Process Control & Instrumentation for Engineers

Induction course for new System engineers

Part 1
Process Control & Instrumentation for Engineers

Upon the completion of this training course The Participant should be able to:

~ Understands the terminology of Process measurements & control.

lEI Understandsthe relation between different types of process variables

[g) Understands the process measurements techniques and Select the most
effective technique for process variables measurements (pressure, flow, level,
temperature and analytical)

~ Understands controllers concept and control theory

~ Understandsdifferent types of controllers and how to select the proper type for
each applicationP, PI, PID Algorithms

(g) Be familiar with contralloop tuning and adjustment

I:gJUnderstands Advanced control methods (cascade, Feedforward, Ratio and

selective control)

[g] Be able familiar with Control Valvesand actuator Selection

~ UnderstandsPLC componentsand logic control building

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Process Control & Instrumentation for Engineers

Course Contents

Part 1

Chapter 1 Process Control terminology

Importance of measurements
Reading drawings
Principles of control

Chapter 2 Process Measurements

Pressure measurements
Flow Measurements
Level Measurements
Temperature measurements
Analytical Measurements

Chapter 3 Controllers and principles of Automatic Control

Principles of Automatic Control
Types of controllers
PID controllers

Chapter 4 Advanced Process control Schemes

Cascade control
Feedforward control
Ratio Control
Selective Control
Valve Position Control

Chapter 5 control valves

Linear motion control valves
Rotary motion control valves
Actuators
Control Valve Accessories

Chapter 6 Programmable Logic Controller ( PLC)

Logic control
Componentsof PLC
PLC Programming
Building logic

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Process Control & Instrumentation for Engineers
Process Control & Instrumentation for Engineers

1.1 Importance of measurements

Measurementhas been defined as the extraction of signals from physical system or

processes which represent parameters or variables.
The output of measuring device is infonnation concerning the state of the process to
which is connected. the output of the measuring device is transduced to a signal
readable by a control system. the signal is compared to a precise reference known
as a standard, which assumed to be unvarying.

Before discussingprocess variablesin details we should have an idea about some

terms and definitions

1.1.1 Linearity
The closeness to which an input! output relationship of a device follows a straight
line.

It is usually expressed as anon-linearity, that is the maximum deviation between an

average curve and a straight line.

The nonlinearity is sometimes denoted angularity as the percent deviation from a

straight line.
Process Control & Instrumentation for Engineers

Output

100%
Actual
Functional Straight line
CIS
ngularity
I
The vertical distance
betweenfunctional CIS &
/" the straight line is the non-
/

0% II (/ linearity

00/0 100%

Figure 1.1

1.1.2Span
The Algebraic difference between the upper and lower range values.

Elevation! Suppression

Zero BasedSpan
Zero~o c
oc IOOC
ISOC
Engineering
value
Process Control & Instrumentation for Engineers

100%

ElevatedSpan
SuppressedZero oc lOOC

Engineering
value

Zero Do
- -50 C
SuppressedSpan
ElevatedZero
Engineering
value

Figure 1.2

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Process Control & Instrumentation for Engineers

1.1.7Dead band
The range through which an input of a device can be varied without initiating a
change in the output of the device.

1.1.8 Dead Time

The interval of time between initiation of an input change to a system or a device
and the time it is seen at the output.

I Time
r ~"""-/ ~ "-""'" / ..
Time

0
Time I ~ ".-./ ~"'- /' ~ ...
-+

cD cD Time

Figure 1.3
Process Control & Instrumentation for Engineers
-
1.2 Principles of Process Instrumentations

To understand the main principles of instrumentation we must be familiar with

instrument symbols and abbreviations, which will lead to fast and easy reading of
drawings.
,-' -
1.2.1 Glossary of Abbreviations & Symbols

1.2.1.1 Meaning of Abbreviations

Letter Succeed~Le-ue-rs
Measured or Modif"aer I -Readoi!tOr Output Modiirer
Initiating Variable Passive Function
Function
IA Analysis IAlann
I'-"~!~
C ~'ii~~
User'-s Choice r.I(\-~\"">
-'/ -rControf
ser's OICC I Differential
E 0 tage Sensor
(Primary
Bement)
F Row Rate IKaiio- -~

I (Fmction)

lJsc(SO!oicc I I Glass,
Viewing ,)
\:or
,-.

Device
!H Hand I Hie;h_- _1
I ~~Level :7:ca!>Dt ectn I Indicate
i I.
I(AifICC,
Li~ht -
II~w~
0 ser's OICC
I Restriction
PPressure.
Vacuum Point (Test)
i Connection
IQ Quantity
j Integrate,
ITotalize y~
tRecord
I Safety It::!~~~::~~~
~Wdl ~ ransmlt
= .J"- I

I Y Axis
-".J."-
Event.State rera y ,
:omput~
I Z Position.Dimension Iz Axis Driver,
Actuator,
Unclassified
Final Control
Element

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Process Control & Instrumentation for Engineers

1.2.1.3 Instruments Symbols

MOUNTING SYMBOLS

local Mounting:

Panel Rear or
RackMounting:
Process Control & Instrumentation for Engineers

Measuring Instruments and Control

5~
Process Control & Instrumentation for Engineers

InstnJment Supply
or Connectionto Process

," ,.'

,:"" ,.~'

OR - ,~:" ,;~"

c c
~ ~ --
ElecU'omagnetic or Sonic Signal """'- """'",,-
(Guided)
Electromagnetic
(Not Guided)
or SonicSignal rv I\.,

-0-0-

MechanicalUnk . . -

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Process Control & Instrumentation for Engineers

Actuators

'} ';:1< ~ S

Without Solenoid
Positioner

i-_-@
Double-Acting EJectrohydrau'ic

Valve Actuator
with Attached EJectTo-
Pneumatic Converter

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Process Control & Instrumentation for Engineers

l x--~
BackpressureRegulator Two- Way Valve,
With External Fail Open
Pressure Tap

Pressure-Reducing
Regulator,Self-COntained,
With Handwh~ Adjustable Pilot Operated
Set Point Relief Valve
Process Control & Instrumentation for Engineers

0
0 lEVEL SWITCH, TO
MEASUREDSOUDS
LEVEL INDICATOR,
FLOATTYPE

0-.
[:~~==~[~~::J
TRANSMIlTER -CONTROLLER, CAPACITANCE TYPE
WITH TWO CONNECTIONS LEVEL ELEMENT

LEVEL TRANSMITTER,
DI FFER ENTIAL -PRESSUR E RADIOACTlVE- OR SONIC-
TYPE, MOUNTED ON TANK TYPE LEVEL TRANSMllTER

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Process Control & Instrumentation for Engineers

...'"

-9

2 n RTD(If-i
~ , -l

~~~Z~
Thermocouple,
TemperatureElement Resistance Bulb
with Well (RTD)Connected to
TemperatureIndicator

Temperature

e l.
1--~<~)---:-
~~ t
Pressure Element, limit Switch That is
Connected to Pressure Actuated When Valve
Indicating 'Tf'8nsmitter is Closed
Pressure Position
Process Control & Instrumentation for Engineers

1.3 Reading PFD { ,,"{

"
Process Control & Instrumentation for Engineers

1 PRELIMINARY DIMENSIONS
R>R LAYOIJT ONLY
8. DESIGN FU)W RATE

~, lPRE.CHOKE~S: 4. WATER FLOW AT TEST - OPERATION '

~: 21 bar (Vo) 60% AT MAX.gsomJ/d
TEMPERATURE: 45 °c FOR OE:SIGN PURPOS!:
2. NORMAlLY NO FlaN, DA~ ~ 5. <S> INDCATES ~ECTk)NS FOR TEST
ARE FORLMSIZING ~LY . BASfO ~ IN SMRE $tAe.U~~ ~
~ «>% FREE WATERAT '3CXX)ms/d 6. WATER DRAW-Off't1) BE ROUTED TO WING-
3 . DESIGNED~ PROO~ FlOW TANt<S.No.3 SEPARATELY FOR FLUSHING
(SPARE OPERATION) QPERATION$.

~~ERATlO~
I~_~~AH
I:;:x_-,

\ 1.(_1
. Of .-
W
,~ifi'i8",r--.IL-
;:J[:
. r
, , u
.
~, ~.

r TESToPER_l IN ~V-101J
~~~~~- IV."
~ '4!} II~-
~
I-~_l
~~~~==!
tQ;t:

.) DENSITY
MW
IS.C/4.C
IIDW CALLEDRELATIVE .~[CULAR
-- -
MA88
.
-- - ~~rii:: ~4

GAS / OIL SEPARATION

! TYPICAL PROCESSFLOW SCHEME
Process Control & Instrumentation for Engineers

1.4 Reading P&ID

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Process Control & Instrumentation for Engineers

1.5 Process Control Terminology

1.5.1 Definition of Control

-Automatic control may be defined as the technique of measuring the value of a

variable and producing a counter response to limit its deviation from a selected
reference. Many other equally suitable definitions could be given,' but automatic
control can be understood better in terms of why it is needed, the advantages it
offers and the forms of energy it controls. A really simple approach is taken in the
discussion of these facets, for a complete understanding of basic principles is
necessary in comprehending and evaluating control problems.

A closed control loop may use several devices to accomplish the control of a
process variable. Regardless of the number of elements used, the loop will contain
at least four basic elements: (a) sensing, (b) measuring, (c) controlling and (d) final
control element. Often, a transmitting element is added to these. More than one
element is often designed into the same housing so that a loop does not always
contain four separate units.

1.5.2 The Purpose of Automatic Control

The one basic purpose for using automatic controls is that production is achieved
more economically. Some processes would not be possible except through the use
of automatic controls. Economy is achieved in several different ways:

. Lowering labor costs

. Eliminating or reducing human errors
. Improving process quality
Reducing the size of process equipment and the amount of space it
requires
Providing greater safety in operation
Minimizing energy consumption

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