‪ٙ‬بص ػٍ‪ ٟ‬اْ ‪٠‬ى‪ ْٛ‬اٌغبئً اٌّشاد ل‪١‬بط ِؼذي عش‪٠‬بٔخ ٌخ ر‪ٛ‬ط‪١ٍ١‬خ و‪ٙ‬شث‪١‬خ‬
‫ِؼ‪ٕ١‬خ ‪ ٚ‬ػٍ‪ٚ ٟ‬ع‪ٛ‬د ٍِف و‪ٙ‬شث‪ ٚ ٟ‬لطج‪ِ ٟ١‬غٕبط‪١‬ظ فؼٕذ ِش‪ٚ‬س اٌغبئً ث‪ ٓ١‬لطج‪ٟ١‬‬
‫اٌّغٕبط‪١‬ظ ‪٠‬ؾبو‪ٚ ٟ‬ع‪ٛ‬د عغُ ِؼذٔ‪ ٚ ٟ‬ثبٌزبٌ‪ ٟ‬رز‪ٌٛ‬ذ ل‪ٛ‬ح دافؼخ و‪ٙ‬شث‪١‬خ ث‪ ٓ١‬اطشاف اٌٍّف‪.‬‬
‫‪٠‬زُ ل‪١‬بع‪ٙ‬ب ‪ ٚ‬ثبٌزبٌ‪ ٟ‬رؾ‪ٍٙ٠ٛ‬ب ف‪ ٟ‬د‪ٚ‬ائش اٌىزش‪١ٔٚ‬خ ِجشِغخ اٌ‪ ٍٍِٟ ٟ‬اِج‪١‬ش ‪٠‬ؾبو‪ِ ٟ‬ؼذي‬
‫اٌغش‪٠‬بْ ‪ ٚ‬انعالقت خطٕت‪.‬‬
‫‪1-‬‬ ‫‪24 Vdc power‬‬
‫‪2-‬‬ ‫‪4 – 20 mA‬‬
‫‪3-‬‬ ‫‪linear Flow measurement‬‬

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‫‪MISR FERTILIZERS PRODUCTION COMPANY‬‬

‫‪Flow Measurements‬‬

‫‪Remote Reading‬‬

‫‪2.3 - Vortex Flow Meter‬‬

‫‪Vortex Internal‬‬

‫‪Theory Of Operation‬‬

‫ل‪١‬بط ِؼذي اٌغش‪٠‬بْ ػٓ طش‪٠‬ك اٌز‪١‬بساد اٌذ‪ٚ‬اِ‪١‬خ ؽ‪١‬ش ‪٠‬زُ ‪ٚ‬ضغ ػبئك داخً اٌغ‪ٙ‬بص وّب ٘‪ِٛ ٛ‬ضؼ ثبٌشىً ‪٠‬ؾذس ٔ‪ٛ‬ع ِٓ‬
‫اٌذ‪ٚ‬اِبد رخزٍف وّ‪١‬ز‪ٙ‬ب ؽغت ِؼذي اٌغش‪٠‬بْ ‪٠ ٚ‬زُ ل‪١‬بط اٌم‪ٛ‬ح إٌبشئخ ِٓ ٘زٖ اٌذ‪ٚ‬اِبد ػٓ طش‪٠‬ك ؽغبط داخٍ‪ِ ٟ‬شوت ف‪ٟ‬‬
‫اٌغ‪ٙ‬بص ‪٠‬م‪ َٛ‬ثزؾ‪ٍٙ٠ٛ‬ب اٌ‪ ٟ‬ف‪ٌٛ‬ذ ‪ّ٠‬ىٓ لشاءرخ ‪ ٚ‬اٌزؼج‪١‬ش ػٕٗ ف‪ ٟ‬دائشح اٌىزش‪١ٔٚ‬خ ِشِغخ اٌ‪ِ ٟ‬ؼذي عش‪٠‬بْ ‪ ٚ‬انعالقت خطٕت‪.‬‬
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MISR FERTILIZERS PRODUCTION COMPANY

Level Measurements

Level Measurements
ُْ‫قٕاص انمسخــــــــــــــــــــــــ‬

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MISR FERTILIZERS PRODUCTION COMPANY

Level Measurements

1- Local Reading ( PHONix Level Indicator )

Isolation Valve
Isolation Valve

Level Indicator

Level Indicator
Isolation Valve

Isolation Valve

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‫‪MISR FERTILIZERS PRODUCTION COMPANY‬‬

‫‪Level Measurements‬‬

‫رؼزّذ ٔظش‪٠‬خ اٌؼًّ ػٍ‪ٚ ٟ‬ع‪ٛ‬د ػ‪ٛ‬اِخ ( ثذاخٍ‪ٙ‬ب ِغٕبط‪١‬ظ) ثذاخً اٌغشفخ رزؾىشن اٌ‪ ٟ‬اػٍ‪ ٟ‬ا‪ ٚ‬اعفً ِغ رغ‪١١‬ش اٌّغز‪ ٚ ٞٛ‬ػٍ‪ٚ ٟ‬ع‪ٛ‬د ِج‪ٓ١‬‬
‫ِٓ اٌضعبط ‪ ٚ‬األ‪ٚ‬ساق اٌّؼذٔ‪١‬خ فؼٕذ رؾشن اٌؼ‪ٛ‬اِخ اٌ‪ ٟ‬ا‪ ٞ‬ارغبح رم‪ َٛ‬األ‪ٚ‬ساق اٌّؼذٔ‪١‬خ ثزغ‪١١‬ش ا‪ٚ‬ضبػ‪ٙ‬ب ثزأص‪١‬ش اٌم‪ٛ‬ح اٌّغٕبط‪١‬غ‪ ٚ ٗ١‬ثبٌزبٌ‪ ٟ‬رج‪ٓ١‬‬
‫اٌّغ‪ٛ‬ة‪.‬‬

‫األ‪ٚ‬ساق اٌّؼذٔ‪١‬خ‬

‫اٌؼ‪ٛ‬اِخ اٌّغٕبط‪١‬غ‪١‬خ‬

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MISR FERTILIZERS PRODUCTION COMPANY

Level Measurements

2- Remote Reading Level Transmitter


Level transmitters used to measure the level inside Tank , Condenser , …
Method of level measurements
2.1- Displacer Level Transmitter
V= r2 1- 24 V dc Power
W0 = W - ρ1 * V 2- 4 -20 mA

ُ‫ اْ اٌغغ‬ٟ٘ ٚ ٛ‫ذط ٌٍطف‬١ّ‫ لبػذح اسش‬ٍٟ‫خ اٌؼًّ ػ‬٠‫رؼزّذ ٔظش‬


W100 = W 0- ρ2 * V ‫صْ اٌغبئً اٌّضاػ‬ٚ ٞٚ‫ح دفغ رغب‬ٛ‫خ ل‬١ٍ‫ٌذ ػ‬ٛ‫ عبئً رز‬ٟ‫س ف‬ّٛ‫اٌّغ‬
‫خ‬١‫خ األسض‬١‫ ػغٍخ اٌغبصث‬ٟ‫ة ف‬ٚ‫ِضش‬

ρ1

ρ2
L = Displacer Length
Torque Tube
V= Displacer Volume chain
W= Displacer Weight ‫سهسهت‬

r = Displacer Radius
Electronic
ρ1= Fluid Density Above Displacer
‫انعُامت‬
ρ2= Fluid Density Blow
ρ=m/v
g = 9.8 N/m2 ‫ اٌىزٍخ‬/ُ‫اٌىضبفخ = اٌؾغ‬
Eckardt Smart Level Transmitter
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MISR FERTILIZERS PRODUCTION COMPANY

Level Measurements

2.2 - dp Level Transmitter

2.2.1 wet leg transmitter

dp = ρ2*hx*9.8 - 1000*h*9.8

ρ1 = 1000 kg/m3
1- 24 V dc Power
P 2- 4 -20 mA
Vapor Water Inside 3- Negative Range

hx
Fluid ρ2

+ -

dp Transmitter 35
MISR FERTILIZERS PRODUCTION COMPANY

Level Measurements

2.2.2 Chemical Seal dp transmitter

Vapor

hx Fluid ρ2

dp = ρ2*hx*9.8 - ρso*h*9.8
+ -
dp Transmitter
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MISR FERTILIZERS PRODUCTION COMPANY

Level Measurements

2.3 - Guided Wave Radar Level Transmitter


High frequency microwave pulses are guided along a steel rod. When reaching the product surface, the
microwave pulses are reflected. The running time is evaluated by the instrument and outputted as distance.

‫ ثغطؼ‬ٟ‫ٍزم‬٠ ٟ‫ ؽز‬ٞ‫ذ‬٠‫د ؽذ‬ّٛ‫ِخ داخً ػ‬ٛ‫ْ ِؾى‬ٛ‫خ رى‬١ٌ‫ُ ػب‬١‫ػخ ِٓ اٌزشدداد ثم‬ّٛ‫بص ثأسعبي ِغ‬ٙ‫َ اٌغ‬ٛ‫م‬٠
.ٞٛ‫زُ ؽغبة اٌّغز‬٠ ‫ اعزمجبٌخ‬ٌٟ‫لذ اسعبي اٌزشدد ا‬ٚ ِٓ ِٓ‫بط اٌض‬١‫ ثم‬ٚ ‫د‬ّٛ‫شرذ داخً اٌؼ‬١‫اٌغبئً ف‬

Type : Vega

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‫‪MISR FERTILIZERS PRODUCTION COMPANY‬‬

‫‪Level Measurements‬‬

‫‪2.4- Servo Level Gauge‬‬

‫جٍاس قٕاص انمسخُِ فّ حىك األمُوٕا بانُحذة‪َٔ 81‬عزف بإسم جٍاسانـ ‪: ENRAF‬‬

‫رؼزّذ فىشح ػًّ ٘زا اٌغ‪ٙ‬بص ػٍ‪ ٝ‬إؽغبط‬ ‫‪‬‬


‫اٌغ‪ٙ‬بص ثبٌزغ‪١‬ش ف‪ ٝ‬ل‪ٛ‬ح دفغ اٌغبئً ٌٍؼ‪ٛ‬اِخ‪ٚ‬اٌز‪ٝ‬‬
‫رى‪ِ ْٛ‬زظٍخ ثغٍه ِشْ ‪ٚ‬ل‪ِ ٜٛ‬زظً ثذ‪ٚ‬سٖ ث‪ٛ‬ؽذح‬
‫اٌـ‪ٚ Measurement Drum‬ػّذ ٘زا اٌذسَ ِزظً‬
‫ثّ‪ٛ‬ر‪ٛ‬س خط‪ٛ‬ح ‪Stepping Motor‬‬

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MISR FERTILIZERS PRODUCTION COMPANY

Valves

Valves and Valve accessories

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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Valves Types

1- Global Valve

2- Butterfly Valve

3- Ball Valve

4- Gate Valve
MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Valves Failure Types

1- Failure Close

2- Failure Open

3- Failure Last Position


MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Valve Accessories
1- Positioner
ٍٍِٟ ‫ اشبسح‬ٚ ‫ ثبس‬4.5 ‫خ‬٠‫اء رغز‬ٛ٘ ‫ك‬٠‫ فزؾخ اٌجٍف ػٓ طش‬ٟ‫بص ثبٌزؾىُ ف‬ٙ‫َ اٌغ‬ٛ‫م‬٠
‫ اٌجٍف‬ٌٟ‫اء ا‬ٛ٘ ‫ خشط‬ٚ ‫ة ٌفزؾخ اٌجٍف‬ٍٛ‫ّخ اٌّط‬١‫ش ِٓ غشفخ اٌزؾىُ رؼزجش اٌم‬١‫اِج‬
‫خ‬١‫خ اٌؼىغ‬٠‫ك صساع اٌزغز‬٠‫خ رزُ ػٓ طش‬١‫خ اٌؼىغ‬٠‫خ اٌغز‬٠‫ اٌزغز‬.‫ٌفزؼ اٌجٍف‬
Eckardt Positioner
Positioner is used to control valve stroke to certain
position given by set point ( 4 – 20 mA ) sent by DCS
The Positioner acts like controller which has input from
FEED BACK ARM and SETPOINT from DCS ( 4-20 mA )
And the OUTPUT ( 0 – 4.5 Bar )
Input Supply : 4.5 Bar
Input Signal : 4 - 20 mA
Output Signal : 0 - 4.5 Bar

Samson Positioner

Neles Positioner
MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Valve Actuator

Details Connection

‫بط اٌؾشوخ‬١‫صساع ل‬
‫خ‬١ٍ‫اٌفؼ‬

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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Actuator

Output Signal

Input Supply

Valve Hookup And Connection


FV - 302401 44
MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Actuator

Positioner

4-20 mA ( Set point) from DCS

Valve Stem Feed Back Arm

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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Life Video Simulation for Valve Motion

This video shows a simulation for valve motion done in the Lab

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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

2- Solenoid Valve
Solenoid valve is used to control valve in case of
emergency shutdown to let the valve in the safe position

Solenoid is pneumatic relay controlled by supply voltage


As shown in figure we have two types of solenoid valve

3/2 Solenoid Valve : Used to control valves with spring action actuator
5/2 Solenoid Valve : Used to control valves with double action actuator

P = Input Supply Air


A = Output Air to Actuator
R = Vent to Air
Supply Voltage 24 vdc or 220 Vac
3/2 Solenoid Valve

5/2 Solenoid Valve

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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Solenoid Valve

Input Supply
Output Signal

Supply Voltage 24 Vdc

Solenoid Valve Hook Up


Solenoid Valve Hookup
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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

3- Booster ( Pneumatic Amplifier ) ٗ١‫ائ‬ٌٛٙ‫ِىجش األشبسٖ ا‬

Booster is used to increase the air quantity supplied to the


valve actuator with the same pressure

When we use Booster In control Valve ?

We use Booster when we control valve with Large


actuator to achieve optimum valve response

Input from positioner P1 P1 Output To Actuator


Q1 Booster Q2

Air Header
P = 4.5 Bar Q > Q2 > Q1
Q Header Flow

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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Booster Installed between positioner and actuator to increase positioner flow

Type : Fisher Actuator

Positioner Output

Positioner Output Booster Valtek Type

Air Supply
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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Type : Eckardt Type : Valtek

Type : Fisher Type : SMC

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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

4- Quick Exhaust

Quick Exhaust is used to vent air from actuators with large size to achieve safe position
in certain specified time in most cases < 3 sec.

What is the difference between Solenoids and Quick exhaust ?

Solenoid Valve Quick Exhaust


Power Electric Power Pneumatic Power
Valve Actuator Not Big Size Big Size

Solenoid Valve is used to control quick exhaust to achieve safe position.

Due to different in actuator size , in some cases where solenoid will vent actuator air in time > 3 sec
which is not safe in trip sequence we need to vent it in T < 3 sec to achieve safe trip sequence so we
use Pneumatic Quick Exhaust

When we use Quick exhaust In control Valve ?

We use Quick Exhaust when we want achieve safe position for a valve in T< certain time
which can not be achieved by solenoid valve.
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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Type : MAC

Input from
Positioner Or
Booster

Output From Quick


Exhaust To Valve

Pilot Signal From


Solenoid

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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup
Hookup with Positioner Quick Exhaust Solenoid Valve

Vent

24 Vdc Solenoid
Air Supply Valve

Pilot Output

Quick
Positioner
Exhaust
To Actuator

4-20 mA Set point


From DCS

Theory Of operation
The quick exhaust has three ports
Input
Output
Pilot
Vent
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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Theory Of Operation

Pneumatic Solenoid with Pilot operation


As pilot input is pressurized with normal pressure the input will pass to output which is the actuator .

In case of Pilot input is not pressurized the accumulated air in actuator will be vented to air causing the
valve to fail.

Controlling the Pilot can be done through Solenoid , Direct from air Header, …

Quick Exhaust Theory Of Operation


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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Hookup with Positioner Quick Exhaust Solenoid Valve

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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

5 – Lockup Relay

Lockup relay is used in case of Failure Last position Valve to keep air inside actuator

Lockup Relay

Type : Fisher
Type : SMC
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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Hookup with Positioner Lockup Solenoid Valve Vent

24 Vdc Solenoid
Air Supply Valve

Pilot
To Actuator
Lockup
Positioner
Relay

4-20 mA Set point


From DCS

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MISR FERTILIZERS PRODUCTION COMPANY

Valves Hookup

Theory Of Operation

Pneumatic Solenoid with Pilot operation


As pilot input is pressurized with normal pressure the input will pass to output which is the actuator .

In case of Pilot input is not pressurized the accumulated air in actuator will be Locked in actuator

Controlling the Pilot can be done through Solenoid , Direct from air Header, …

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MISR FERTILIZERS PRODUCTION COMPANY

Turbine Speed Controller (Woodward)

Turbine Control

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MISR FERTILIZERS PRODUCTION COMPANY

Turbine Speed Controller (Woodward) .Axial Displacement . Radial Vibration

This speed controller is used to control turbine speed by


controlling steam inlet to turbine

Woodward Speed Controller

ُ‫ك اٌزؾى‬٠‫ رٌه ػٓ طش‬ٚ ٕٗ١‫ عشػٗ اٌزشث‬ٟ‫مٗ ف‬٠‫زُ اٌزؾىُ ػٓ طش‬٠
‫ي ثٍف اٌجخبس‬ٛ‫ فزؾٗ دخ‬ٟ‫ف‬

Input : Speed from probes as frequency


‫سٖ رشدداد‬ٛ‫ ط‬ٟ‫بط اٌغشػٗ ف‬١‫ ِٓ ؽغبعبد ٌم‬ٟ‫أر‬٠ ُ‫اٌذخً ٌٍّزؾى‬

Output : mA ( 4 – 20 mA) to CPC Current Pressure Converter


‫ش‬١‫ اِج‬ٍٍِٟ 20 – 4 ٟ‫شث‬ٙ‫بس و‬١‫ط ػجبسٖ ػٓ ر‬ٚ‫اٌخش‬

Power : 24 Vdc
‫ش‬١‫ٌذ ِزغ‬ٛ‫ ف‬220 ٗ٠‫اٌزغز‬

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MISR FERTILIZERS PRODUCTION COMPANY

Turbine Speed Controller (Woodward) .Axial Displacement . Radial Vibration

‫احجاي انفخح‬
‫بهف انخحكم فٓ دخُل انبخار‬
HP Valve

‫بخار‬

24 Vdc ً‫حساساث قٕاص انسزع‬


2 – 4 Bar Speed Sensors

‫محُل انخٕار انكٍزبٓ انٓ ضغط‬ Turbine


CPC Current Pressure Converter

Woodward Speed Controller

‫انخزَج‬ ‫ماء مخكاثف‬


Speed Condensate
4-20 mA
Controller MV ‫انذخُل‬

‫سٔج انخحكم‬ 24 Vdc


Control oil 9 bar

Set point DCS

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MISR FERTILIZERS PRODUCTION COMPANY

Turbine Speed Controller (Woodward) .Axial Displacement . Radial Vibration

1- Speed Probes , axial displacement , radial vibration

‫ٌذي انحساساث حسخعمم فٓ قٕاص انسزعً َ انمسافت َ األٌخشاساث‬

‫فكزي انعمم‬

‫حخكُن دائزي قٕاص انسزعً َ انمسافً َ األٌخشاساث مه ثالد عىاصز رئٕسٕت‬

1- Proximitor
2- Extension Cable Proximitor
3- Probe

Probe

Extension Cable

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MISR FERTILIZERS PRODUCTION COMPANY

Turbine Speed Controller (Woodward) .Axial Displacement . Radial Vibration

The picture show complete connection for Probe , Extension Cable , Proximitor

RF Signal ‫ذ‬١ٌٛ‫َ ثز‬ٛ‫م‬٠ ٞ‫ٌذ ِغزّش اٌز‬ٛ‫ ف‬24- ‫زٗ ثــــ‬٠‫زُ رغز‬٠ Proximitor ‫اٌـــــ‬
‫ش ؽغت‬١‫ اٌضبغظ ؽ‬ٚ‫ٕٗ ا‬١‫د اٌزشث‬ّٛ‫ ػ‬ٌٟ‫ب ا‬ٙ‫َ ثجض‬ٛ‫م‬٠ ٚ ‫ش خالي اي اٌؾغبعبد‬١‫رغ‬
ُ‫ز‬٠ ‫ش‬١‫ ؽ‬Proximitor ٌٟ‫شرذ ا‬٠ ‫ اٌغضء األخش‬ٚ ‫زُ اِزظبص عضء‬٠ ‫ثؼذٖ ػٓ اٌؾغبط‬
‫ اٌغشػٗ ؽغت اٌىبسربد‬ٚ‫ األ٘زضاصاد ا‬ٚ‫ؼجش ػٓ اٌّغبفٗ ا‬٠ ‫ٌذ‬ٛ‫ ف‬ٌٟ‫ً ٘زا اٌغضء ا‬٠ٛ‫رؾ‬
Bently Nevada ٟ‫دٖ ف‬ٛ‫ع‬ٌّٛ‫ا‬

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MISR FERTILIZERS PRODUCTION COMPANY

Turbine Speed Controller (Woodward) .Axial Displacement . Radial Vibration

Axial Displacement Probes Speed Probes

Radial Vibration Probes Over Speed Probes


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MISR FERTILIZERS PRODUCTION COMPANY

Turbine Speed Controller (Woodward) .Axial Displacement . Radial Vibration


2- CPC (Current Pressure Converter ) ‫ذ‬٠‫ ضغظ اٌض‬ٌٟ‫بس ا‬١‫ي اٌز‬ٛ‫ِؾ‬

HP Valve Output 2 – 4 Bar

‫انٓ بهف انبخار‬ To Actuator HP valve

Hydraulic Servo Motor

4-20 mA
From Woodward CPC ‫محُل انخٕار انكٍزبٓ انٓ ضغط‬

CPC Current Pressure Converter

Control Oil 9 Bar


24 Vdc

Drain
Hydraulic Servo Motor
‫ فزؾخ اٌجٍف‬ٟ‫َ ثبٌزؾىُ ف‬ٛ‫م‬٠ ‫ش‬١‫ ؽ‬Positioner ‫َ ِمبَ اٌـــ‬ٛ‫م‬٠
CPC . ‫ذ‬٠‫ك ضغظ اٌض‬٠‫ػٓ طش‬ 66
MISR FERTILIZERS PRODUCTION COMPANY

END

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