Fundamental of Process

Control
Chapter 2: Process elements
and P&ID
Dr. Nguyen Trong Tai
2 Contents
- Process control loop
- Control system instrumentation
- Process Flow Diagram and Pipe & Instrument Diagram

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3 Instrumentation
- Instrumentation is the process of controlling, measuring and
analyzing physical quantities using various types of interconnected
process control instruments.
- Various types of instrumentation are used to measure variables
including temperature, gas and fluid flow rates, fluid levels, pressure,
and pH in production and manufacturing settings.
- These instrumentation and process control products include flow,
pressure & level sensors, detectors and analyzers, controllers,
monitoring systems, and much more.

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4 Instrumentation
- Engineers use sensors and various other types of instrumentation to
monitor and maintain process control equipment for improved
production, product consistency and quality management, and
workplace safety in manufacturing and processing facilities.
- Process control instrumentation is also critical for preventing fire or
explosion in facilities that store or process oil, gas, chemicals and
other combustible substances.

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5 Instrumentation
 There are numerous industries that utilize process control equipment
and instrumentation, including:
 Oil and gas
 Mining
 Food & beverage
 Marine
 Semiconductor manufacturing
 Water/Waste Water
 And several others

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6 What Type of Instrumentation Do You Need?
 Process instrumentation responsible for any application, from gas
analytics to automation to pressure monitoring.
 Instrument and process control equipment can be listed as following
figure:

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 Automation Devices:
 Automation instrumentation products are used to streamline
automated manufacturing processes and improve workplace safety.
 There are various types of instrumentation including:
 encoders;
 machine safety monitoring products;
 signal conditioners;
 e-stops;
 HMI displays;
 on/off sensors,
 and more.

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 Automation Devices:
 Controllers & Data Acquisition:
Data acquisition stations and controllers gather and digitize measurement
signals for control and/or storage and analysis. This process collects data
for monitoring and analyzing testing and manufacturing processes.

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 Automation Devices:
 Encoders
Rotary, incremental, and absolute encoders monitor the position of a
shaft and convert the data into an analog or digital signal to measure
changes in position, speed, or linear distance.
That may include optical encoders for high resolution and operating
speed and magnetic encoders for dusty and dirty working environments.

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 Automation Devices:
 Human Machine Interface (HMI) Displays:
Industrial HMI touch panels provide a textual or graphical interface
between industrial automation systems and users.
They can display data, graphics, and animation to provide control and
monitoring of automation systems.

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 Automation Devices:
 Industrial Computing:
Controls and automation instrumentation require software, HMIs, ethernet
switches, data stations, and other equipment to provide communication
between different devices and users

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12 Applications
 Automation Devices:
 Machine Safety:
Facilities that utilize industrial automation are required to adhere to
guidelines aimed at preventing workplace injuries and related economic
consequences such as equipment downtime and fines related to non-
compliance.
Inventory includes emergency stop shutdown relays, light curtains,
interlock switches, access monitoring devices, and other industrial
instrumentation

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 Automation Devices:
 Machine Vision:
Image-based inspection and processing technology is used to decode
labels and inspect and sort products in an automated production line.
In robot applications, it helps robots grasp products by determining the
location and orientation of a product.

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 Automation Devices:
 Photoelectric & Inductive Sensors:
Photoelectric sensors, also called photo eyes, use infrared light transmitters
to detect the presence and proximity of an object without making
physical contact.
Inductive proximity sensors perform that same function but use an
inductive switch to sense an object and are specifically designed for the
detection of metal objects.
Typical applications for both types of instruments include manufacturing,
packaging, positioning, and counting .

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 Pressure:
 Pressure instrumentation includes various pressure gauges, transmitters,
sensors, and transducers that are used to measure and display the units
of pressure of a fluid or gas.
 Transducers, transmitters, and sensors measure the pressure in pumps,
pipes, tanks, and other processes and then send a signal to a display,
controller, HMI, or other device .
 Pressure gauges are analog or digital devices used to display the
readings and provide local real-time measurement for effective
pressure monitoring.

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 Pressure:
 Regularly measuring the pressure levels of gas, steam, and liquids is
critical for safety and quality control in commercial and industrial
applications.
 Some of the industries where pressure measurement is used include
chemical plants and oil, gas, petroleum or other petrochemical
applications, Water and Wastewater, Food and Beverage, Concrete,
heating and cooling, lumber and paper products and more.

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 Pressure:
 Pressure gauges and other devices for pressure measurement are a
cost-effective and reliable solution for preventing equipment failure.
Considerations in selecting the right pressure instrumentation solution for
your application include:
 Type and range of pressure reading required
 Operating environment temperature and chemical compatibility of wetted
parts
 Level of accuracy required
 Any industry specifications

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 Pressure:
 Pressure instrumentations include:
 Pressure Controller.
 Diaphragm Seals.
 Analog & Digital Gauges.
 Pressure Transmitter and Transducers.
 Pressure regulator.
 Pressure switches.
 Etc…

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 Temperature Instrumentation:
 Temperature instrumentation includes a wide range of field instruments
and sensors used to measure temperature in commercial and industrial
systems.
 These temperature control systems include manual and automatic
processes for monitoring and controlling the temperature to maintain
an ideal operating range to optimize production and prevent
equipment damage or failure.

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 Temperature Instrumentation:
 Local temperature instrumentation is typically reserved for non-critical
applications or when temperature fluctuations are minimal and occur
slowly.
 Automatic applications utilize sensors and other field instruments that
provide a signal or alarm when temperatures reach a specified level.
These are used for critical applications where temperatures can quickly
change.
 Depending on the application, they can be more convenient than
manual field instruments because they do not require an operator to
take the measurements.

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 Temperature Instrumentation:
 Temperature instrumentations include:
 Temperature Controllers.
 Heaters.
 Infrared Pyrometers.
 Temperature Transmitter.
 Thermal Imagers.
 Temperature switches.

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 Flow Instrumentation:
 Flow measurement involves determining the movement of a fluid or gas
through a pipe or channel.
 There are two forms of measurement typically used: volume and mass.
 The devices used to measure the mass or volumetric flow rate of a
liquid or gas include mechanical flow meters, differential pressure-
based meters, variable area meters, electromagnetic flow meters,
thermal mass flow meters, and more.
 A combination of one or more devices may also be used as part of a
flow measurement process.

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 Flow Instrumentation:
 Industrial applications use flow instrumentation include:
 Oil & Gas
 Power
 Pulp & Paper
 Boiler Control
 Chemical
 Food production
 Wastewater & water treatment facilities

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 Flow Instrumentation:
 Flow instrumentation include:
 Flowmeters.
 Flow indicators.
 Metering pumps.
 Flow control valves.

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 Level Instrumentation:
 Level instrumentation includes a range of level measurement
equipment including switches, controllers, transducers and radars.
 These instruments play a vital role in ensuring silos, tanks and vessels
maintain levels that are within safe operating limits.
 This not only protects equipment but also helps prevent environmental
and safety hazards.

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 Level Instrumentation:
 Continuous level and point level instrumentation can be used for
applications involving gases, liquids, powders, bulk solids and slurry and
are used by several industries, including:
 Water & Wastewater
 Food & Beverage
 Marine Equipment
 Irrigation Equipment
 Wood Product Manufacturing
 Aggregate & Cement
 Mining

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 Level Instrumentation:
 Level instruments include:
 mechanical and digital tank level indicators,;
 point level switches and continuous level switches;
 transmitters,;
 indicators,;
 liquid level sensor modules.
 Etc…

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 Communication Instrumentation:
 Control and monitoring systems require cordsets, communication
converters, and other devices and accessories to connect process
instrumentation to data acquisition devices.
 These products allow you to manage and maintain multiple processes
throughout a facility or for remote site management across numerous
locations.

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 Communication Instrumentation:
 Communication instruments include:
 Connectors and Cordsets
 Communication Converters
 SCADA System
 Remote Monitoring
 Wireless Radio
 Signal Conditioners
 Etc…

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 Gas Analytics Instrumentation:
 Gas analytical instrumentation includes gas analysis equipment and
continuous emissions monitoring systems that are used to detect and
monitor levels of various gases.
 This includes oxygen, hydrogen, nitrogen, methane, carbon dioxide,
carbon monoxide and other gases, as well as emissions caused by gas
and pollutants.
 Some gas analyzers are designed to detect and measure a specific
type of gas where multi gas analyzers are configured for applications
involving two or more gases.

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 Gas Analytics Instrumentation:
 Gas analyzers play a crucial role in protecting human health and
safety, and preventing explosions and other catastrophic events.
 They are widely used by the mining and petrochemical industries, and
for landfill management, wastewater management, manufacturing
and other applications.

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 Gas Analytics Instrumentation:
 The different types of gas analysis systems include:
 Continuous gas analyzers
 Multi gas analyzers
 Toxic gas detectors
 Flame detection sensors
 Gas analysis systems
 Ambient air monitoring systems
 And more

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 Liquid Analytic Instrumentation:
 Liquid Analytic Instrumentations are widely used in chemical, cosmetic
and food industrial.
 Liquid analytic devices can measure:

• Ammonia • ORP
• Calcium • pH
• Chlorine • Silica
• Conductivity • Sodium
• DO • Turbidity
• Fluoride • and more

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34 Finish Section
In summary, this section provides
 An overview about industrial instrumentation.
 Types of instrumentation in industrial process.
 Devices and instrumentation need in process control system, such
as: temperature, pressure, level, flow..

N T Tai - HCMUT 5/4/2020