VOCATIONAL TRAINING

REPORT
SAIL ISP-BURNPUR

SUBMITTED BY

AKRIT PRASAD

BRANCH

ELECTRONICS AND COMMUNICATIONS

GREATER NOIDA INSTITUTE OF

TECHNOLOGY
 INTRODUCTION

 Instrumentation department at ISP came into existence on the

11th March, 2011 as essential need for an independent
Instrumentation department was envisagedfor smooth running
of the new state-of- the-art 2.5 MT Plant.
 The department is divided into 5 Zones and 11 sections.
There are 33 Duty Posts to cater to the process
monitoring and control needs of different shops of IISCO
Steel Plant.
 section Each has a team of engineers and technicians
working in close tandem with the operation personnel on
a round-the -clock basis for meeting the
departmentobjective.


DEPARTMENT OBJECTIVE

To ensure 100% availability & reliability of Process

Parameter Measurements, Interlocks, Protections and
Control Systems for safe operation and resource
optimization leading to enhanced quality and
productivity in all sections of the Plant.
 Roles and Responsibilities
 Interlock and Protection systems related to process
control

 Testing, Calibration & Maintenance of Level, Temp,

Flow, Differential Pressure, Pressure measurement
transmitters and turbo visory systems

 Level#1 control systems (DCS & PCS) related

toprocess

 Process Gas/Liquid Analyzers & Gas detectors

 Moisture/Humidity Analyzers and

calorific(CV)value Analyzers
 Vibration Monitoring/ Protection systems

 Flame Detectors/Scanners

 Positioners, I/P Converters, Air Lock

Relays, limit switches of Pneumatic
Control Valves/Power Cylinders
 Testing, calibration and repair of
instruments and temperature measuring
lances at Laboratory/Instrument Repair
Shops

 Dip type temperature measurement system.

 THERMOCOUPLE

When 2 dissimilar metals are joined together to

form a junction, an emf is produced which is
proportional to the temperature being sensed.
TEMPERATURE MEASUREMENT

TYPICAL INSTALLATIONS
 PRESSURE TRANSMITTER

A transducer creates a low-level electronic signal in

response to changes in applied or differential
pressure. As with transmitters, transducers feature
an internal sensor that converts the applied force
into an electrical signal, from which the
measurement is derived.

 Transmitters for measuring pressure or

differential pressure, comprise two basic parts. A
primary element directly or indirectly in contact with
the process collects the measurement, while a
secondary electronics package translates the output
from the primary element into a standard 4-20mA dc
output signal.
 These secondary electronics are highly
sophisticated and perform many functions
that transducers cannot. Variations in
process or ambient conditions measured by
the primary sensor can be automatically
compensated for before being converted
into a 4-20mA signal. Thus giving a stable
output.
FLOW MEASUREMENT

DIFFERENT METHODS

 Differential Pressure Sensing

element:

 1. Orifice Plates
 2. Flow Nozzles
 3. Venturi Tubes

1. Ultrasonic flow meter

2. Variable Area Rotameters
 FLOW MEASUREMENT
Orifice Plate

With an orifice plate, the fluid flow is measured

through the difference in pressure from the
upstream side to the downstream side of a
partially obstructed pipe. The plate obstructing
the flow offers a precisely measured obstruction
that narrows the pipe and forces the flowing
fluid to constrict
 FLOW MEASUREMENT

Venturi Tube

Due to simplicity and dependability, the Venturi

tube flowmeter is often used in applications
where it's necessary with higher turndown rate,
or lower pressure drops, than the orifice plate
can provide.
 FLOW MEASUREMENT

Electromagnetic Flowmeter

An electromagnetic flowmeter operate on

Faraday's law of electromagnetic induction that
states that a voltage will be induced when a
conductor moves through a magnetic field. The
liquid serves as the conductor and the magnetic
field is created by energized coils outside the flow
tube.
INSTALLATIONS
VARIOUS SECTION UNDER INSTRUMENTATION
DEPARTMENT:
Power & Blowing Station

 maxDNA DCS System for

Monitoring of overall
Instrumentation system of PBS-02.
(62 nos. of CPU)
 Turbolog PLC system for
Monitoring of Instrumentation
system of Blowers. (9 nos. of CPU)
 Turbosupervisory
Instrumentation for condition
monitoring of turbines and
blowers.(8nos.)
 Vibration Monitoring System of
BFPs(4nos) & ID FD Fans (12nos)
Blast Furnace

 Siemens and Yokogawa PLC based

PCI & BF Gas Analyzers (9 Nos.)
 Stove Dome Temperature
measurement system (3 Nos.)
 Gas Analyzers – CO, CO, H2,O2
 (9 Nos.)
 Amanoscope (1 No)
 Gas air Ratio Control in Stoves
 Top pressure AG control and BF gas
network pressure control
 Radar Based Stock level measurement
system (2 Nos.)
Major Highlights
Up-gradation of PLC systems of Exhauster #3
& 4 of COB#10 from MAN TURBO to
SIEMENS PLC.
Development of DCS modules testing and In
House DCS training facility.
Development of UPV & TLMS.
Relocation of REST panels (02 Nos.) of
Tundish car in CCP.