Instrumentation

& Process Control

EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control
Instrumentation & Process Control

Instrumentation is a branch of science that deals with
measurement and control in order to increase efficiency and
safety in the workplace.

Instrumentation is a speciality in permanent and close
communication with Process, Operation and Safety specialists at
any time during process unit life time.

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 2
 Why should we control the process?

Because it is inherently unstable

Because it can become unsafe

To control product quality

To optimise production and reduce production loss

To reduce operators’ workload (automatisms)

To monitor production data
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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 3
Domains

Process sensors

Fire & Gas sensors

Control valves

On/off valves actuators

Electrical, electronic, pneumatic, hydraulic automatisms

Metering skids, tanks gauging

Process analysers

Industrial Information System
• Process Control systems
• Safety systems

(Pressure Safety valves)

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Involved in Engineering, Construction,
Commissioning and Operation
EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 4
 Process measurements

Level
Density

Flow
Composition: gas, smoke

Pressure
Calorific value

Temperature
Viscosity

Position
Flash point

Vibration
Vapor pressure

Speed
Cloud point

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Radiation: UV/IR
EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 5
Input documents

P&ID’s

Safety logic diagrams

Causes & effects matrices

Process descriptions

National or international regulations

Standards (ISA, API..)

Company technical specifications

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 6
 Produced documents

Data bases (Intools, S4I…)
• Instruments list
• Data sheets
• Trouble shooting diagrams
• Termination blocks drawings
• DCS Inputs/outputs lists

DCS Functional analyses © 2015 - IFP Training
EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 7
Instruments identification
GS EP INS 102 (Total)
Base ISA-5.1

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 8
 Instruments identification
Piping & Instrumentation Diagram (P&ID)
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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 9
Instruments identification
Examples

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 10
 P&ID
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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 11
Standard signals ranges

Pneumatic
• 0.2-1barg
• 3-15psig

Electrical analogue
• 4-20mA

Electrical discrete
• 0-24Vdc

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 12
 Standard signals ranges
EXAMPLE

A temperature transmitter with a calibrated range of 00c to
1600c will have the following output

Electronic transmitter:
Temperature
0 40 80 120 160
(deg C)
Transmitter output
4 8 12 16 20
( mA)

Pneumatic Transmitter:
Temperature
0 40 80 120 160
(deg C)

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Transmitter output
0.2 0.4 0.6 0.8 1
( barg)
(psi) 3 6 9 12 15
EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 13
Control loop
MANUAL LEVEL CONTROL AUTOMATIC LEVEL CONTROL

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 14
 Control loop
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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 15
Control loop

Process reaction
First order with
no dead time
Second order with
no dead time

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 16
 Control loop
Comments on the previous slide

Dead time is partly introduced by the control loop lag time.

Systems that have a quick initial rate of response to input changes are generally referred to as first order
response.
Systems with a slow initial rate of response to input changes are generally referred to as second order.

If the time constant is greater than the dead time, control should not be too difficult to achieve. On the reverse
it is difficult to control a process for which the dead time is greater than the time constant.
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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 17
Control loop
Setpoint
Measured value Controller Actuator
Controller
Setpoint Output value
Measured
value
I
Sensor P
Transmitter
+ Supply

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Control valve
EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 18
 Controller functions

Related to Process
• To keep the process at a predetermined value (set point)
• To reduce effects of process disturbances
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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 19
Controller functions

Related to Operator
• To provide process data and give access to process control

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 20
 Controller functions
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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 21
Controller parameters

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 22
 Controller parameters

Proportional term
• The proportional term, gain, makes a change to the output that is
proportional to the current error value
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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 23
Controller parameters

Integral term
• The contribution from the integral term (sometimes called reset) is
proportional to both the magnitude of the error and the duration of
the error
Iout

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 24
 Controller parameters

Derivative term
• The rate of change of the process error is calculated by determining
the slope of the error over time (i.e. its first derivative with respect
to time) and multiplying this rate of change by the derivative gain
Kd
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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 25
Controller parameters
Key points to keep in mind
PID effects summary

Kp: Proportional gain – larger Kp typically means faster response
since the larger the error, the larger the Proportional term
compensation. An excessively large proportional gain will lead to
process instability and oscillation.

Ki: Integral gain – larger Ki implies steady state errors are eliminated
quicker. The trade-off is larger overshoot: any negative error
integrated during transient response must be integrated away by
positive error before we reach steady state.

Kd: Derivative gain – larger Kd decreases overshoot, but slows down
transient response and may lead to instability due to signal noise
amplification in the differentiation of the error.

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 26
 Controller parameters tuning

Trials and errors
• The trial and error tuning method is based on guess-and-check.
− In this method, the proportional action is the main control, while the
integral and derivative actions refine it.
− The controller gain, Kc, is adjusted with the integral and derivative
actions held at a minimum, until a desired output is obtained.
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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 27
Controller parameters tuning

Ziegler-Nichols closed-loop tuning method
• Based on transient step response of a process system.
Determining the ultimate gain value, Ku, is accomplished by finding
the value of the proportional-only gain that causes the control loop
to oscillate indefinitely at steady state.

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 28
 Controller parameters tuning

Ziegler-Nichols Open-Loop Tuning Method
• Based on transient step response of a process system
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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 29
Controller parameters
Proportional only
Different
gains

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 30
 Controller parameters
Proportional only
Too high gain
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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 31
Controller parameters
P,I parameters
Same tuning, different process conditions

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 32
 Controller parameters
Derivative
Risk of unstability
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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 33
Complex control loop
Cascade
SIMPLE LOOP USE OF CASCADE
Analyze the effect of an increase in the drum pressure:
- DP at control valve: - DP at control valve:
- Liquid flow rate: - Liquid flow rate:
- Drum liquid level:
- LC005 the opening of the valve - FC008 the opening of the valve, before
the level starts decreasing
- Drum liquid level:

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- Control: RAPID SLOW - Control: RAPID SLOW
- Level: STEADY NOT STEADY - Level: STEADY NOT STEADY
EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 34
 Complex control loop
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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 35
Complex control loop
Split-range (1)

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EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 36
 Complex control loop
Split-range (2)

As the Pressure controller output increases, the export valve (valve 1) begins to
open and continues until at 50% it is fully open.

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During the first 50% of controller output the flare valve (valve 2) remains closed
and will only begin to open once the controller output passed the 50% mark.

Valve 2 saturates fully open with a controller output of 100%
EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 37
Complex control loop
Ratio control
Fuel Gas
A/F ratio 14:1
FT
X
* 14
SP
FC
PV
Y1 FT
Combustion Air

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Set-point of the combustion air flow controller FC is 14 times the
output of the uncontrolled Fuel Gas flow.
EP 20302_d_A_ppt_00 Introduction to Instrumentation Process Control 38