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Introduction To Instrumentation and Control Engineering

The equation is: y = (16/100)x + 4 Where: x = percentage of range (50psi/100psi * 100 = 50%) y = ? m = 16mA (span between 4mA and 20mA) b = 4mA (live zero) Plugging in: y = (16/100) * 50 + 4 = 12mA Therefore, if the PV is 50psi, the equivalent output signal is 12mA. b) PV Range = 0 to 150°C, Output Range = 1 to 5VDC. If PV = 100°C, what is the output? The equation is: y = (4/150

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4K views38 pages

Introduction To Instrumentation and Control Engineering

The equation is: y = (16/100)x + 4 Where: x = percentage of range (50psi/100psi * 100 = 50%) y = ? m = 16mA (span between 4mA and 20mA) b = 4mA (live zero) Plugging in: y = (16/100) * 50 + 4 = 12mA Therefore, if the PV is 50psi, the equivalent output signal is 12mA. b) PV Range = 0 to 150°C, Output Range = 1 to 5VDC. If PV = 100°C, what is the output? The equation is: y = (4/150

Uploaded by

James Gupo
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Introduction to

Instrumentation and
Control Engineering
INSTRUMENTATION
 branch of physics which deals with the
measuring, monitoring and controlling
variables in a process industry.

INSTRUMENT
 device that measures, monitors and control
process variables.
Instrumentation based on
industrial application:
“It is a collection of instruments, devices,
hardware or functions or their application
for the purpose of measuring,
monitoring or controlling an industrial
process or machine, or any combination of
these.”
What is an instrument?
“It is device used for direct or indirect
measurement, monitoring, and/or control
of a variable including indicators,
controllers, and other devices such as
annunciators, switches and pushbuttons.”
Instrument Examples:
• Instrument Society of America
• Instrumentation, Systems &Automation Society

• International Society for Automation

• Philippine Instrumentation and Control Society


Classification of Instruments
Critical
 An instrument which, if not conforming to specification, could
potentially compromise product or process quality and safety.

Non-critical
 An instrument whose function is not critical to product or
process quality, but whose function is more of an operational
significance.

Reference Only
 An instrument whose function is not critical to product quality, not
significant to equipment operation, and not used for making quality
decisions.
CONTROL
in process industries it refers to the
regulation, command or direction of all
aspects of the process.
2 Types of Control:
• Manual Control – maintaining the PV and SP by
manual or operator manipulation of the controller output
• Automatic Control – maintaining the PV and SP by
the controller manipulating the controller output
PROCESS
 refers to the methods of changing or
refining raw materials to create end
products.

PROCESS CONTROL
 the regulation or manipulation of variables
influencing the conduct of a process in such a way
as to obtain a product of desired quality and
quantity in an efficient manner.
SYSTEM
 an arrangement, set or collection of physical
components connected or related in such a
manner as to form and/or act as an entire
unit.

CONTROL SYSTEM
 an arrangement of physical components
connected or related in such a manner as to
command, direct or regulate itself or
another system.
Process Variable- any variable property of a process
Set point (SP)- any input variable that seats the desired value of the measured variable.
Controller Output – outputs signal generated in response to a change of a process
variable.
Manipulated variable- a process variable linked to the controller output that is used to
influence the measured variable.
Disturbances

MV PV
PROCESS

Final Control
SP Measuring Element
Element

CO PV
Receiving Element
MAJOR PROCESS VARIABLE
PRESSURE
LEVEL
FLOW
TEMPERATURE
MINOR PROCESS VARIABLE
ANALYSIS
POSITION
SPEED
VIBRATION
. . . . . . +many others
Control System Example:
INSTRUMENTATION SYSTEM
 an arrangement of two or more
instruments connected together to
perform a unified task.

CONTROL LOOP
 a process management system designed
to maintain a process variable at a
desired set point.
2 Types of Control Loop

1. Open Control Loop – exist when the process variable


is not compared, and action is taken not in response
to on the condition of the process variable.

2. Closed Control Loop – exists when a process variable


is measured, compared to a setpoint and action is
taken to correct any deviation from setpoint.
2 Types of Control loop
Four Basic Elements of a Control Loop

• Primary Element/Sensor
• Secondary Element/Signal-generating Element
• Controlling Element/Controller
• Final Control Element
Primary Elements
• Measures process parameters and variables.
• Measurement of the variables or properties are based on
certain unique phenomena, such as physical, chemical,
thermo-electrical factors.

Note: Process Variables sensed by the primary element


cannot be transmitted unless converted to an electrical (or
pneumatic) signal by a secondary element.

Process Variable – a condition of the process fluid that can


change the manufacturing process in some way.
Sensors
 Integral part of loop that first senses the value of a
process variable that assumes a corresponding
predetermined state and generates an output signal
indictive of or proportional to the process variable.

Detectors
 a device that is used to detect the presence of
something, such as flammable or toxic gases or
discrete parts.
Secondary Elements/Signal Generating Element

Transducer
 A general form of a device that receives information in the form of one
or more physical quantities, modifies the information and/or its form,
if required, and produces a resultant output signal.
The transducer can be primary element, transmitter, relay,
converter or other device.
Because the term “Transducer” is not specific, its use for specific
applications is not recommended.

a device that translates a mechanical signal into an


electrical signal.
Secondary Elements/Signal Generating Element

Transmitter
 a device that converts a reading from one sensor
or transducer into a standard and transmits that
signal to a monitor or controller.

*Transducers and transmitters are virtually the same


thing, the main difference being the kind of electrical signal
each sends. A transducer sends a signal in volts
(V) or millivolt (mV) and a transmitter sends a signal in
milliamps (mA).
Types of Signal
Standardized Signals
1. Analog Signal - a signal that has no discrete positions or states
and changes value.

Pneumatic and Electrical Signals


Pneumatic : 3-15 psi
Electrical : 4-20 mA (Current)
: 1-5 VDC (Voltage)

1. Digital Signal - a signal that generates or uses binary digit


signals to represent continuous values or discrete states.
Controlling Element

 Known as the controller and is the brain of


the control system

 Performs appropriate functions for


maintaining the desired level (set point) of
parameters to restore quality and rate of
production.
Controller

a device that receives data from a


measurement instrument , compares that
data to a programmed setpoint, and, if
necessary, signals a control element to
take corrective action.
Common examples of controller:
• Programmable Logic Controller (PLC) – usually
computers connected to a set of input/output (I/O)
devices. The computers are programmed to respond to
inputs by sending outputs to maintain all processes at
setpoint.

• Distributed Control System (DCS) – are


controllers that, in addition to performing control
functions , provide readings of the status of the process,
maintain databases amd advance man-machine-
interface.
Final Control Element

 The part of the control system that acts to


physically change the manipulated
variable.

 Typically used to increase or decrease


fluid flow.
Actuator
 the part of a final control device that causes
a physical change in the final control device
when signalled to do so.

Control Valves
 manipulate the flow rate of gas or liquid;
whereas, the control switches manipulate the
electrical energy entering a system.
Additional Definition of Terms
Measurement VS Detection
Measurement: The determination of the magnitude of a variable (VALUE)
Detection: The determination of the existence or the presence of a variable.

RANGE: The limit or extent of variation. The lower limit is called LRV & the upper
limit is called URV. 0 to 400°C
SPAN( of a range): The number of units between two limits, the LRV and URV.
(Span = URV-LRV)

Instrumentation and control loop / Instrument loop - A combination of two or


more instruments or control functions arranged so that signal pass from one to
another for the purpose of measurement and/or control of a process variables.
Instrument applications:
Factory automation instruments
Plant safety or safeguarding instruments
Product Quality monitoring/control instruments
Environmental condition monitoring /control
instruments.
Process variable measurement and control
instruments.
FIGURE A.

Desired temp. = 50 C Actual temp = 58 C


Transmitter range = 0 to 100 C

TE
Conversion of a PV into SIGNAL
Measuring Range = 0 to 8 Bars

Measuring
Element

PV Signal
Current Std. = 4mA 20mA
Pressure Std. (English)3psig 15psig
Pressure Std. (Metric) 0.2 Bars 1.0 Bars
Output Range
Range, Input/output calculations

1. Given the PV Input to a Transmitter,


determine the equivalent output signal.
PV Input Signal Output
Measuring Element

a) PV Range = 0 to 100 psi, Output Range= 4


to 20mA. If PV =50psi, What is the output?
Relating 4 to 20 mA signals to instrument variables
To calculate the equivalent milliamp value for any given
percentage of signal range, the equation takes the form of the
standard slope-intercept line equation y=mx + b.
y = equivalent current in milliamps
x = the desired percentage of signal
m = the span of the 4-20 mA (16mA)
b = the offset value, or the “live zero” of 4mA

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