Umnik-)\ Pre Process refers to the method of changing or refining raw materials to create end product. Raw material —+ Desired product ‘The raw material which is either pass through or remain in a liquid, gaseous or slurry (Mix of solid or liquid) state during the process are transferred, measured, mixed, heated or cooled, filtered, stored to produce the end product. Vive FIGURE 1.2 ‘A human can regulate the level using a sight tube, S, to compare the level, fh to the objective, H, and adjust a valve to change the level. Now the height can be regulated apart from the input flow rate using the following strategy: The human measures the height in the sight tube and compares the value to the setpoint. If the measured value is larger, the human opens the valve a little to let the flow out increase, and thus the level lowers toward the setpoint. Ifthe measured value is smaller than the setpoint, the human closes the valve a little to decrease the flow out and allow the level to rise toward the setpoint. By asuccession of incremental opening and closing of the valve, the human can bring the level to the setpoint value, H, and maintain it there by continuous monitoring of the sight tube and adjustment of the valve. The height is regulatedContraler Cove : Vane FIGURE 1.3 to measure the level, eee Automatic Control To provide automatic gontrol, the system is modified as shown in Figure 1.3 so that machines, electronics, or computers replace the operations of the human. An instrument called a sensor is added that is able to measure the value of the evel and convert it into a proportional signal, s. This signal is provided as input to a ma- chine, electronic circuit, or computer called the controller. The controller performs the: function of the human in evaluating the measurement and providing an output signal, u, change the valve setting via an actuator connected to the valve by a mechanical jinkage. ‘When automatic control is applied to systems like the one in Figure 1.3, which are » designed to regulate the value of some variable to a setpoint. itis called process control.Elements of process control loop: | Final Control Signal | Actuator Element Conversion Process Controller > (BLOCK DIAGRAM OF PROCESS itself, and the liquid all constitute a process to be placed undes control with respect to the Measurement Clearly, to effect control ofa variable ina Process, we must have information about the variable itself. Such information is foun by measuring the variable In general(& measurement refers tothe conversion ofthe variable into some corresponding analog of the variable, such as a pneumatic pressure, an electrical voltage or current, of a igitally encoded signal. A sensor i a device that performs the initial measurement and en- ‘ment function, The result of the measurement is a Tepresentation of the variable value in Some form required by the other elements in the process-control dosti Inthe system shown in Figure 1.3, the conttolied variable is the Ieee of liguid in the Error Detector In Figure 1.2, the human looked at the difference between the ac- tual level, h, and the setpoint level, H, and deduced an error. This error has both a ‘magni- tude and polarity, For the automatic control system in Figure 1 3 hs sane Kn of enor i can be taken by the controller. Al tion must be made before any control action ean he co eves detector is often a physical part of the controller device, it is important 10 keep a clear distinction between the to. oo MeasurementController The next step in the process-control sequence is to examine the error and determine what action, if any, should be taken. This part of the control system has many names, such as compensator ot filter butcontroller isthe mostcommon. The evaluation may be performed by an operator (asin the previous example), by electronic signal processing, by pneumatic signal processing, or by a computer. In modern control systems, the operations of the controller are typically performed by microprocessor-based computers. The controller re- quires an input of both a measured indication of the controlled variable and a representation of the reference value of the variable, expressed in the same terms as the measured value. The Teference value of the variable, you will recall, is referred to as the setpoint. Evaluation con- sists of determining the action required to drive the controlled variable to the setpoint value. 7.2.1 Signal Conversions This step refers to the modifications that must be made to the control signal to properly in terface With the next stage of control—that is, the actuator. Thus, ifa valve control element is to be operated by an electric motor actuator, then a4- 10 20-mA de control signal must be modified to operate the motor. Ifa de motor is used, modification might be current-to- voltage conversion and amplification, Standard types of signal modification are discussed in Section 7.3. The devices that perforn such signal conversions are often, wers because they Convert control signals from one form to another, such as current to pressure, current to voltage, and the like. A corollary to the signal-conversion process is the development of special electronic devices that provide « high-energy output under the control of a low-energy input. This is generally described by the term industrial electronics, Section 7.4 presents an overview of this important topic. 7.2.2 Actuators ‘The results of signal conversions provide an amplified and/or converted signal designed to operate (actuate) a mechanism that changes a controlling variable in the process. The direct effectis usually implemented by something in the process, such as a valve or heater that must be operated by some device, The actuator isa translation of the (converted) control signal into action on the control element, Thus, ifa valve is to be operated, then the actuator is a device that converts the contfal signal into the physical action of opening or closing the valve. Sev- eral examples of actuators in common process 7.2.3 Control Element : AL last we get to the final control element itself. This device has direct influence on the 229s dynamic.variable and is designed as an integral part ofthe pracess, Thus, if flow is to be controlled, then the control element, a valve, must be built directlpinto the flow sys- tein, Similarly, if temperature is to be controlled, then some mechanism or control element that has a direct influence on temperature must be involved in the process. This could be a heater/cooler combination that is electrically actuated by relays or a pneumatic valve to control influx of reactants,Process Variable: [A process variable is a condition of the process fluid (a liquid or gas) thet can change the manufacturing process in some way. In the example of you sitting by the fir, the process variable was temperature. If we are measuring level inside a tank, here process variable is level ‘Common process variables include: Pressure, Flow, Level, ‘Temperature, Density, Ph (acidity or alkalinity), Mass, Conductivity Set Point: In process control the basic objective is to regulate the value of some quantity. To regulate means to maintain the quantity at some desired value regardless of external influences. The desired value is called reference value or set point value. The sct point is a value for a process variable that is to be maintained. Controlled Variable (CV) ‘The variable that must be controlled, Level, Temperature etc. Manipulated Variable (MV): It is the variable used to maintain the controlled variable at its set point. CV- Level inside the tank MYV- Out put flow [= dour CV- ‘Temperature inside the tank MV: Flow of steam CV- Flow. of water MV- Valve positionContratier Measurement ory Seipoint Disturbance Variable: These are the variables other than the manipulated variables which affect the Controlled variable. Normally disturbance enters into the process from input side. Here disturbances are inlet flow rat, Inlet flow temperature, Steam temperature. Load Variable: The effect of this variable i sas same as that of disturbance variable. Normally load vari: ables are affecting the process from output side of the process, Sudden draw of hot water from the vessel affect the temperature of liquid inside e the vessel.:xample of Various process: ‘Temperature Process: es Conval vahe Contra fe Measurement f Setpoint Ouipat * Here the controlled variable is the temperature of liquid inside the vessel and manipulated variable is the flow of steam, When the temperature of liquid is deviated from set point it is sensed by thermocouple. Then the thermocouple output goes to controller where it is compared with the sét point. Controller decides what action should be taken and controller outpyt goes to final control element * [tthe liquid temperature is above the set point value then control valve will be closed to reduce the low of steam so that the temperature will reduee. If the liquid temperature 1s below set point then control valve will open to allow more Sicam 10 flow to increase the temperature of liquid inside the vessel till the temperature equa! :0 set point value. Proc components - Thermocouple Temperature Transmitter Temperature controller . I/P Convertor Control valve AeneElow process: Bae er a= 4 > Qouk * ‘The controlled variable is input flow rate. Orifice is used as flow sensor. ‘* When input flow deviate from set point flow rate is measured by differential pressure generated across orifice. DPT convert this differential pressure to electrical quantity and this value ‘compared with the set point value in flow controller. + Ifthe flow rate is above the set point control valve will close till flow rate equal to set point value. If the flow rate is below the set point control valve will open till flow rate equal to set point value. Provess Components: VP Convertor Control valve |. Orifice 2. Differential Pressure Transmitter 3. Flow controller : e 5.Level Proce: Cot © Here the controlied variable is the level inside the vessel. Capacitive level sensor sense the level. Level transmitter converts it to electrical quantity and it -ompared with set point in level controller * If the level inside the vessel is above the set point then control valve opens till the level equal to set point value. If the level inside the vessel is below the set point then control valve closes till the level equal to set point value. Proc Components Capacitive level sensor Level transmitter Level controller UP Convertor Control valve wewnePressure Process: ereggune : - ee ee Pale + The pressure inside the closed vessel depends on the level of water inside the vessel. If the level of water inside the vessel is more then air pressure inside the vessel is more and vice versa. + Pressure sensor is bourdon tube or capsule or diaphragm. * When pressure inside the vessel deviates from set point sensor sense the pressure. Pressure transmitter converts it into clectrical quantity and it compared with set point in pressure controller. * If pressure is more than the set point Control valve close to reduce the flow of water to reduce the pressure and bring it down to set point. If pressure is less control valve opens to allow more water to vessel to increase the pressure to to match with set point. Process components: Pressure Sensor Pressure transmitter Pressure Controller UP Convertor Control Valve yaene@ ScADA DB SuPtEWiSetY Chey B oat Bute. pee —> Parytimrnn ble Leyic cre “e TQ Vatious : “TVeansmitctess ! I+ fs bastcaily A teansduced. whitch | tespands. te. measueed varioble..& ConvehtS that Tip. te standaed oP WEE © 4-28 mad pleed of Teansmittea 2 UY Centicl on Is. ck need ie lweres Mast? d x - see ett pais nepal —=— [Te oo Ife [scao qe Gae TE oF modes plan + Cyuipments — ile eactoes , wapotatots , dayees € botices. att. Cemtesticd ( monitetect feo the corel Asam 1) _ this gees goss of plant opcéayt on r@. fo Fu-f1n ths opcéation are need Vomlsus Tarsmitreas which only sense vatious - plant — patamnetee £ Sends SYgnal to el trom, whee th ate eithet displuged op con Feat Se, Systum C PES, Scapa, PLEO 4 ocised fot fuethee ctl putpose-© Thes, by +his.. .optkadion is oss ble. l | | | a it i by the Pict Sen itreés ® Thus, Hoe | teansmittees 1S wo ds Wee component tA paecess Fete | Conttoi Room Fred © plant). @® oes ®O sensots @Q scaoa "© Local ‘tndiratess| | @ PL @® Surtches | @ cLasteum ent @ Final wntesl i Pane} eens tts I Cre valve GB Aas or uct ots i Annundatst = © Anodysbs ;©O Painrees | Cecoedees C conductivity A: a epHA (Dora lozycts Bea A ag GLP Ge oonvics a leah, cts) f- pan be Insta tied \w Cte] arom | of on Fretd : only ° or plant . te the used of pRamsvaittees . Taans mitt in: the syne tier | ctel| Proam. fs aehuvedae Stan datd sation? : : ole Signals based capon U ¢ Pp an ayy Ased Se Foam. of Actual Io En etyy oP , ae 4-20 mAs! o- 20 mA 2 Voltage : ide 3 Preamatics Cete Bris pst C ompssed LloKs? oe" 1° Kele at) oe @ Ss atin dat d's ator : O) ANSE >. Ameitan National Standadd Engr tresor ® wsAk > “Ensttument sy steans £ ero tian Seatety. © Naty good Vincowity th this eatin FeDead Zee fF. Live Zeee ato Teansmrittee eo sve. a: Oe \ mA > Tete of tea \ So. gp AP SPAR + 2 ws om > then i |* oo 4 1 Chen pete 8 off then dead | | Oued Comay O of of +eanser is 4720 mA f eee 4 mA > webo 22 mA —> span :@ Duein, power Failte of one | of +he “earoponent tp +he [oop zee value oF the stan re Cites \ wort sixach to tebe mA. fem. 4.74 i thts fs . Catied as ped cae of Fenn T@... Eo .seme. Teansm AC Can't iePeten trate eka. value of teense duging lve & poutt fallnte - t+ ts also culled OF dead eto of Teansm srrclaseaate. Tyrts Miurtion of teangmittea : Based Upon @’Seraee Tr the Capes sce eee agro ttte : ae Ceo ea Tens : 2 - i C campe: altl . teans Gee os NS ttenic Tans Prelate rmibers Hechpnie x!mitters Cone: Aim’) C Hlechcity) il ot totion balance Nae Ceara) ee gece ie jPae. trans: Free balance Hype 4 SMART x'miHer 1 Preurmabic emitterTeansmittet > Teansmr+tee Load Arata imeted Souéced Seutcee & Sepetatred Sometinne loop bert” Joop RegiStan ce.clusseute. @- B~ wite teansmictet ¢ Tans ttt e& "s powered olen Tramsna ttt ek Signet, Lemmon fs. .Connecte to. SOnece Common Signak. 4. Souter loop . eet cee Sametime Stanet loop Consists hor st Sign othOQ a D 2- woee. cf éansontt: = feansroittee fs. Soutcec! Seute ~ Signat Leop. ckeststance c& ° el VEIT loop js F upto PA det dog cHeauns mitt tees in Incluss ty He noise signot in oIP bX Cero mehoC i 24 v-De Stpnat $ Souter wee ta the Same faap in dhs tans No nese / pick-up Signats Modeth cleuge Teans 4 widely. used fin tele 548, a Diagnost it fact lt 1S available They ate Aten Holset pick-«p sige mats ade in. the loop Ragesy nds} So men ia used Thoin bo csmse of butl+ [inst tot fens Mo Such Facet te is vod [ables obsceered |eq: “Temp. xtmitter. : . : dj. Diagram. ob. Preumatic xtinikhen ts as. Glau e iD), Jeoportont component..of the mitlers are 1). Temp. bulb 49) Bourclan. sping ; 8) connecting linkage - cotton: 1) Flapper clazale sy 5- + 5) Relay j W) Increase in the bulb Fenyp Cas pee proiess).cezes hourdan Png to Unte] + This metion is + tanamitled -to the Hopper thr connecting 4 linkage hence Happer moves -in olowanraare) - dlrection f decreases the gap beth Foppera iar increase. 2 inthe al: WITThus , as..tetop...increases._o1P ofso_ inereanes___... reverse is the caise.ahen. demp-..of process. decreases 2: by. relay Mody) next jocrease.jathe. dep. | balance Aype of the..dvansmibter oti Jeo adjustment. 1s provide. on. AA ayes. 3 ||P. span. adjustment 13.a4tach be. the. Connecting sity |Moaion ob dhe. tarmeeting hokage... is. calibrobed \fos hy shee indication of tensp. xmitter i | 2 [Ree Balance Pyyymnatis.gmitter mx (ese anit! gfe op exible stip | A ea" = © folow-up Bello ni “I lipel ag la : Eo Hes wf Pionesy oO measusng Clement (gavel i This, the motion created by Goweddn ts balanerc} Ve hence ..the antler is_calied.as. fhetion, aa cm Nin kee. i 4. the pointer is | Fore indication purpose - ai)i || Taree balance type. inewmobic rebeithersy iE £9: frees xiaitter — Sie esau ea a Des as 4 “The. .sschmatic diageam of the force. emo, S| i Ape of x'witter. “is shonin dig: i) Trop: conoponents are NY Measuring element ( Bellaa) : : 2) force. Beam. 6” D)Mapper-nozle sys- Relay Ide ; ) Follow: Up. Bellow. see eee meee coting bo THe. xtmoitter operates an force: bealainee ponciple oan oo i e-sForce developed by measuring.clemen}is_ ghee [balanced bythe force created. by olf ressure £. -—-/lacting.on the follow-up below: a vPose . | y-An inenease..in. the process. presse ods an the i “bellow .in..measweing. charmber..which develapes _ Gs eo ee eet ye end of tbe force. beam. 3. ocimib ber, WMHs deewases. the gap between Flapper € plzzde and Nozzle backpressure incase in tne Relay chimber £ hence the ximitter olf also inmeasey vi). Thus. as the process pressure jnctrases ofp of: the xImitter cs increases L acvense js The Case Nhen process presare decvases- ai): This increased force in the relay chamber ix Fed do the follow-up Bellow» phich applies the force -lo the span level, “This force is transtaitHed or trans feed through Flexible sbeip to Force. beam. which restores ihe gap bein #)N- thus Origine) eguilibrium is established -os = Lom adjuclnen is provided. on bree heam i 1). | =span.adjustment. is_jaovided .on follow-up Ri eS fe i: Motion Balan(e. 0. Foner. Balance, we Minter: _ximiben i 1).[These required more space.' 1) Compach..1 CBulkey in. nadure’) 2). | These. are. very... easy. ta. 2) Dibliald: foe | hroubleshoo!- Arubleshsoting cat =, Cotyam ee; | Conuentinnal Blech 7 | 4 D.TBis 4 basically deviled into 2 farrts T) Measweing cell cH) Blechonic pasts i) The meastring cell consists oF Holle Cerumjc Chamber cehich is clivicleol in 2 parts by the sensing alicaphyogny in\The sensing dliaphregm acts as imoving plate 4 of the capacitorSiN} Thuo.the. meauring..preaaires cor...scniteal. the! y\[Borh the chambers are sealed. at the-end Lby Hexible comrgated . jso'biting diaphragm d whch polects he cenheel Senshay clieipliveagan —|-prom ne. process Fluids. ae Ni The. interiors 01- chamber are filJeab cath. Ise Nquids eadleo 4s sillicon.oil & sealed by ing diaphreiqrys af the dop..f bottom of He Hoel} ca ee *a) Migh & tora fress:.. from. Hoe proces dor applica |} -sko..the cella. shownin tig: es Haid to sensing diaphragn. \Wi"Thuo the Mecousing cel subjected. do q_dithoe! | Pressuve (is Pr).. The Sens}ng. clicaphreayey a. 4), defects te slighthy cawing the change in | Capacitance » i — x\IThis change jy the aipdeltance. Is gnen do i the elechonic part where ib is. converted to c-asmye proportional —-e. cunvent using | Signal conditioning —akh - mY The olp. current is std: x'missioy oH ynab suck, | as Heo mA de> xi), Zero - span adyustmen) decility is provided on | electronic — part Fi} These ave also called ao fixed ran Foxinitlers since Tange change is litotted) oolMEThe.intedor parts of both the chambers ar a -—..[-metallised. 2 -Bytns.the. Fixed plate of ase eC Qp adie ee ee Se | idl | | 2)i Son cullsebion punpace. “Theoe. ae of etnibbers. coe.dp. be acmoved... fromn.the site. .ot do. : \ J jdolale fron... the. process e.end.. | vai) - The conventivne) Slechsnnic technic. ave el hragm { far. signesl cond. yspose....6 thio Jo the Vegan timation of such bype of mi Mer by vb the | Med | sma = ee eee Pyel : trmstnission.- eee ditteotnbail.. 9 ABC YP) wu. i. Prpplicertion, te inkegreuked. cekks- : Pe : aysenton reodul-e ee 7%) Blectronic Goasd.— Seni oe ae if tes 7 d a 1 ' sing ; Sensor module inemory Cemocey aL weeny Ik Re-ra1g € He Damping, oil Filled ‘seneot Bk \ 4 iagnostic b Engineering + Cornu cariHART oe The Wk dragram.of SMART _D-Rx'mi Her is as choo | 19 -fig This. is bwaclly.. devidled_into cto. parts yD Sensor. module. I) Fechonic modade . i) The sensov module Canlebnds oj) Lillecl sensor ie yster This js exacHy. .similordo. sensor. 5 1. fane eleohenicD:Px'mitker: [8) The .sensoy. elechonies...are. installed. thin | elechonic. tmdules 2. inchules. 10 Ot Alled sensor bk - fone IS) dep sensox : oe ae | | i Memory mochule. ‘ iy Capacitance de te) . signal._converday. 5) Hechical signads. Bom..sensor. module are fensmitted to. olf. eleckmnies. in derrome heusin 18) The cleohonic. Module consists of. 9) Micro computer 1 ») Memory roclale. i i (0 OAc | 4) Lecal cero spin ad e) Digna Communication AE When ditt. pre: Sensor Mocsinisstoy.|__ ——-changes_the -Capercitence. This henge in : elie 4) Capacitance signed 13._then. -cherngedl to = ie A digitce) Signal by clo converter. aan 18) The micro - processor Hyon fukes the signal shown dom. RID. &. clp Convertor, Labculciten the cortene olf of the. hansmi Her . This signa] wl bs then send do 00 tof) convertor othich fi eo Converts the. signs] &. supedmpasas the I Heep aighco} on 420. mA Oy. Wor... — ~ a ——————____-__ a toa) = D._ Since they axe HAMA. commmunicodan Facility, - : - hand neld—.ceromanicartors ore Gasal fone n =e —1.Prernsrai Her calitration. ne | (ethan ane ee B78. Coulibya Leal ~ toe Motehy kde, nok aquired -to 2emove i dom._loop: aa | oe ) Since they are beised on Inier0- Compuder technology » they are having ‘5e)f dioqnosdie’ facility tera) tere LP span ‘elechonic boerrd? ily is prvidled on 1) Dothvore locks Che poovideel on body -for — calibroition Prot efion 4i IL ‘ SMART. Llectanic + | Conventional. Slechonic |. transmitter wo) oo Airnitter- le : 1). || Signal conditioning is. simplt D Lalest techniques are (84-8 1s done analytically) Used far..s-G Csiqned cond) i i Cteme:& Press cmeckows cre i . used) 3) Range is Limited. a) wide Tangs is. dvailable , i i : : i rs 9 | Ontine calibreifion...is 3) OL. cob bration is "neh possible - Cr'nmber gossible ide be xemoved. from process)) BY! Comparer Compatibility is nob possible » 4) Computer compatible SB) undo comm” post is J5) Lelesk tech mauen fer TOvaluble be Hage) Comm ave available here.a © . | —=— ait < plots —-}[email protected] signa) to eloise -- rao. my lo self test self teat fealty efeoci ly a (Diagnose. 49 .avadlable’) Over -r0ing reel 5] © ov auee ssnssaid Zupuoaai © pana pur "yun Bupuooasw sueaus x sono] puones“ansseud surat s8muvou ‘29 ane stoquike asap Ip 998 ue> hos “LS'Y 2IGEL, puE Z'S'y 2INBIY 01 sy analy “aria 219 us voxewwounnu oj pasn ave souls eoeds ze aunod Boe lO alt alc a | aes pases lesa tevwdent) | oye Tryendoan | MDS 129 | s10aWAS area SNOWLONN YO SLNAINNULSNI WHaNID E°G"'y s0uy ss30014 pe ub aR bs aun Pep eu 9008 0H eis auosing pap) “| | mer ono | s x1anagav | 029622 | APPENDIX. F sree! ° @ lettermumber coaing FIGURE AS.4 The PLC includes many math‘80001 eoueyp €10) qrpd 8 jo uoneasrH ) on) ss aunDls sueweyo joe ey ‘ebenoraieen [Sem umwan it ar aL SLN3W31a SSIOOUd GNY SYOLVNLOY P'S Ss xionaaay | 1281. Develop an operational amplifier circuit that can provide an output voltage related to input voltage by the equation Vout= 3.4 Vin + 5 (8) 2. bein the following P & ID symbols giving application and specific the location of the instruments. (10) iil, : iv Vo eR State the advantages of SMART over conventional transmitter. (6) 4, ixpliin with the help of neat block diagram two wire RTD temperature transmitter. (8) 5. Compare two wire and four wire transmitters. (4) 6. Detine & explain the following using a typical level loup. (10) Process b. Disturbance, c. Manipulated variable d. Load Variable. e. Controlled Variable.7. A sensor outputs a voltage ranging from 0 to 30 mV. For interface to an ADC the signal needs to be in the range of 0 to 2.5V. Develop the signal conditioning circuit, : (8) 8. Dyaw P & ID symbols for the following & give examples for the same. (10) i) Control valve. ii) Hydraulic signal. iii) /P converter. iv) High/Low alarm. v) Orifice. 9. Resistances in a bridge circuit are Ri= Ro= Rs= 130Q, Rs= 1310. If the supply voltage is 12V. Find the offset voltage. Also design a signal conditioning circuit to get output 0 to SV. (8) 10.A pressure sensor outputs a voltage varying as 90 mV/psi. Develop signal conditioning to provide 4 to 20mA as the pressure varies from 50 to 120 psi.(12) Pew temperature control loop using standard symbols and explain its components in brief. (6) 12.Explain zcro elevation and zero suppression with respect to DPT for level measurement. (6) 13.What is the need of standard signals? Explain various standard signals used in process industries. (6) 14.A sensor resistance changes linearly from 100 to 180 Q as temperature changes from 20 to 120 °C. Find a linear equation resistance and temperature. (6) 15,Define and identify the following with respect to a typical flow control loop. (8) i) Controlled variable. ii) Manipulated variable iii) Set point. iv) Disturbances. 16.Explain the use of DPT jor level measurement. Explain zero elevation and zero suppression. (8) 17.Explain need of transmitter18. Explain various standard signals used in process industries. Explain the concept of field area and control room area. Write any 2 components in each area, (8) 19. Design signal conditioning circuit for Pt-100 for a temperature range of 0°C to 150°C to provide 4 to 20 mA output signal. (10) TPeaca@ures & va shave meen hoo