Abu Dhabi Gas Liquefaction Company Ltd

Basic Operator Course

Module 11

Instrumentation

ADGAS Personnel & Training Division

 Personnel & Training Division Basic Operator Course

Contents

Page No.

Abbreviation and Terminology ……………………..………….. 4

1 Introduction ……………………………………………………….. 6

2 Identify A Control Loop ………………………………………….. 7

3 Fundamentals of Instrumentation ………….………………….. 9

3.1 Measuring System …………………………………………. 9

3.2 Controller ……………………………………………………. 10
3.3 Final Control Element …………………………………….. 10
3.4 Closed Control Loop ……………………………………… 11

4 Control Loop Instrumentation ………………………………….. 12

4.1 Primary Element …………………………………………… 12

4.2 Thermocouple ……………………………………………… 13
4.3 Transmitters ………………………………………………… 14
4.4 Indicators and Recorders ………………………………... 15
4.5 Controllers ………………………………………………….. 16
4.6 Transducers ………………………………………………… 16
4.7 Final Control Elements …………………………………… 17

5 Control Loop Applications ……………………………………… 18

6 Distributed Control Systems …………………………………… 22

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Pre-Requisite Completion of A.T.I Operator Programme

Programme The Basic Operator Course is the first phase of the development
Objectives programme for the operator developee.

On completion of the programme the developee will have

acquired an awareness of the generic equipment, terminology,
and safety requirements related to the ADGAS LNG Plant.

Module Objectives On completion of this module, the developee will be able to

demonstrate an awareness of the function and identify types of
instrumentation used in the ADGAS process.

He will be able to correctly :

• Identify different types of instrumentation

• State how a control loop works

• State how control loops are used in the ADGAS process

Methodology The above will be achieved through the following:

• Pre-test
• Post test
• Classroom instruction
• Site visits
• Tasks & exercises
• Audio visual support

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Abbreviations and Terminology

The following are common terms used when working with Instrumentation:

Actuator A device that causes something to move. Pneumatic actuators on

control valves cause the valve element to open and close.
Bottoms Product The liquid that falls to the bottom of a process vessel or column.
Cold Junction The end of a thermocouple that is located away from the process.
Also called the measuring junction.
Convert To change the form of something into an equivalent, but
different, form.
Critical Extremely important.
Detect To sense; to discover the presence of something. Thermocouples
can detect temperature changes.
Displacer A device that is used to measure the level in a vessel by the
displacement of liquid.
Element A basic part of something.
Hot Junction The end of a thermocouple that is in contact with the process
fluid. The detecting end of the thermocouple.
Indicator An instrument (like a gauge) that gives a measurement
indication.
Monitor To watch closely
Pneumatic Air powered.
Positioner A device on a control valve that controls the position of the valve
element.
Proportional A relationship between two variables such that a change in one
variable causes a similar change in the other variable. Flow rate
is proportional to the differential pressure across an orifice plate.
Response A reply or reaction.
Specifications The precise characteristics or conditions that are required for a
product.
Variable A measurable characteristic that can change
Cascade Control A special type of control loop that consists of two controllers and
one control valve. The control signal of one controller adjusts
the set point of the second controller.
Closed Loop A Control loop in which the controller receives continuous
feedback.

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Controlled Variable The process variable that is held at set point by a control loop.
Controller The instrument in a control loop that compares a process
measurement to a desired set point and sends a corresponding
correction signal.
Deviation A movement away from an established set point.
Feedback Information that is returned to a loop controller to show the
results of its corrective actions.
Master Controller The controller for the primary process variable in a cascade
control loop. The output signal from the master controller
determines the set point of the slave controller.
Open Loop Is an instrument loop which has no feedback signal that detects,
indicates and often records changes in a process variable by
direct contact with the process.
Range A series of values between a minimum and maximum.
Recorder A recording instrument that uses an ink pen to keep a record of a
process variable.
Set Point The desired measurement setting for a process variable / Process
Parameter.
Slave Controller The secondary controller in a cascade control loop. The slave
controller adjusts a final control element to maintain a set point
that is provided by the master controller.
Transducer An instrument that converts one type of signal to a different type.
A transducer is used to change electrical instrument signals to
pneumatic signals.
Transmitter An instrument that sends a measurement signal to other
instruments on the control panel or to the final element of a
closed loop controller, or to the controller.

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1 Introduction
Instrumentation plays a very important part in the efficient operation of the ADGAS
processing operations.

Instrument control systems enable the plant to operate smoothly and safely with a
minimum of operating staff.

As materials flow through the process equipment they are subjected to various
conditions. These conditions change the material composition and chemical structure.
It is important that these process changes are accurately controlled and recorded at all
times.

This control and recording is done by instruments, and are often linked to fully
computerised systems.

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2 Identify A Basic Control Loop

In ADGAS, all process and utility variables such as pressure, flow, level and
temperature must be measured and maintained at desired settings. This allows the plant
and machinery to operate in a stable and safe condition.

Control loops satisfy this need for stable and controlled variables. Loops are vital
systems that are capable of sending feedback signals, to correct any deviation from the
set, desired value.

For example, as we sit in a room, we wish to be comfortable and feel that the room
temperature suits us. When we feel too hot, we respond to this by changing the setting
on the air conditioning control switch. As a result, the air conditioning unit will operate
to provide more cooling air, allowing the temperature in the room to decrease to a value
that we find more comfortable to sit in. This is a control loop which we have manually
affected, by altering a setting, to provide a desired result.

Out skin is a sensing element that feels heat and cold. When too hot, the temperature
change to our skin is transmitted to our brain; the controlling element. The brain will
decide to act, since it finds that the sensed temperature is not the most comfortable
temperature to be in (i.e. our preferred or desired temperature). So it sends a signal to
the final control element, to make the necessary adjustment to the air conditioner. The
air conditioner output will cause more cooling air to be produced and passed into the
room.

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The Process

The objective of the control loop is to maintain a steady temperature in the room that
suits us. We may repeat this action many times each day, to keep the room to our
desired temperature. By installing a room thermostat and connecting it to the air
conditioner however, this operation can be performed automatically and there is no
need for us to continually make our own manual adjustments, by regular adjustments of
the air conditioner switch by hand.

The example provides a basic model of process control. Even the most complicated
control systems in hydrocarbon processing plant perform similar functions. In a plant
however, individual instruments take place of your skin, brain and the hand that adjusts
the setting of the air conditioner.

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3 Fundamentals of Instrumentation
ADGAS uses thousand of different control loops to maintain all of its process and other
plant systems and machines, in a stable and safe condition. The four main process
variables which are controlled are flow, level, pressure and temperature.

On order to ensure that the process produces specific results or outputs, at least one
variable must be constantly measured and controlled.

Three main elements are required to control a process variable.

The three control loop main elements are:

• A measurement system

• A controller

• A Final control element

3.1 Measuring System – all control loops contain instruments to measure the
condition of the controlled variable. A number of instruments are used in a
measurement system, these are normally:-

• A primary element to detect changes in the process variable condition.

• A transmitter, which is used to communicate these, changes to other

instruments.

• An indicator to display the current measurement value of the process variable.

• A recorder to keep a record of these measurements over a period.

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3.2 Controller – the automatic controller is the brain of the control loop. Its job is
to keep the process variable at a constant value. The controller compares the
measurement signal to the set point. It then responds to any difference between these
values by changing its output signal.

3.3 Final Control Element – the controller keeps the measurement on the set
point by adjusting a final control element. In most control loops the final control
element is a control valve. The control valve receives a signal from the controller,
which adjusts the position of the control valve.

SET POINT

CONTROLLER
+ -

FINAL MEASUREMENT
CONTROL SYSTEM
ELEMENT

PROCESS
CONTROLLED
VARIABLE
MANIPULATED
VARIABLE

Figure 3.3: Basic Elements of a Control Loop

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The control loop operates continuously. The controller receives feedback on the results
of its control action. This means that the loop will continue to measure the results as it
makes adjustments to the process. The controller will also continue to change its output
signal until the controlled variable returns to the set point.

3.4 Closed Control Loop

In a Closed Control Loop, instruments continuously monitor and adjust the process to
keep it on set point.

In a control loop with feedback, the measuring instruments immediately tell the
controller the effects of its adjustments.

Indicating Controller
Air Supply
Cold Water In
Primary Element

Hot Water
out

Steam In

Control
Valve
Condensate Out

Figure 3.4: Closed Control Loop

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4 Control Loop Instrumentation

Control loops use pneumatic (air) and/or electronic instruments. The main difference
between these instruments is the way they send signals to each other. Pneumatic
instruments use compressed air to transmit signals and electronic instruments send
electrical signals. No matter what signal they use, most control loops perform the same
basic function and consist of the same basic components.

4.1 Primary Element

The primary element is the first part of the measurement system. It senses the condition
of the controlled variable, normally by having direct contact with the process.

An orifice plate, is one type of primary element, which is used for flow measurement.
Flow through an orifice plate creates a differential pressure and this differential pressure
across the plate can be converted into a measurement of flow rate. The primary element
is in fact one type of flow meter.

Low Pressure Pipe Tap

High Pressure Pipe Tap

Orifice Plate

Flow Pipe

Figure 4.1: Orifice Plate Installation

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A thermocouple is another common type of primary element, which is used for

temperature measurement. The end of a thermocouple is installed in the process line,
where it senses the temperature. The other end of the thermocouple is connected to a
transmitter.

Thermocouples are most often fitted into thermowells, which are integral components
of piping, tanks or process vessels.

4.2 Thermocouple

Thermowell

Thermocouple Element
Electrical Cable (Hot Junction)

To Cold Junction

Figure 4.2: Thermocouple

The drawing shows a cutaway view of the end of a thermocouple that is installed in a
process line (hot junction). The other end of the thermocouple (cold junction) is
normally connected to a transmitter.

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4.3 Transmitters

The transmitter receives information about the process condition from the detecting
(primary) element. It then sends this information as a standard electrical or pneumatic
signal to other instruments that indicate, record, or control the process variable.

A transmitter D P Cell, used to measure flow rate, senses the differential pressure
created across an orifice plate. It then sends a signal to a controller. The signal
corresponds to the differential pressure in the flow meter (across the orifice plate).

Flow Transmitter

Orifice Plate

Figure 4.3(a): Flow Transmitter

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A transmitter used to measure process pressure has a built in detecting element, which
is connected directly to the process. The transmitter detects process pressure and sends
a signal to the control room for recording, or to a controller as feedback.

A transmitter used to measure liquid level uses a displacer as a built in detecting

element. Piping connects the transmitter to the process vessel. As the level in the vessel
goes up or down, the weight of the displacer will change and the transmitter converts
the change in weight into an electrical signal.

Level Transmitter

Displacer

Figure 4.3(b): Level Transmitter

4.4 Indicators and Recorders

Indicators and recorders are two devices that can receive signals from a transmitter and
display measurement values. Indicators use a pointer on a scale to show a measurement
value.

Recorders record the measurement value over time. An ink pen moves up and down on
the recorder in response to the measurement signal. A roll of paper turns slowly inside
the recorder, keeping a record of the variable. A roll may last for 2 weeks.

Indicators and recorders are still used in ADGAS but the majority of the recording is
done by the computer control system. The transmitters send their signal to the
computer system and this is displayed on a computer screen.

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4.5 Controllers

The measurement signal from the transmitter also goes to a controller. The controller
determines what adjustments are necessary to keep the process at the desired value.

There are a number of difference types of controllers that can be used, pneumatic
(air operated), electrical, and digital (computer control).

The controllers basically, all work in the same way, they receive a signal from the
transmitter and compare this value with the set point to determine the difference, or
deviation, between them. The set point being the preferred value of the process
parameter.

The controller then produces an output signal to adjust the final control element.

All controllers can be switched to manual control when needed, which allows the
operator to directly adjust a valve position. This is often used on start-ups or upset
conditions. Once the controlled variable is at set point, the controller can be switched to
automatic control.

4.6 Transducers

Transducers are devices, which convert one type of signal into another type. The most
common transducer converts electrical signals into pneumatic (air) signals. In ADGAS
you will also find transducers which do the reverse.

Most control valves are air operated, while most controllers send out electrical signals.
The controllers send their electrical signal to a transducer and the transducer changes
the electrical signal to a pneumatic signal that drives the final element.

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4.7 Final Control Elements

The final control element makes adjustments to the process in response to the signal
from the controller. The purpose of the final control element is to adjust the process as
required to keep the measured variable at the set point value.

The control valve is the most common type of final control element. The valve
positioner receives the pneumatic signal and sends airflow to the valve actuator, which
moves the valve element to a more closed or open position.

In the event of a instrument air failure, the valves will go to fully open or full closed
position depending on their duty. For example, a pressure control valve on a column
will fail to the open position. While most gas supply valves will fail in the closed
position.

Actuator

Positioner

Valve

Figure 4.7: Control Valve with Positioner

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5 Control Loop Applications

In the following section you will see how several control loops are combined in a
process to maintain product specifications.

The process we will look at is the De-ethaniser system. The de-ethaniser removes the
ethane from the heavier hydrocarbons by the process of distillation.

1. The temperature in the column is controlled by the amount of steam going to the
reboiler. This is controlled by cascade control loop.

A cascade control loop has two controllers and one control valve.

The main purpose of a cascade control loop is to make the control system act
more quickly. This reduces the amount of time it takes to get the process
variable back to the required set point and protects against large swings in the
column temperature.

The temperature of the column is checked by a thermocouple, this is the primary

element in the control loop. This measurement goes to the transmitter, which
sends a signal to the temperature indicator controller (TIC). This controller has
a set point temperature that has been set by the control room operator.

This TIC is known as the master controller. The output signal from the master
controller is obtained by comparing the set point temperature with the process
temperature.

The second controller is the flow indicated controller (FIC), this is known as the
slave controller.

The output signal from the master controller is the set point for the slave
controller. The FIC therefore responds to a set point that may vary.

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The output signal of the slave controller is obtained by comparing its set point
(which it gets from the master controller) to the amount of steam flow going to
the reboiler. Using these two measured variables a signal is sent out to the final
control element, the control valve which adjusts the steam flow as needed

If the temperature is lower than the set point, the valve will start to open to allow
more steam into the reboiler. If the temperature is higher than the set point, the
valve will begin to close.

2. A liquid level must always be maintained in the bottom of the column.

This level is measured by a primary element and this measurement goes to the
transmitter, which sends a signal to the level indicator controller (LIC).

This signal is then sent to a flow indicator controller (FIC) which controls the
valve position, which is the final control element. If the level is lower than the
set point the valve will start to close to allow less liquid out of the column, if the
level is higher than the set point the valve will open.

3. The pressure of the column must always be controlled. This is controlled by a

split range control loop.

A split range control loop has one controller and two final control elements.

The pressure is measured by the primary element and this measurement goes to
the transmitter, which sends a signal to the pressure indicator controller (PIC).

The output range of the controller is 0 to 100%. In split range control, part of
that range acts on one of the final control elements and the remainder of the
range acts on the second final control element.

The pressure is controlled by releasing the vapours from the reflux drum,
through the first control valve, when this valve is fully open the controller
output will be at 50%. If the output goes above 50% the second control valve
will start to open to release more of the pressure to the flare.

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When both valves are fully open the output signal from the controller would be
100%.

This split range controller normally operates from 0 to 50% output signal for
normal process control. Over 50% output signal provides extra process control
for abnormal process conditions.

4. All the other instrumentation used in the de-ethaniser system works in one of the
same ways as the above.

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COLUMN PRESSURE
CONTROL
SWEET VAPOUR FLARE

PV
LIQUID PROPANE PIC XV SWEET VAPOUR FLARE
USED TO CONDENSE
THE VAPOUR
3
VAPOUR & LIQUID OVERHEADS COOLER
LP PROPANE JOIN TOGETHER
AND COOLED BY
PV LIQUID PROPANE LIQ
LIC
VAPOUR LV
OVERHEADS C2 VAPOUR WHICH
CONDENSER HAS VAPORISED LIQ
LP PROPANE LIC (FLASHED) IN THE
REFLUX DRUM
XV LIQUID
TIC OVER HEADS
C2
REFRIGERANT FIC
MAKE UP LP C3
HYDROCARBONS TV REFLUX DRUM LIC
ENTER THE
COLUMN AT
THE 46TH TRAY LP C3
XV
LIQUID REFLUX
USED TO CONTROL FV
TEMPERATURE
FV FIC
FROM
LV
SCRUB COLUMN
1 TIC
DE ETHANISER

SL VAPOUR REFLUX PUMP FIC

LIQUID
FIC
STEAM TO
HEAT THE LIQUID C2
BOTTOM LIQUID LIC COLUMN LIQUID
TV LEVEL CONTROL
FIC
REBOILER
XV
2
LV

SCL TO DEPROPANISER
LIQUID C3+
COLUMN

Figure 5: De-Ethaniser System

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6 Distributed Control Systems

In ADGAS most of the instrumentation is controlled by a computerised system called a
Distributed control system (DCS).

Distributed control systems means that the control of the various process units in the
plant is distributed (located) around the plant.

Each processing unit has a Local Control Unit (LCU) and all the control loops in that
unit are controlled by the one Local Control Unit.

The information that the control room needs is sent by a single cable from the Local
Control Unit to the control room. This cable is called the Data Highway. The Data
Highway is connected to the control room by different Process Interface Units.

Figure 6(a)

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The information from the Data Highway is shown on a Video Display Unit (VDU), this
is also called the operator console. All of the plant instrumentation can be monitored
and changed from this console.

Figure 6(b): Operator Console

When a change is made from the console to an instrument, the signal goes back along
the same Data Highway.

Set Point

Process Variable
OperatingVariable

Set Point
Process Variable
OperatingVariable

Figure 6(c): Control Display

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