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Instrumentation and Control: 10.1 Objectives

This document discusses instrumentation and control objectives and various measurement and control techniques used in industrial processes. The primary objectives of instrumentation and control design are safe plant operation, high production rate, good product quality and low cost. It describes common temperature, pressure and flow measurement methods and different types of control loops like feedback, feedforward, ratio and cascade control loops. The document also provides examples of instrumentation used to control the temperature of furnace and reactor streams and across a heat exchanger.

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211 views8 pages

Instrumentation and Control: 10.1 Objectives

This document discusses instrumentation and control objectives and various measurement and control techniques used in industrial processes. The primary objectives of instrumentation and control design are safe plant operation, high production rate, good product quality and low cost. It describes common temperature, pressure and flow measurement methods and different types of control loops like feedback, feedforward, ratio and cascade control loops. The document also provides examples of instrumentation used to control the temperature of furnace and reactor streams and across a heat exchanger.

Uploaded by

Muhammad
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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CHAPTER 10 Instrumentation & Control

INSTRUMENTATION AND CONTROL

10.1 OBJECTIVES:
The primary objective of designer when specifying instrumentation and contorl scheme
are:

1- Safe plant operation


2- Production rate
3- Product quality
4- Cost

10.1.1 SAFE PLANT OPERATION:


 To help the process variables within known safe operating limits.
 To detect dangerous situation as they develop and to provide alarms and
automatic shutdown systems.
 To provide inter locks and alarms to prevent dangerous operating procedures.

10.1.2 PRODUCTION RATE:


 To achieve the design product output.

10.1.3 PRODUCT QUALITY:


 To maintain the product composition within specified quality standards.

10.1.4 COST:
To operate at the lowest production cost, commensurate with the other objective. These are not
separate objectives and must be considered together. Measurement is a fundamental requisite of
process control either the control will be affected automatically, semi- automatically or

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CHAPTER 10 Instrumentation & Control

manually. The quality of the control obtainable is a function of the accuracy, repeatable and
reliability of the measuring devices employed.

The objective of an automatic process control is to use the manipulated variable to maintain the
controlled variable at its set point inspite of disturbances. Instruments are provided to monitor
the key process variables during plant operations. Instruments monitoring critical process
variables will be fitted with automatic alarms to alert, the operations to critical and hazardous
situation.

Pneumatic instruments are used in this plant. The main process parameters are all indicated in the
control room where automatic or remote control is carried out centrally.

he process parameters e.g. temperature, pressure, flow, level liquid etc. are converted to signals
with transducers and the indicated, recorded and controlled with secondary instruments.

10.2 TEMPERATURE MEASUREMENT AND CONTROL:


This is used to control the temperature of outlet and inlet streams in heat exchanger, condenser,
heater and column. Most temperature measurements in the industrial processes are made by
means of thermocouples of facilitate bringing measurements to centralized location.

Usually where high measurement accuracy is required resistance thermometer is used. For the
control of temperature, pneumatic feedback control is used. Outlet temperature of the system is
measured with the help of thermocouple. This temperature is fed to a comparator. The difference
between the set point and the input signal is called error is fed to the controller which controls
diaphragm valve to adjust the flow of hot or cooling medium.

10.3 PRESSURE MEASUREMENT AND CONTROL:


The temperature and pressure are valuable indications of material state and composition. In fact
these two measurements considered together are the evaluating devices of industrial materials. In
compressed gas systems, pressure measurement is of primary importance; pumping equipment’s
is furnished with pressure measuring devices. Pressure measurement becomes an indication of
the energy increase or decrease. Most pressure measurements in the industry are made through
elastic devices, either directly connected for local use or transmission type to a centralized
location.

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CHAPTER 10 Instrumentation & Control

10.4 FLOW MEASUREMENT AND CONTROL:


For instrumentation and control of different sections and equipment’s of plants, following
control loops are most often used.

1- Feedback control loop


2- Feed forward control loop
3- Ratio control loop
4- Auctioneering control loop
5- Split range control loop
6- Cascade control loop

Here is given a short outline of these control schemes, so that to justify our selection of a control
loop for specified equipment.

10.4.1 FEED BACK CONTROL LOOP:


A method of control in which a measured value of a process is compared with the desired value
of the process variable and any necessary action is taken. Feedback control is considered as basic
control loops system. Its disadvantage lies in its operational procedure. For example if a certain
quantity is entering in a process, then a monitor will be there at the process to note its value. Any
changes from the set point will be sent to the final control element through the controller so that
to adjust the incoming quantity according to desired value (set point). But in fact change has
already occurred and only corrective action can be taken while using feedback control system.

10.4.2 FEED FORWARD CONTROL LOOP:


A method of control in which the value of disturbance is measured than action is taken to
prevent disturbance by changing the value of a process variable. This is a control method
designed to prevent errors from occurring in a process variable. This control system is better
feedback control because it anticipates the change in the process variable before it enters the
process and take the preventive action. While in feedback control system action is taken after
change has occurred.

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CHAPTER 10 Instrumentation & Control

10.4.3 RATIO CONTROL:


A control loop in which the controlling element maintains a predetermined ratio of one variable
to another. Usually this control loop is attached to such a system where two different streams
enter a vessel for reaction that may be of any kind. To maintain the stoichiometric quantities of
different streams this loop is used so that to ensure proper process going in the process vessel.

10.4.4 AUCTIONEERING CONTROL LOOP:


This type of control loop is normally used for huge vessel where readings of a single variable
may be different at different locations. This type of control loop ensures safe operation because it
employs all the readings of different locations simultaneously, and compares them with the set
point. If any of these readings is deviating from the set point then the controller sends
appropriate signal to final control element.

10.4.5 SPLIT RANGE LOOP:


In this loop controller is present with different values corresponding to different actions to be
taken at different conditions. The advantage of this loop is to maintain the proper conditions and
avoid abnormalities at very differential levels.

10.4.6 CASCADE CONTROL LOOP:


This is a control in which two or more control loops are arranged so that the out put of one
controlling element adjusts the set point of another controlling element. This control loop is used
where proper and quick control is difficult by simple feed forward or feed backward control.
Normally first loop is feedback control loop.

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CHAPTER 10 Instrumentation & Control

10.5 INSTRUMENTATION
In every process industry proper instrumentation is very important for the safer and good quality
products. In our project we have done instrumentation on some of the equipment’s. The
instrumentation is as under.

10.5.1 Instrumentation across furnace and reactor


The critical parameters which are controlled using instrumentation involve the temperature of the
stream going into the reactor and the temperature inside the reactor. Instrumentation diagram is
under.

Comparator

TI
T
Set
Controller Point
Quench Gas
(H2)
Fuel
TI

Controller
U
Set
Point
M

Figure: Instrumentation across furnace and reactor

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CHAPTER 10 Instrumentation & Control

10.5.2 Instrumentation across Exchanger (EX-1)


The critical parameters which are controlled using instrumentation involve the temperature of the
process stream using cooling water. Instrumentation diagram is under.

A2
TI

CW5 CW6
EX-1
Controller
A3

TI
Set
Point

Figure: Instrumentation across Exchanger (EX-1)

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CHAPTER 10 Instrumentation & Control

10.5.3 Instrumentation across Absorber

The critical parameters which are controlled using instrumentation involve the flow rate of Lean
Ammine into the Absorber and level of Rich Ammine in the bottom of Absorber.
Instrumentation diagram is under.

Comparator

Controller
Set
Point F

FI

Absorber
LIC

RA

Figure: Instrumentation across Absorber

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CHAPTER 10 Instrumentation & Control

10.5.4 Instrumentation across Stripper


The critical parameters which are controlled using instrumentation involve the temperature
Set
inside stripper, pressure inside stripper and level inside stripper. Instrumentation diagram is
under. Point

B C
TI PIC

SP-2
Controller
Stripper

D
LIC

Figure : Instrumentation across Stripper

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