By AMIR ABD ELRAHMAN ABD ELSAMAD Supervisor Dr. ZAKARIA ANWAR ZAKARIA

116 Pages·2017·4.26 MB·English

(cid:1)(cid:4)(cid:5)(cid:6)(cid:7)ا (cid:10)(cid:11)(cid:5)(cid:6)(cid:7)ا (cid:12)ا (cid:1)(cid:2)(cid:3)
Sudan University of Science &Technology
College of Graduate Studies

(cid:3)(cid:4)(cid:5)(cid:6)(cid:7)(cid:8)ا (cid:10)(cid:11)(cid:12)(cid:13)(cid:8)ا م(cid:15)(cid:16)(cid:17) ما(cid:18)(cid:19)(cid:13)(cid:20)(cid:15)(cid:21) م(cid:15)(cid:19)(cid:8)ا (cid:22)(cid:23)(cid:24)(cid:8)ا ت(cid:15)(cid:17)ا(cid:26)(cid:27) (cid:28)(cid:29)(cid:5)(cid:23)(cid:30)و ء!(cid:4) "#$(cid:7)%
(cid:22)(cid:23)(cid:24)(cid:8)ا ل'() *+ عز'(cid:7)(cid:8)ا
Process of Crude Oil Tanks Filling and Discharging
Using Distributed Control System (DCS) at Oil Fields

A Thesis Submitted as a Partial Fulfillment of the requirements
for the degree of master in Mechatronic Engineering

By
AMIR ABD ELRAHMAN ABD ELSAMAD

Supervisor
Dr. ZAKARIA ANWAR ZAKARIA

January 2017

1
(cid:1)(cid:4)(cid:5)(cid:6)(cid:7)ا (cid:10)(cid:11)(cid:5)(cid:6)(cid:7)ا (cid:12)ا (cid:1)(cid:2)(cid:3)
Sudan University of Science & Technology
College of Graduate Studies

Process of Crude Oil Tanks Filling & Discharging Using
Distributed Control System (DCS) at Oil Fields

A Thesis Submitted as a Partial Fulfillment of the requirements
for the degree of master in Mechatronic Engineering

By:
AMIR ABD ELRAHMAN ABD ELSAMAD

Supervisor
Dr. ZAKARIA ANWAR ZAKARIA

January 2017

i
(cid:1)(cid:2)(cid:3)ا

: (cid:6)(cid:7)(cid:8)(cid:9)(cid:10) ل(cid:8)(cid:12)
)
(cid:5)H (cid:6)َ(cid:8)ْا *+ِ (cid:15)(cid:4)َ (cid:10)ُ$َMْ (cid:29)َوَ 'َ هُ PO إِ (cid:15)Rَ (cid:7)ُ $َMْ (cid:29)َ َP Sِ #ْTَ (cid:8)ْا Uُ (cid:30)ِ(cid:15)(cid:23)َ(cid:4)َ Vُ(cid:18)َ (cid:24)%ِ وَ
تِ (cid:15)(cid:7)َ $ُWُ *+ِ "ٍ (cid:6)O)َ Pَ وَ (cid:15)Rَ (cid:7)ُ $َMْ (cid:29)َ PO إِ "ٍ Yَرَ َو [(cid:4)ِ (cid:22)ُ (ُ\ْ (cid:30)َ (cid:15)(cid:4)َ وَ (cid:5)ِ (cid:12)ْ (cid:6)َ(cid:8)ْاوَ

([ٍ #(cid:6)ِ(cid:4)] بٍ (cid:15)(cid:13)َآِ *+ِ PO إِ `ٍ (cid:21)ِ(cid:15)(cid:29)َ Pَ وَ Sٍ aْ رَ Pَ وَ ِضْرcَ ا

(cid:1)(cid:4)(cid:13)(cid:14)(cid:7)ا (cid:12)ا ق(cid:16)(cid:17)
(59 (cid:28)(cid:29)(cid:30)ا) م(cid:19)(cid:14)(cid:20)(cid:21)ا ةر(cid:24)ــــ(cid:26)

ii
Dedication

To my father& mother, they taught me to persevere and prepared me
to face challenges with faith and humility. They were a constant source of
inspiration to my life. They give me strength and support I always thanks
them that used to urge me to strive to achieve my goals in life.

iii
Acknowledgement

So many people have encouraged and supported me throughout the
writing of this research. I would like to acknowledge their contribution. My
thanks and gratitude to Dr. Zakaria Anwar Zakaria for all supports and
guidance.
Special thanks to my best friends without specification for their
advice, support and endless patience.
Thanks are extended to my colleagues for their great effort and
encouragement work without them would not have been possible

iv
Abstract
A distributed control system (DCS) is a modern control system used
to automate electromechanical processes, is frequently used when DCS
implementing automated control, which is an important part of many
modern industries.
This research is based on monitoring Level, Pressure and flow of
crude oil in the crude oil storage tank by using ABB Program. Automatic
control of crude oil in vessel can work continuously and can provide
accurate quantity of crude in less time. In such process there is no need of
labor so there is no human error. Without human error, the quality of
product is better and the cost of production would definitely decrease.
The purpose of the research is to replace the manual system being
used in the industry, compare the time, and manpower requirement for both
the existing system with the proposed automated system. Using of DCS
turns to a higher performance, great efficiency, minimize hardware and
maintenance costs. So the automatic control system is better than manual
control system

v
789:;<=ا

ﻲـﻓ ﻡﻜﺤﺘـﻠﻝ ﻡﺩﺨﺘﺴـﻴ لـﻤﺎﻜﺘﻤ ﻡﺎـﻅﻨ ﻥـﻋ ﺓﺭﺎـﺒﻋ ﻉﺯﻭـﻤﻝﺍ ﺞﻤﺭﺒﻤﻝﺍ ﻡﻜﺤﺘﻝﺍ ﻡﺎﻅﻨ
ﻡﻜﺤﺘـﻝﺍ ﻡﻴﻤﺼـﺘ ﻲـﻓ ﻉﺯﻭـﻤﻝﺍ ﺞﻤﺭـﺒﻤﻝﺍ ﻡﻜﺤﺘـﻝﺍ ﻡﺎـﻅﻨ ﻡﺩﺨﺘﺴﻴ ،ﺔﻴﻜﻴﻨﺎﻜﻴﻤﻭﺭﻬﻜﻝﺍ ﺕﺎﻴﻠﻤﻌﻝﺍ
.ﺔﺜﻴﺩﺤﻝﺍ ﺕﺎﻋﺎﻨﺼﻝﺍ ﻥﻤ ﺭﻴﺒﻜ ﺀﺯﺠ ﻲﻓ ﻡﻬﻤ ﺭﻭﺩ لﻜﺸﻴ ﺍﺫﻫﻭ ﻲﻜﻴﺘﺎﻤﻭﺘﻭﻷﺍ
ﺩﻭـﺠﻭﻤﻝﺍ ﻡﺎـﺨﻝﺍ ﻁﻔﻨـﻠﻝ ﻕﻓﺩـﺘﻝﺍ ﻭ ﻁﻐﻀﻝﺍﻭ ﻱ ﻭﺘﺴﻤﻝﺍ ﺔﺒﻗﺍﺭﻤ ﻲﻠﻋ ﻲﻨﺒﻤ ﺙﺤﺒﻝﺍ ﺍﺫﻫ
. ﻲـﺒ ﻲـﺒ ﻱﺃ ﺔﻜﺭـﺸ ﻥـﻤ ﻉ ﺯﻭـﻤﻝﺍ ﺞ ﻤﺭـﺒﻤﻝﺍ ﻡﻜﺤﺘـﻝﺍ ﻡﺎﻅﻨ ﻡﺍﺩﺨﺘﺴﺎﺒ ﻥﺍﺯﺨ ﻭﺍ ﺀﺎﻋﻭ ﻲﻓ
ﻥـﻜﻤﻴﻭ ﺭﺍﺭﻤﺘـﺴﺎﺒ ﺙﺩـﺤﻴ ﻥﺍ ﻥـﻜﻤﻴ ﻥﺍﺯﺨ ﻲﻓ ﺩﻭﺠﻭﻤﻝﺍ ﻡﺎﺨﻝﺍ ﻁﻔﻨﻝﺍ ﻲﻓ ﻲﻜﻴﺘﺎﻤﻭﺘﻻﺍ ﻡﻜﺤﺘﻝﺍ
ﺔـ ﺠﺎﺤﻝﺍ ﺩـﺠﻭﺘ ﻻ ﺕﺎـﻴﻠﻤﻌﻝﺍ ﻩﺫـﻫ ﻲﻓ .ﻥ ﻤﺯ لﻗﺃ ﻲﻓ لﻭﺭﺘﺒﻝﺍ ﻥﻤ ﺔﻘﻴﻗﺩ ﺔﻴﻤﻜ ﻲﻠﻋ لﺼﺤﻨ ﻥﺍ
ﻑﻭـﺴ ﺕﺎـﺠﺘﻨﻤﻝﺍ ﺓﺩﻭـﺠ ﻱﺭﺸـﺒﻝﺍ ﺄﻁﺨﻝﺍ ﺩﻭﺠﻭ ﻡﺩﻋ ﻊﻤ .ﻱ ﺭﺸﺒ ﺄﻁﺨ ﺩﺠﻭﻴ ﻻ ﺍﺫﻬﻝﻭ لﺎﻤﻌﻠﻝ
.لﻘﺘ ﻑﻭﺴ ﺩﻴﻜﺄﺘ لﻜﺒ ﺕﺎﺠﺘﻨﻤﻝﺍ ﻩﺫﻫ ﺔﻔﻠﻜﺘﻭ ﺓﺩﻴﺠ ﻥﻭﻜﺘ
ﻊﻨﺎﺼـﻤﻝﺍ ﻲـﻓ ﻡﺩﺨﺘﺴـﻴ ﻱﺫـﻝﺍ ﻱﻭﺩـﻴﻝﺍ ﻡﺎـﻅﻨﻝﺍ لﺍﺩﺒﺘـﺴﺍ ﺙـﺤﺒﻝﺍ ﺍﺫﻫ ﻥﻤ ﺽﺭﻐﻝﺍ
ﺭـﻜﺫ ﺎـﻤﻤ.ﺔ ـﻠﻤﺎﻌ ﻝﺍ ﻱﺩـﻴﻷﺍ ﻰـﻝﺇ ﺔﺠﺎﺤﻝﺍﻭ ﻥﻤﺯﻝﺍ ﺙﻴﺤ ﻥﻤ ﻲﻜﻴﺘﺎﻤﻭﺘﻻﺍ ﻡﺎﻅﻨﻝﺍ ﻊﻤ ﺔﻨﺭﺎﻘﻤﻝﺎﺒ
ﺔـﻴﻝﺎﻌﻓ ﺭ ـﺜﻜﻻﺍ لﻭـﻠﺤﻝﺍ ﺩـﺤﺍ ﻥﻤ ﻉﺯﻭﻤﻝﺍ ﺞﻤﺭﺒﻤﻝﺍ ﻡﻜﺤﺘﻝﺍ ﻡﺎﻅﻨ ﻡﺍﺩﺨﺘﺴﺎﺒ ﻡﻜﺤﺘﻝﺍ ﺔﺘﻤﺘﺍ ﺭﺒﺘﻌﺘ
.ﻯﻭﺩﻴﻝﺍ ﻡﺎﻅﻨﻝﺍ ﻊﻤ ﺔﻨﺭﺎﻘﻤﻝﺎﺒ ﻑﻴﻝﺎﻜﺘﻝﺍ ﺭﻴﻓﻭﺘﻭ ﺓﺀﺎﻔﻜﻝﺍ ﺓﺩﺎﻴﺯﻭ ﺔﻴﻗﻭﺜﻭﻤﻝﺍ ﻥﻴﺴﺤﺘﻝ

vi
Table of Contents
CONTENTS Page
Number

"(cid:29)yا................................................................................................................ ii
Dedication...................................................................................................iii
Acknowledgement........................................................................................iv
Abstract.........................................................................................................v
z$(cid:19)(cid:13)\(cid:7)(cid:8)ا........................................................................................................vi
Table of Contents....................................................................................... vii
List of Figures..............................................................................................xi
List of Symbols and Abbreviations...........................................................xiii
List of Appendices......................................................................................xv
CHAPTER ONE................................................1
Introduction......................................................1
1.1 Control System Overview.......................................................................1
1.2 Historical Background............................................................................2
1.3 Problem Statement..................................................................................3
1.4 Objectives................................................................................................4
1.5 Methodology...........................................................................................4
1.6 Outlines of The Thesis............................................................................4
CHAPTER TWO.................................................5
Literature Review................................................5
2.1 The Importance of Process Control........................................................5
2.2 Purpose of Automatic Control................................................................5
2.2.1 Process..............................................................................................7
2.2.2 Measuring Unit.................................................................................7
2.2.3 Controlling Unit................................................................................7
2.2.4 Correcting Unit.................................................................................8
v ii
2.3 Process Control Terms............................................................................9
2.3.1 Process Variables..............................................................................9
2.4 Types of Control System.......................................................................10
2.4.1 Closed Loop Control System.............................................................11
2.4.2 Open Loop system .............................................................................12
2.5 Components of Control system.............................................................14
2.5.1 Primary Elements/Sensors..............................................................14
2.5.2 Transducers and Converters...........................................................15
2.5.3 Transmitters....................................................................................15
2.5.4 Signals.............................................................................................16
2.5.5 Indicators........................................................................................17
2.5.6 Recorders........................................................................................18
2.5.7 Controllers......................................................................................18
2.5.8 Correcting Elements/Final Control Elements.................................20
2.5.9 Actuators.........................................................................................20
2.6 System Connection Overview...............................................................22
2.7 System Description..............................................................................22
2.8 Technological Architecture...................................................................25
2.9 Main Features........................................................................................27
2.10 Basic Functions...................................................................................28
2.11 DCS Components................................................................................29
2.11.1 Hardware modules........................................................................29
2.11.2 DCS Software Modules...............................................................33
2.12 Advantages of DCS.............................................................................35
2.13 Disadvantages of DCS........................................................................36
2.14 Differences between DCS and PLC....................................................36
CHAPTER THREE...........................................38
DCS Hardware...............................................38
3. 1 DCS hardwares ....................................................................................38
v iii
3.1.1 Controllers AC800F (process station)............................................41
3.1.2 I/O Module -S800 I/O...................................................................45
3.2 An Engineering Station.........................................................................46
3.3 Operator Workstation............................................................................47
3.4 Field Elements.......................................................................................47
3.4.1 Transmitters (level –temperature- pressure)...................................47
3.4.2 Diaphragm Actuator.......................................................................47
3.4.3 Motor Operated Valve (MOV).......................................................48
CHAPTER FOUR...............................................50
DCS Softwares...................................................50
4.1 DCS Softwares......................................................................................50
4.1.1 Control Builder F Engineering Software........................................50
4.1.2 DigiVis Operator Station Software ................................................50
4.3 System Configuration ..........................................................................51
4.3.1 Project Manager..............................................................................51
4.3.4 Commissioning..............................................................................63
4.4 Process Description..............................................................................66
4.4 .1 Level Monitoring..........................................................................66
4.4.2 Processes.........................................................................................66
4.4.3Tank Filling & discharge Process....................................................66
CHAPTER FIVE ................................................77
Conclusion and Recommendations..............................77
5.1 Conclusion.............................................................................................77
5.2 Recommendations................................................................................78
Referances...................................................................................................80
Appendices..................................................................................................82
Appendix A: Creating New Projects...........................................................82
Appendix B: Starting The Project Tree ......................................................83
Appendix C: Create Operator Station.........................................................84
ix