INSTRUMENT AND CONTROL ENGINEERING COURSE

General information
Course objective:
• Understand the basic of instrument and control system engineering.
• Tuning the process applying PID tuning method.
• Be capable of reading and understanding the Process Flow Diagram – PFD, Piping
and Instrumentation Diagram (P&ID)
• Understand the important drawings which are commonly used in instrument and
control engineering.

What does the C&I engineer do?

In project team:

• Control and instrumentation engineers (C&I engineers) are responsible for designing,
developing, commissioning and installing a control system (from controllers to
instruments and control valves)
In operation team

• C&I engineers are responsible for maintaining the system operable, modify the
control logic as required by Production/ Process engineers. C&I engineers also need
to do the routine maintenance, and in case of any failure C&I engineers have to
troubleshoot or provide a solution to a problem.

Which systems is C&I engineer responsible for?

• Basic Process Control System (BPCS)/ Process Control System (PCS): Distributed
control system (controllers, I/O cards, communication cards, servers, historian
servers)
• BPCS instrumentation: Pressure, Temperature, Level, Flow, Analysers ( Gas
Chromatograph, Oil in Water, Hydrocarbon dewpoint analyser, ect.)
• Control Valves, On/Off Valves, Pressure Relief Valves.
• Emergency Shutdown system (ESD)/ Safety Instrumented System (SIS)
• ESD/SIS control system (controllers, I/O cards, communication cards, historian
servers, ect.)
• ESD/SIS instrumentation: Pressure, Temperature, Level.
• Shutdown valve, Blowdown valves
• Fire and Gas system (FGS):
• FGS control system (controllers, I/O cards, communication cards, historian servers,
ect.)
• Field fire & gas detectors, PAGA system.
• Package control system such as Hypochlorite system, Instrument air system, HVAC
system, compressor package, Gas turbine and Generator control system.
• Telecom system

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CONTROL SYSTEM BASICS

We have control system in our company for three main reasons:

• Make money by reducing the size, weight and footprint of process equipment,
minimizing the effect of disturbances, reducing downtime, optimizing production,
controlling better product quality, reducing energy and raw materials, reducing labor
cost (by reduce number of people for process control)
• Reduce risk by eliminating human errors, safety improvement 24/24, lowering the
emissions.
• Enhance security: reducing human errors, alarming threats, recording history,
integration with security systems.
Instrumentation provides various indications used to operate the process. The process
measurement is required for control such as flow, level, temperature and pressure.

1. THE CONTROL LOOP

Function of a process control system is to maintain stable operating conditions (flow,
temperature, level and pressure) in the process when operating variables such as feed rate,
composition, temperature, equipment performance, ect. are changing.
Basic elements of control:

• A process requiring control

• A process measurement
• A controller
• A final control element (control valve, remote on/off valve, shutdown/blown down
valve.)
Open loop control
Open control loop is one in which the control action is independent of the output

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Closed control loop

Closed control loop is one in which control action is dependent on the output

Feedback control loop

Feedback control loop is information in a closed‐loop control system about the condition of
a process variable. This variable is compared with a desired condition to produce the proper
control action on the process. Information is continually "feedback" to the control circuit in
response to control action.

Example: Loop Oil cooler and its associated temperature control system

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Process time lag:

Process time lag is a term that describes the process delay and retardation, caused by three
main factors:

• Capacitance: ability of process to store the energy

• Resistance: opposing the transfer of energy.
• Transportation time: time from one point to another point
Capacitance is the ability of a process to store energy. For example, the walls of the tubes in
the lube oil cooler, the cooling water, and the lube oil can store heat energy. This energy‐
storing property gives the ability to retard change. If the cooling water flow rate is
increased, it will take a period of time for more energy to be removed from the lube oil to
reduce its temperature.
Resistance is that part of the process that opposes the transfer of energy between
capacities. In above example, the walls of the lube oil cooler oppose the transfer of heat
from the lube oil inside the tubes to the cooling water outside the tubes.

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Transportation time is time required to carry a change in a process variable from one
point to another in the process. If the temperature of the lube oil is lowered by increasing
the cooling water flow rate, some time will elapse before the lube oil travels from the lube
oil cooler to the temperature transmitter. If the transmitter is moved farther from the lube
oil cooler, the transportation time will increase. This time lag is not just a slowing down or
retardation of a change; it is an actual time delay during which no change occurs.
Control loop stability:
Stable: The amplitude of process variable is decreasing to its desired point (98%) within 4
cycles or less (Figure A)
Conditionally stable: The amplitude of process variable is constant over the period of time.
Controlled variable will never reach the desired point.
Unstable: the amplitude of process variable is oscillated and increased, consequentially
result the out of control process.

Variables
Variable is a process condition that can change over time

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For example, we want

w to conttrol the leveel in the tannk, this is a level
l contro
ol process. The
T
level wiill change/ be
b variable over time because
b liqu
uid is draineed through control valvve
located at the tank bottom. Iff we want thet level at the specificc point, we should
s man nipulate
the conntrol valve to maintain the level att setpoint.

System deadtime
Deadtim me defined as the timee delay betwween changge in the con ntrol signal and the beginning
of its efffect on the measured value of thee controlled
d variables.

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System Capacitancce:
Capacittance referss to that porrtion of the process wh here energyy and/or maass can
accumuulate. The laarger the veessel in relattion to the flows,
f the laarger the caapacitance and
hence tthe more sloowly the co ontroller varriables channges for a giiven changee in the
manipuulated variable. The cap pacitance of the processs tends to reduce distturbances and
therefo
ore makes co ontrol less difficult.
d
Processs capacitancce is measured by Timee constant which
w is calculated fromm differenttial
equatio
on used to model
m the process,
p butt approximaately is equaal to processs residencee time.
Example: Tank B has larger caapacitance than
t tank A although th
hey are at the same vo
olume.

Understtanding thee response characterist

c tics of vario
ous processees allows co
ontrol and
instrum
ment engineer to designn an effectivve control system
s inclu
uding selectting the con
ntrol
methodd and controol valve.
Fluid flo
ow:

• Small capaccity

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• Negligible deadtime
• RC time constant from 0.1 to 0.5 seconds
• Fast responding process and is therefore subject to noise resulted in instability
process
Pressure:

• General large capacity

• Small deadtime
• RC constant is same as flow
• Fast responding process but is somewhat self regulating and large capacity and gas
compressibility helps dampen process oscillations making this stable process (low
noise/ disturbance)
Liquid level:

• General large capacity

• Small deadtime
• RC time constant is large in atmospheric vessels, and is small in the high‐pressure
vessels.
• Precise control can be sacrificed for stability. That is, the level can usually oscillate
for the sake of maintaining the stable flow.
Temperature:

• Large capacity
• Large deadtime
• Long time constant
• Slow to respond to load changes

2. Types of control systems

On/off control
On/off control is simplest of all control modes and easy to understand.

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Proportional control
The proportional control mode is in most cases the main driving force in a controller. It
changes the controller output in proportion to the error. If the error gets bigger, the control
action gets bigger. This makes a lot of sense, since more control action is needed to correct
large errors.
The adjustable setting for proportional control is called the Controller Gain (Kc). A higher
controller gain will increase the amount of proportional control action for a given error. If
the controller gain is set too high the control loop will begin oscillating and become
unstable. If the controller gain is set too low, it will not respond adequately to disturbances
or set point changes.

Integral (Reset) control

Integral action (reset) is added to the controller to minimize or eliminate the offset. In
proposional action, the amount of valve movement is proportional to the error. By contrast,
the amount of correction applied with integral action depends both on the magnitude and
duration of the error. The prime purpose of reset is, therefore, to prevent offset and keep
controlled variable at the control point even as the process load change.

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Derivative control
Derivative control can be defined as a crude prediction of the error in future, based on the
current slope of the error. Once the derivative mode has predicted the future error, it adds
an additional control action equal to Controller Gain * Future Error.
For example, if the error changes at a rate of 2% per minute, and the derivative time Td = 3
minutes, the predicted error is 6%. If the Controller Gain, Kc = 0.2, then the derivative
control mode will add an additional 0.2 * 6% = 1.2% to the controller output.

The first point to consider when thinking about using derivative is that a PID control loop
will work just fine without the derivative control mode. In fact, the overwhelming majority
of control loops in industry use only the proportional and integral control modes.
Proportional gives the control loop an immediate response to an error, and the integral
mode eliminates the error in the longer term. Hence – no derivative is needed.
On dead‐time dominant processes, PID control does not always work better than PI control
(it depends on which tuning method you use). If the time constant (tau) is equal to or longer
than the dead time (td) , PID control easily outperforms PI control.
PID control in Application
Temperature and Level Loops
Temperature control loops normally have smooth measurements and long time
constants. The process variable of a temperature loop tends to move in the same direction
for a long time, so its slope can be used for predicting future error. So temperature
loops are ideal candidates for using derivative control – if needed. Level measurements can
be very noisy on boiling liquids or gas separation processes. However, if the level
measurement is smooth, level control loops also lend themselves very well to using
derivative control (except for surge tanks and averaging level control where you don’t need
the speed).

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Flow Control Loops

Flow control loops tend to have noisy PVs (depending on the flow measurement technology
used). They also tend to have short time constants. And they normally act quite fast already,
so speed is not an issue. These factors all make flow control loops poor candidates for using
derivative control. P+I method is recommended
Pressure Control Loops
Pressure control loops come in two flavors: liquid and gas.
Liquid pressure behaves very much like flow loops, so derivative should not be used, P+I
method is recommended.
Gas pressure loops behave more like temperature loops (some even behave like level loops
/ integrating processes), making them good candidates for using derivative control.
Summary:
Choosing which control mode depends on the application and the process in overall. Here is
the control mode versus the application in table:

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Control Mode vs Application

Load Changes
Process Reaction
Control Mode Rate Size Speed Application

Large capacity temperature and

level installations. Storage tanks,
On‐off: Two hot‐water supply tanks, room
position with heating, compression suction
differential gap Slow Any Any scrubber.

Pressure, temperature and level

where offset is not
objectionable. Kettle reboiler
level, drying oven temperature
Proportional (P) Slow to moderate Small Moderate and pressure reducing stations.

Where increased stability with

minimum offset and lack of reset
Proportional‐plus‐
wind‐up is required.
derivative (rate)
Compressure discharge
P+D Moderate Small Any pressure.

Proportional‐plus‐
Most applications, including
integral (reset)
Slow to flow. Not suitable for batch
P+I Any Large moderate operations.

Proportional‐plus‐
integral‐plus‐
Batch control, processes with
derivative
sudden upset, temperature
P+I+D Any Large Fast control.

Typical PID settings

Likely Likely
Controller Setting Minimum Maximum Typical Value Unit of Settings
Flow and Liquid Pressure
Gain 0.2 1.5 0.5 gain
Integral 0.05 0.5 0.2 minutes
Derivative 0 0 0 minutes
Filter 0 0.2 0.02 minutes
Scan 0.5 2 1 seconds
Inline Temperature

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Gain 0.5 4 1 gain

Integral 0.2 1 0.5 minutes
Derivative 0 0.25 0.1 minutes
Filter 0 0.1 0 minutes
Scan 1 5 2 seconds
Column or Reactor Temperature, Gas Pressure
Gain 2 10 5 gain
Integral 2 20 5 minutes
Derivative 0 5 1 minutes
Filter 0 0.2 0 minutes
Scan 1 15 10 seconds
Tight Level Control
Gain 1 10 5 gain
Integral 2 30 10 minutes
Derivative 0 2 1 minutes
Filter 0 0.5 0.2 minutes
Scan 1 5 2 seconds
Surge Tank Level
Gain 1 4 2 gain
Integral 10 None 60 minutes
Derivative 0 0 0 minutes
Filter 0 1 0 minutes
Scan 5 30 10 seconds
Composition
Gain 0.1 1 0.5 gain
Integral 10 30 20 minutes
Derivative 2 5 3 minutes
Filter 0 0.5 0 minutes
Scan 10 30 20 seconds

Exercise: Tuning a control loop by using Matrikon Simulator (trial version)

In manual mode:
¾ Step (pump test) the CO. (up or down)
¾ Trend PV response and CO
¾ Compute Gp(deltaPV/deltaCO) in %PV/%CO
¾ Compute td (delay time/ dead time)
¾ Compute Tau (time constant ‐ time to 63.2% of total change less deadtime)

3. Control strategy:

Cascade control

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In a casscade controol arrangemment, there are two (orr more) con ntrollers of which
w one
controller’s outputt drives the set point of
o another controller. For examplee: a level con ntroller
driving the set poin w controller to keep thee level at its set point. The
nt of a flow T flow
controller, in turn, drives a co
ontrol valve to match thhe flow with h the set pooint the leveel
controller is requesting.

The con
ntroller drivving the set point (the level
l contro
oller in the example
e above) is calleed the
primaryy, outer, or master conntroller. The
e controller receiving thhe set pointt (flow conttroller in
the example) is callled the secondary, innner or slave controller.
Cascadee control haas advantagges:
‐ Loops that correctly em mploy the cascade
c architecture reespond morre effectively to
disturbance es. This is because the inner loop is both closser to the soource of thee
disturbance e and fasterr than the outer
o loop. That
T combination allowws the proccess to
correct for upsets morre quickly.
‐ The inner looop helps to o correct fo
or nonlinearrities such as
a Stiction th
hat are assoociated
with the coontrol valve.
‐ A faster inn
ner loop red bility experienced by the process. Since
duces the ovverall variab
the inner lo
oop is able tot respond more quickkly to disturbances than n the outer loop, it
reduces thee severity ofo a given disturbance and
a limits th he degree of
o variabilityy that
would otheerwise impaact the proccess.
Cascadee control haas three disadvantagess:
‐ It requires an addition
nal measureement (usuaally flow rate) to work.
‐ There is an additional controller that
t has to be tuned. And
A three,
‐ The control strategy iss more complex – for engineers
e an
nd operatorrs to operatte and
maintenance
Feedforrward
Feedforrward contrrol can be used
u very su
uccessfully to
t improve a control lo
oop’s responnse to
disturbaances. Feed
dforward coontrol reactss the momeent a disturbance occurs, without having

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to wait for a deviattion in proccess variable

e. If any pro
ocess contro
ol loop is su
ubject to
large, m
measurable disturbancees, it can beenefit greatly from feed dforward co ontrol.
In contrrast to feedback contro ol, feedforw
ward controol acts the moment
m a disturbance occurs,
withoutt having to wait for a deviation
d in process varriable. This enables a feedforward d
controller to quickkly and direcctly cancel out
o the effeect of a distuurbance. Too do this, a
feedforrward contrroller produces its conttrol action bbased on a measureme
m ent of the
disturbaance.

Ratio co
ontrol
Processs design and d operations often callss for keepin
ng a certain ratio two or
o more flow
w rates.
One of the flows in n a ratio‐con
ntrol scenarrio, sometim
mes called the
t master flow or wildd flow,
is set acccording to an external objective like
l producttion rate.
The ratio controlleer manipulattes the otheer flow to maintain
m thee desired raatio between the
two flowws. The floww controlledd by the rattio controlleer is called the
t controllled flow. Foor
example, when treeating drinkking water with
w chlorine, the wateer is the wild d flow, and the
chlorinee is the controlled flow
w.

Split range control

Split‐range controll has been widely
w d in industriaal processes for contro
used olling pressu
ure,
temperrature, and flow, and itt is normallyy used to co
ontrol a two
o‐mode opeeration.

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Controller output 0% Both valves are closed.

Controller output 25% Valve A is 50% open and Valve B still closed.
Controller output 50% Valve A is fully open and Valve B closed.
Controller output 75% Valve A is fully open and Valve B 50% open.
Controller output 100% Both valves are fully open.

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C&
&I ENGINEEERING
G DOC
CUMEN
NTATIION
There aare several documents
d that C&I en
ngineers havve to use in
n daily workk as the follo
owing:
• Proccess Flow Diagrams
D (PFD)
• Piping and Insttrument Diaagrams (P&IID)
• Loop Numberin ng
• Insttrument Listts
• Insttrument dattasheets
• Specification Forms
• Logic Diagramss
• Locaation Plans (Instrumennt Location Drawings)
• Insttallation Dettails
• Loop Diagramss
• Inteerconnectioon Drawingss
• Conntrol Narratives
• Stanndards and Regulations
• Opeerating Instrructions
Below image illustrates a posssible sequence for document deveelopment. Information
I n from
one doccument is used
u to deveelop succeeeding documments.

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Process Flow Diagram (PFD)

Drawing that shows the general process flow between major pieces of equipment of a plant
and the expected operating conditions at the target production rate.
Piping and Instrument Diagrams (P&ID)
Drawing that shows the instrumentation and piping details for plant equipment.
Instrument Lists
The Instrument List (or instrument index) is an alphanumeric listing of all tag‐marked
components.
Each tag mark will reference the relevant drawings and documents for that device.
Specification and Instrument datasheet
The documents that specify specific requirements in selecting, design the control system
and the field instrument based on international or local standards. The requirements of
selecting a device should meet the international standard and local standards.
Datasheet is a form which provides details of process information, and specific requirement
for procurement of an instrument. Datasheet provides very comprehensive information.
Location Plans (Instrument Location Drawings)
Plans show the location and elevation of control components on plan drawings of a plant.
Installation Details (Hook up drawing)
Installation Details define the requirements to correctly install the tag‐marked devices. The
Installation Details show process connections, pneumatic tubing, or conduit connections,
insulation requirements, and support methods.
Loop Diagrams
Loop diagram shows information of the wiring for one instrument from field to control
room. Loop diagram is commonly used by Instrument engineers as it help them to carry out
loop check.

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Reference of International and Local Standards.

ANSI (American National Standards Institute)

ANSI MC96.1 Temperature Measurement Thermocouples
ASME PTC 19.3 TW‐2010 Thermowell Stress Calculation
AGA (American Gas Association)
AGA Report 3 Orifice Metering of Natural Gas and Other Related
Hydrocarbon Fluids
AGA Report 9 Measurement of Gas by Multi‐path Ultrasonic Meters
API (American Petroleum Institute)
RP 14C Analysis, Design, Installation and Testing of Basic Surface
Safety Systems on Offshore Production Platforms
PR 14G Recommended Practice for Fire Prevention and Control on
Open Type Offshore Production Platforms
PR 14J Recommended Practice for Design and Hazards Analysis for
Offshore Production Facilities
MPMS 12.2 Manual of Petroleum Measurement Standards, Chapter 12,
Section 2, Calculation of Liquid Petroleum Quantities
Measured By Turbine or Displacement Meters
MPMS 14.3 Manual of Petroleum Measurement Standards, Chapter 14,
Section 3, Orifice Metering of Natural Gas and other Related
Hydrocarbon Fluids (AGA Report No. 3; ANSI/API 2530)
RP 505 Recommended Practice for Classification of Locations for
Electrical Installations at Petroleum Facilities Classified as
Class I, Zone 0, and Zone 2
RP 520 Sizing, Selection, and Installation of Pressure‐Relieving
Devices in Refineries, Parts I and II
RP 521 Guide for Pressure‐Relieving and Depressurizing Systems
RP 526 Flanged Steel Pressure Relief Valves
RP 527 Seat Tightness of Pressure Relief Valves
RP 551 Process Measurement Instrumentation
RP 552 Transmission Systems

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RP 554 Process Instrumentation and Control

RP 555 Process Analyzers
RP 574 Inspection Practices for Piping System Components
STD 598 Valve Inspection and Testing
STD 607 Fire Test for Soft‐Seated Quarter‐Turn Valves
STD 2000 Venting Atmospheric and Low‐Pressure Storage Tanks, Non‐
Refrigerated and Refrigerated
API‐1101 Measurement of Petroleum Liquid Hydrocarbons by Positive
Displacement Meter
API‐2531 Manual of Petroleum Measurement Standards, Mechanical
Displacement Meter Provers
ASME (American Society of Mechanical Engineers)
ASME Section VIII ASME Boiler and Pressure Vessel Code, Section VIII Pressure
Vessels, Division I ‐ Rules for Construction of Pressure Vessel
ASME B1.13M Metric Screw Threads: M Profile
CFR (Code of Federal Register)
Section 30, 250, Subpart H Production Safety Systems
IEC (International Electrotechnical Commission)
IEC 60028 International Standard of Resistance for Copper
IEC 60079‐0~20 Electrical Apparatus for Explosive Gas Atmospheres
IEC 60085 Electrical Insulation ‐ Thermal Evaluation & Designation
IEC 60092 Offshore & Marine Cables
IEC 60189 Low‐frequency cables and wires with PVC insulation and PVC
sheath
IEC 60227 PVC Insulated Cables of Rated Voltages up to and Including
450/750V
IEC 60228 Conductors of Insulated Cables
IEC 60331 Characteristics of Fire Resistant Cables
IEC 60332 Characteristics of Flame Retardant Cables
IEC 60344 Guide to the Calculation of DC Resistance of Plain and Coated
Copper for Low Frequency Cables and Wires

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IEC 60529 Classification of degree of protection provided by enclosure

IEC 60754 Test on Gases Evolved During Combustion of Materials from
Cables
IEC 60811 Common Test Methods for Insulating and Sheathing
Materials of Electric and Optical Cables
IEC 60885 Electrical Test Methods for Electric Cables
IEC 60751 Industrial Platinum Resistance Thermometer Sensors
IEC 60446 Basic and safety principles for man‐machine interface,
marking and identification – Identification of conductors by
colors or alphanumeric
IEC 61000 Electromagnetic Compatibility‐Testing and Measurement
IEC 61034 Measurement of Smoke Density of Cables Burning Under
Defined Conditions
IEC 61131‐3 Programmable Controllers ‐ Programming Languages
IEC 61508 Functional safety of Electrical/ Electronic Programmable
Electronic Safety‐related Systems
IEC 61511 Safety Instrumented Systems for the Process Industry Sector
IEC 61892 Mobile and fixed offshore units – Electrical installations
IEC 61892‐4 Mobile and fixed offshore units ‐ Electrical installations ‐ Part
4: Cables
IEC 61892‐7 Mobile and fixed offshore units ‐ electrical installations ‐
hazardous areas
IEC 62061 Safety of Machinery‐ Functional Safety of safety related
electrical, electronic and programmable electronic control
systems
IEC 62444 Cable Glands for Electrical Installations

ISA (International Society for Measurement and Control)

RP3.2 Flange Mounted Sharp Orifice Plates for Flow Measurement
ANSI/ISA‐5.1 Instrumentation Symbols and Identification
ANSI/ISA‐5.2 Binary Logic Diagrams for Process Operations
ISA‐5.3 Graphic Symbols for Distributed Control/Shared Display

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Instrumentation, Logic and Computer Systems

ANSI/ISA‐5.4 Instrument Loop Diagrams
ANSI/ISA‐7.0.01 Quality Standard for Instrument Air
ANSI/ISA‐18.1 Annunciator Sequence and Specifications
ISA‐20 Specification Forms for Process Measurement and Control
Instruments, Primary Elements and Control Valves
ISA‐RP31.1 Specification, Installation, and Calibration of Turbine
Flowmeters
ISA‐RP60.6 Nameplates, Labels and Tags for Control Centres
ISA‐RP60.8 Electrical Guide for Control Centres
ISA‐RP60.9 Piping Guide for Control Centres
ANSI/ISA‐75.11 Inherent Flow Characteristics and Rangeability of Control
Valves
ANSI/ISA‐84.01 Application of Safety Instrumented Systems for the Process
Industries
NACE (National Association of Corrosion Engineers)
MR0175‐2000 Sulphide Stress Cracking Resistant‐Metallic Materials for
Oilfield Equipment
NFPA (National Fire Protection Association)
NFPA 70 National Electrical Code (NEC)
NFPA 72 National Fire Alarm and Signaling code
NFPA 496 Purged and Pressurized Enclosures for Electrical Equipment
ISO (International Organization for Standardization)
ISO 3864 Safety Colour and Safety Sign
SOLAS
SOLAS International Convention for Safety Of Life at Sea
Vietnamese Standards
TCVN 6171: 2005 Fixed Offshore Platforms: Technical Supervision and
Classification
TCVN 6767‐2: 2000 Fixed Offshore Platforms, Part 2: Fire Protection, Detection
and Extinction

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TCVN 6767‐3: 2000 Fixed Offshore Platforms, Part 3: Machinery and Process
Systems
TCVN 6767‐4: 2000 Fixed Offshore Platforms, Part 4: Electrical Installations

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