Receiving Elements

Instrumentation & Control

Basic Elements of the I&C System (Loop)
𝐷𝑖𝑠𝑡𝑢𝑟𝑏𝑎𝑛𝑐𝑒

𝑃𝑟𝑜𝑐𝑒𝑠𝑠
𝑀𝑉 𝑃𝑉

𝑆𝑃
𝐹𝑖𝑛𝑎𝑙 𝑀𝑒𝑎𝑠𝑢𝑟𝑖𝑛𝑔
𝐶𝑜𝑛𝑡𝑟𝑜𝑙 𝐸𝑙𝑒𝑚𝑒𝑛𝑡
𝐸𝑙𝑒𝑚𝑒𝑛𝑡
𝑅𝑒𝑐𝑒𝑖𝑣𝑖𝑛𝑔
𝐶𝑂 𝐸𝑙𝑒𝑚𝑒𝑛𝑡 𝑃𝑉
Typical Process Control Loop (Pictorial)

CE-TI-IPC-09 Receiving Elements-rev08-060609

Types of Receiving Elements
• Indicators
• Recorders
• Controllers
• Alarm Units
Indicators
• Produce a value display or reading of some
process variable in a system or process
• Not capable of recording the data
• Can be analog or digital
• Despite the main disadvantage of analog
indication, sophisticated displays always include
analog readout with digital readout
Indicators
• Produce a value display or reading of some
process variable in a system or process
• Not capable of recording the data
• Can be analog or digital
Indicators
Analog Indicators Digital Indicators
• Indication can show • Indication is difficult to
how fast a variable see how fast a variable
changes and in what changes because the
direction just by characters seen are
observing the pointer garbled, until the time
(mechanical pointer or that the variable is already
bargraph) steady or changing very
slowly
Single Channel Indicator

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 Dual Channel Indicator

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Multi Channel Indicator
Recorders
• Produce a permanent record of some process
variable in a system or process
• In most instances the values of the variable are
recorded on a time basis; that is, the value at any
moment in a given period becomes a matter of
record
• Used extensively where temperature, pressure,
voltage, current, humidity, and many other
variables are important to a given system or process
Circular Chart Recorder
• Product Description
Physical inputs to monitor & record:
- Temperature, Current, Voltage
- Humidity (%RH), PH, Frequency
- Pressure, Conductivity, Flow, Event
• Applications:
• Pharmaceuticals: Autoclaves, DHS (Dry Heat Stabilizer), DM water plants,
cold rooms, etc.
• Drug storage rooms, cold rooms, stability chambers, etc., Tire and
Rubber Processing
• Dairy Pasteurization Plants, Low / Ultra-low temperature, HVAC
Applications
• Hydro-testing / Piping, Textile and Dye Processes
• Water and Waste Water Treatment, Breweries, distilleries, and sugar
processing
• Cold storages, beverage / food processing, Humidity Chambers / ovens
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Strip Chart Recorder
• Digital and Bar Graph Display
• 1, 2, 3, 4 Continuous Pens or 6-
Point Dot Printing Models
(RD1800B Also Has 12, 18, 24 Dot
Printing)
• Universal Inputs: Thermocouple,
RTD, Voltage
• Programmable Input Types, Full
Scale Ranges, Alarms, Chart Speed

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Multivariable Recorder
• HONEYWELL DPR 250
• Chart Recorder (250mm)
• The DPR250 recorder is a
250mm (10 inch) wide chart
recorder. It is able to monitor
up to 64 analogue inputs or
any combination of analogue
inputs, digital inputs and
outputs that total up to 80.

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Paperless Recorder
• HONEYWELL
• EZTREND V5
• Digital Video Recorder
(5 Inch Display, 6 Analog
Inputs, Fuzzy Logging)
• The Honeywell eZtrend V5 is a
graphic recorder with LCD
display and up to 6 analog
inputs.
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Controllers
• Devices that incorporate a built-in indicator, or
less common, a recorder function, that uses the
process variable measurement and compare it
with the required value of that variable, and
then produces a correction signal necessary to
maintain the variable at that value, called a
SETPOINT
Controllers
• The correction signal is the control output of the
controller and results from processing the error
(PV – SP) with a set of formulas or calculation,
called ALGORITHMS
• Typical of the algorithms is the so-called P, I, D
calculation
Types or Classification of Controllers
• 1. According to Display:
• Analog
• Digital
• 2. According to the Operating Technology:
• electronic > solid-state / digital /
microprocessor-based
• pneumatic
Types or Classification of Controllers
• 3. According to the No. of Variables Handled:
• single-loop
• dual-loop
• multi-loop
• 4. According to the Process Variable:
• pressure controller
• temperature controller
• etc.
Types or Classification of Controllers
• 5. According to Flexibility of Functions:
• Fixed-function
• Micro-processor based, Multi-function,
Programmable, Configurable
Types or Classification of Controllers
• 6. According to Application & Operating System:
• Stand-alone, Conventional, Process Controller
• DCS
• SCADA
• PLC
• DAS (Data Acquisition System)
• etc
 Description
• PLC is an industrial control product that regulates
various automation and mechanical processes in
manufacturing plants
• A PLC controls various automation applications in a plant
by maintaining direct connectivity with various field
devices such as sensors, transmitters, and actuators
• A PLC receives command and signals from field devices
and other industrial systems through a control system
communication protocol
WHAT IS A PLC?
•A Programmable controller is a solid state user
programmable control system with functions
to control logic, sequencing, timing, arithmetic
data manipulation and counting capabilities.
PLC can be found in:
• Instrumentation
• flow meter, temperature, position….
• Control
• programmable logic controllers with digital
peripherals & field bus
• Visualization
• HMI in PLCs (when it exists) is limited to service
help and control of operator displays
HISTORY OF PLCs
• Higher Efficiency and
Productivity
• Easy Maintenance and ( present )
Troubleshooting
• Flexible System Operation
• Cost and Time Efficient
• Tedious Work in Installation and
Troubleshooting
• Higher Costing in Maintenance
( before 1960s ) • Difficulty in System Operation Change
 HISTORY OF PLCs
Comparison between a Purely Relay panel and a PLC
Panel
RELAY PANEL

PLC PANEL
APPLICATIONS OF PLCs

• Relay Logic Control • Arithmetic Operations

• Timer/ Counter • Analog Process Control
Functions • Servo / Stepper Motor
• Auto / Manual Control
Control • Supervisory Control And
Data Acquisition
 TYPES OF PLCs

• Small and compact • Flexible and versatile

• Fix number of I/Os • Huge I/O capabilities
• Designed for simple applications • Designed for complex and sophisticated
• Suitable for stand-alone systems applications
• Suitable for centralized control systems
PLC COMPONENTS
PLC COMPONENTS

CENTRAL PROCESSING UNIT

• MICRO PLC – less than 100 I/Os
• SMALL PLC – less than 526 I/Os
• MEDIUM PLC – less than 1028 I/Os
• LARGE PLC – less than 5120 I/Os
PLC COMPONENTS

POWER SUPPLY
•100 – 240 VOLTS AC
•24 VOLTS DC
PLC COMPONENTS

INPUT
•100 – 240 VOLTS AC
•12/24 VOLTS DC
PLC COMPONENTS

OUTPUT
•RELAY / CONTACT TYPE 24VDC/220VAC
•TRANSISTOR TYPE 24VDC
•TRIAC TYPE 100/240VAC
 Plc in a Cabinet
CPU1 CPU2

serial
connections
inputs/outputs

Picture Courtesy of Prof. Dr. H. Kirrmann, ABB Research Center, Baden, Switzerland
PLC Used in Turbine Control

Picture Courtesy of Prof. Dr. H. Kirrmann, ABB Research Center, Baden, Switzerland
Global PLC Market Players
• Key Vendor *Other Prominent
• Mitsubishi Electric Vendors
• Rockwell Automation *ABB *Omron
• Schneider Electric *Bosch Rexroth *Honeywell
• Siemens *Beckhoff International
*GE *Panasonic
*Idec *Toshiba
*Keyence
*Koyo
Advantages of PLC
• Highly reliable
• Highly versatile (universal applicability)
• Simple troubleshooting
• Simple installation
• Quick modification of the program (highly flexible)
Advantages of PLC
• Capable of task not possible with relays before as
indicated by the following:
• Calculation, information exchange, text and
graphic display, data processing, networking
• Low space requirement
• Low power consumption
• High processing speed
• No moving parts, hence no wearing parts
• Wide operating temperature
Disadvantages of PLC
• High initial cost ( for a simple process )
• Sensitive to dust, high temperature and high
humidity
• Repair must be made by a qualified personnel
• Not very widespread
• No uniform programming language
 PLC System block diagram

PLC Program

Input CPU/ Output

Module CCU Module

Input Output
devices Devices
(Sensors) (Actuators)
PLC Programming
• IEC 61131 – 3 Standard
• The standard includes the definition of the Sequential
Function Chart (SFC) language, used to structure the internal
organization of a program, and the four inter – operable
languages:
1. Ladder Diagram (LD)
2. Function Block Diagram (FBD)
3. Sequential Flow Chart (SFC)
4. Structured Text (ST) – high level language
5. Instruction List (IL) – low level language
IEC 61131-3 Programming languages
Function Block Diagram (FBD)
AUTO CALC1
DI CALC PUMP

V IN1 OUT >=1 DO

MAN_ON V
ACT IN2

Ladder Diagram (LD)

CALC1

AUTO CALC PUMP

IN1 OUT
ACT
IN2
MAN_ON

Figure Courtesy of Prof. Dr. H. Kirrmann, ABB Research Center, Baden, Switzerland

Ronel V. Vidal, PECE

IEC 61131-3 Programming languages
Sequential Flow Chart (SFC)

START STEP

T1
N ACTION D1 D1_READY
STEP A
D ACTION D2 D2_READY
T2
N ACTION D3 D3_READY
STEP B
D ACTION D4 D4_READY
T3

Pfigure Courtesy of Prof. Dr. H. Kirrmann, ABB Research Center, Baden, Switzerland

Ronel V. Vidal, PECE

IEC 61131-3 Programming languages
Structured Text (ST) VAR CONSTANT X : REAL := 53.8 ;
Z : REAL; END_VAR
VAR aFB, bFB : FB_type; END_VAR
bFB(A:=1, B:=‘OK’);
Z := X - INT_TO_REAL (bFB.OUT1);
IF Z>57.0 THEN aFB(A:=0, B:=“ERR”);
ELSE aFB(A:=1, B:=“Z is OK”);
END_IF
Instruction List (IL)

A: LD %IX1 (* PUSH BUTTON *)

ANDN %MX5 (* NOT INHIBITED *)
ST %QX2 (* FAN ON *)

Figure Courtesy of Prof. Dr. H. Kirrmann, ABB Research Center, Baden, Switzerland
PLC in an industrial set up
Actuators PLC
HMI,
Management, Business
Sensors PC based Monitoring Systems
system and Data
Acquisition
Other field Systems
devices Other
controllers
PLC in an industrial set up
Enterprise Network
Engineer Operator Supervisor
gateway
station station Station

Control Bus
(e.g. Ethernet)

PLC
large

COM1
Control Station

COM 2
PLC

COM1
COM1

COM 2

CPU
I/O
with Field Bus

CPU
CPU

PLCs gateway

I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O

direct I/O
Field Bus Field Bus

COM
COM

COM

COM
COM
I/O
I/O
I/O
I/O

I/O
I/O
I/O
CPU

CPU

CPU
directly connected
I/O
Field Stations FB
gateway Field Devices
small PLC
data concentrators,
not programmable,
but configurable
Sensor Bus (e.g. ASI)
Picture Courtesy of Prof. Dr. H. Kirrmann, ABB Research Center, Baden, Switzerland
End