You as instrumentation technologist need to do a process instrument design for an

industrial plant with the following specifications:

$1.$ A distillation column must be designed to distil diesel and petrol. There are two

separate feed tanks about $500$m from the distillation column. The design must include

all the distillation column components and the feed tanks.

$2.$ The bottom part of the distillation column must use wired field instruments for the

distillation column and it related components. These field instruments must be wired

through a junction box in the plant area and from the junction box to the

instrumentation equipment room which is connected to the BPCS hardware parts,

which is $125$m away from the control room and server room.

$3.$ The top part of the distillation column must use WirelessHART$$ field instruments that

must be connected to the distillation column parts and related components. These

WirelessHART$$ field instruments must be wireless connected to the BPCS hardware in

the instrumentation room which is $125$m away from the control room and server room.

$4.$ The distillation column is located in a hazardous area, zone $2$ and the feed tanks is

located in zone $1.$

$5.$ You have to design and implement an emergency shutdown system $($ESD$)$ using a SIS

that are interfaced to the BPCS to ensure that the distillation column is shut down

before going into an abnormal situation when there is a major control problem on the

plant. The design must cater for both mentioned systems.

$6.$ The instruments that are selected for the distillation column and associated

components of the plant must indicate which is for the BPCS control and what

instruments are used for the SIS as part of the ESD. The placement of the ESD

instruments are very critical and must clearly be indicated in your design as well as

motivated in the design why you have put them in the plant.

$7.$ All the field instrumentation on the distillation column for the BPCS and ESD must be

selected for the correct hazardous area classification specifications. The same goes for

all the WirelessHART$$ field instruments connected on the distillation column and feed

tanks.

$8.$ All the installed field instruments $($hard wired and wireless$)$ must show their respective

EX ratings for the area where they will be installed. Make a list of the instruments that

will be used and indicate the required ratings for each of the instruments to make sure

they will be safely used in the correct hazardous zone as indicated for each of the

plant components.

$9.$ You must indicate where you would use intrinsic safe $($IS$)$ loops on the plant. Also

indicate a typical IS setup for each of your loops.

$10.$ You must select the correct type of field instruments that would be needed on the

distillation column and the feed tanks. The same must be done for the WirelessHART$$

field instruments required as per above specification for implementation. These field

instruments need to be connected to the BPCS as required in points $2$ and $3$ above.

$2$

$11.$ You also need to indicate what type of valves will be used on your distillation column

design and how they will be interfaced to the BPCS and SIS.

$12.$ Indicate how the ESD using a SIS will be connected with the required protection field

instruments and output control devices to protect the distillation column.

$13.$ Use a map to indicate the location of the distillation column and the feed tanks. This

map must be used to indicate the WirelessHART$$ field instruments placement and

their respective signal paths as part of the asset management system that need to be

used for managing the WirelessHART$$ wireless network.

$14.$ As part of your installation process of the control valves where you would need them,

indicate a typical valve signature for a newly installed control valve using a DVC$.$ You

can use any make of control valve.

$15.$ You must indicate the interfacing of the BPCS$,$ the SIS and the field instruments in

basic block diagrams so that the design can be used as the basis for the required

design as indicated in the above specifications.

$16.$ As part of the design, give a short description of each of the systems that were

designed, the basic working of the distillation column and how the feed tanks are used

with the distillation column.

$17.$ Explain what criteria you used for selecting the specific field instruments in your

hardwired design for the distillation column, feed tanks, the wireless field instruments

that will be used on the distillation column, the feed tanks, the BPCS and SIS

components. Refer to the types of IO cards used and how the typical hardware

installation for these requirements would look like.

$18.$ Show the typical loop drawings for each of your selected field instruments installations

up to the BPCS I$/$O cards. Do the same for the SIS loops.