Basic Instrumentation
Basic Instrumentation
Basic Instrumentation
2
1
Fe
Constantan
Cu
Cu
U (
2
-
1
)
U
i = constant
4
2 or 4 wire connection (to compensate voltage drop)
2,3- or 4-wire connection
reference temperature
(cold junction)
4..20 mA
4..20 mA
measured temperature
(hot junction)
two dissimilar
electrical
conductors
one material whose
resistance is
temperature-
dependent
extension
wire
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Cold junction box
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2.1.3.3 Hydraulic measurements
Flow,
Mass Flow,
Level,
Pressure,
Conductivity,
pH-Sensor,
Viscosity,
Humidity,
special requirements: intrinsic safety = explosive environment, sea floor = high pressure
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Level measurement
pulsed laser
load cell
pulsed microwave
nuclear
ultrasonic (40-60 kHz)
low power ultrasonic
detector
row
see Control Engineering, Aug 2003
F = mg
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Flow measurement
Distinguish:
volumetric flow ( m
3
/s)
mass flow: (kg / s)
identical when the density of the liquid is constant
main methods:
-floater
-turbine
-pressure difference
-vortex
-temperature gradient
-ultrasonic
-electrodynamics
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Flow velocity measurement: differential pressure
occultation
(Verengung)
membrane
the flow velocity is proportional to the square root of the pressure difference
piezo-electric
sensor
p
2
- p
1
= r v
2
1
2
(Bernoulli effect)
p
2
p
1
v
fluid of
viscosity r
occultation
(Blende)
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Flow measurement
Other means:
Magnetic-dynamic
Coriolis
Ultra-sound
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Flow measurement in a plant
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2.1.4 Actors
2.1 Instrumentation
2.1.1 Market
2.1.2 Binary instruments
2.1.3 Analog Instruments
2.1.4 Actors
2.1.5 Transducers
2.1.6 Instrumentation diagrams
2.1.7 Protection classes
2.2 Control
2.3 Programmable Logic Controllers
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Actors (Actuators)
About 10% of the field elements are actors (that influence the process).
Actors can be binary (on/off) or analog (e.g. variable speed drive)
The most common are:
- electric contactors (relays)
- heating elements
- pneumatic and hydraulic movers (valve, pump)
- electric motors (rotating and linear)
Solenoids,
DC motor
Asynchronous Motors (Induction)
Synchronous motors
Step motors, reluctance motors
Actors are controlled by the same electrical signal levels as sensors use
(4..20mA, 0..10V, 0..24V, etc.) but at higher power levels (e.g. to directly move a
contactor (disjoncteur).
Stellantriebe, Servomoteurs
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Drives (variateurs de vitesse, Stellantriebe)
Variable speed drives control speed and acceleration and protect the motor
(over-current, torque, temperature).
High-power drives can feed back energy to the grid when braking (inverters).
Drives is an own market (Automation & Drives)
simple motor control cabinet for power of > 10 kW small drive control < 10 kW
(Rockwell)
Motors and drives are separate businesses
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Linear Motors
source: LinMot (/www.linmot.com)
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Hydraulics and fluidics
Pumps, valves, rods,
source: www.bachofen.ch
fluidic switches
switchboard ("Ventilinsel")
the most widespread actor in industry
(lightweight, reliable, cheap)
I/P or E/P = electro-pneumatic transducers
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2.1.5 Transducers
2.1 Instrumentation
2.1.1 Market
2.1.2 Binary instruments
2.1.3 Analog Instruments
2.1.4 Actors
2.1.5 Transducers
2.1.6 Instrumentation diagrams
2.1.7 Protection classes
2.2 Control
2.3 Programmable Logic Controllers
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Transducer
A transducer converts the information supplied by a sensor (piezo, resistance,)
into a standardized signal which can be processed digitally.
Some transducers have directly a digital (field bus) output and are integrated
in the sensor.
Other are located at distances of several meters from the sensor.
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Example of analog transducer
Emergency panel
PLC
Control Room
Current
Transformer
0..1A rms
Field house
Transducer
4..20 mA
R = Load
High voltage
Protection
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4-20 mA loop standard
The transducer acts as a current source which delivers a current between 4 and 20 mA,
proportional to the measurand (Messgrsse, valeur mesure).
Information is conveyed by a current, the voltage drop along the cable induces no error.
0 mA signals an error (wire disconnection)
The number of loads connected in series is limited by the operating voltage (10..24 V).
e.g. if (R1 + R2+ R3) = 1.5 k, i = 24 / 1.5 = 16 mA, which is < 20 mA: NOT o.k.)
Simple devices are powered directly by the residual current (4mA) allowing to transmit
signal and power through a single pair of wires.
Transducer
instrument
1
instrument
2
instrument
3
0, 4..20 mA
R1
R2 R3
Object
i = f(v)
10..24V
voltage
source
measurand
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Analog measurements processing in the transducer
Acquisition (Erfassung/Saisie)
Correction of pressure and temperature measurement for moist gases,
correction of level in function of pressure,
power and energy computation, cumulative measurements
Range, Limit supervision, Wire integrity
Error report, diagnostic, disabling.
Combined measurement
Plausibility
Filtering against 50Hz/60Hz noise and its harmonics
Scaling,
Linearization of sensors (Pt100, Fe-Const), correction (square root for flow).
Averaging and Computation of Root Mean Square (Effektivwert, valeur efficace),
Analog-Digital Conversion
Shaping (Aufbereitung/conditionnement)
Normalized Signals: 0-10V, 2-10V, (0/4-20mA), 20mA,
Resistance thermometer (Pt100),
Thermo-element
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2.1.6 Instrumentation diagrams: P&ID
2.1 Instrumentation
2.1.1 Market
2.1.2 Binary instruments
2.1.3 Analog Instruments
2.1.4 Actors
2.1.5 Transducers
2.1.6 Instrumentation diagrams
2.1.7 Protection classes
2.2 Control
2.3 Programmable Logic Controllers
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Instrumentation Diagrams
Similarly to electrical schemas, the control industry (especially the chemical and
process industry) describes its plants and their instrumentation by a
P&ID (pronounce P.N.I.D.) (Piping and Instrumentation Diagram),
sometimes called P&WD (Piping and wiring diagrams)
The P&ID shows the flows in a plant (in the chemical or process industry) and the
corresponding sensors or actors.
At the same time, the P&ID gives a name ("tag") to each sensor and actor, along with
additional parameters.
This tag identifies a "point" not only on the screens and controllers, but also on the
objects in the field.
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P&ID example
4, Combustor C2
2, Air Heater C1
3, SOFC Outlet
3, SOFC Inlet
TA51B
TI
TE TE TE PT
TA51A
TI
TA51C
TI
Chimney
Emission
Analysis
PT22
PI
TA22B
TI
TE TE TE PT
TA22A
TI
TA22C
TI
Process Air Exhaust
Blow Off Valve
BE
10 x
TE
TC2M1 - M10
TI
FLAMDETC2
BS
Ingnitor
Box
BE
10 x
TE
TC1M1 - M10
TI
Fuel Supply
S
SVGAS3
IC
Atmosphere
PT21
PI
TA21B
TI
TE TE TE PT
TA21A
TI
TA21C
TI
Rotary block valve
V52
IC
TE
TA62
TI
7, Heat
exchanger
6, Recuperator
TE
Latchable
Check Valve
S
SVGAS2
IC
FLAMDETC1
BS
TA32B
TI
TE TE TE
TA32C
TI
TA32A
TI
PT32
PI
PT
TY
I
P
Regulator Valve
TY
I
P
SVGAS1
IC
S
S
EMICO
E
EMIUHC
E
EMICO2
E
EMIO2
E
EMINOX
E
AIT
AIT
AIT
AIT
AIT
PT51
PI
F
r
o
m
s
a
m
p
l e
p
r
o
b
e
a
t
C
1
e
x
i t
TBVCOOL
IC
TBVDEP
IC
PT
TE
PT12
PI
TA12
TI
IGNITC2
IC
TW72
TI
PT
PT52
PI
TE
TA52
TI
G
AC Grid
Modulatable
Load
PCS
1,
C
5,
T
LOP
PI
SPEED
SI
PT ST
0
,
A
i r
I
n
l e
t
PT
TE
PT02
PI
TA02
TI
S
V12
IC
R
Ingnitor
Box C1
IGNITC1
IC
Piping and Instrumentation Diagram for MTG100FC Engine Tests
S
VPPWMC2
IC
FO
VMPWMC2
IC
S
S
VMPWMC1
IC
S
S
S
VPPWMC1
IC
FO
Fuel flow C2 MFM
Fuel flow C1 MFM
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P&ID
The P&ID mixes pneumatic / hydraulic elements, electrical elements
and instruments on the same diagram
It uses a set of symbols defined in the ISA S5.1 standard.
Examples of pneumatic / hydraulic symbols:
pipe
valve
binary (or solenoid) valve (on/off)
350 kW
heater
vessel / reactor
pump, also
heat exchanger
analog valve (continuous)
one-way valve (diode)
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Instrumentation identification
V1528
FIC
S
tag name of the
corresponding
variable
here: V1528
function
(here: valve)
mover
(here: solenoid)
The first letter defines the measured or initiating variables such as Analysis (A), Flow (F),
Temperature (T), etc. with succeeding letters defining readout, passive, or output functions such
as Indicator (I), Record (R), Transmit (T), see next slides, here: flow indicator digital
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ISA S5.1 General instrument or function symbols
Primary location
accessible to
operator
Field mounted
Auxiliary location
accessible to
operator
Discrete
instruments
Shared
display, shared
control
Computer
function
Programmable
logic control
1. Symbol size may vary according to the user's needs and the type of document.
2. Abbreviations of the user's choice may be used when necessary to specify location.
3. Inaccessible (behind the panel) devices may be depicted using the same symbol but with a
dashed horizontal bar.
Source: Control Engineering with data from ISA S5.1 standard
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Example of P&ID
FT101 is a field-mounted flow
transmitter connected via
electrical signals (dotted line) to
flow indicating controller FIC
101 located in a shared
control/display device
Square root extraction of the
input signal is part of FIC 101s
functionality.
The output of FIC 101 is an electrical signal to TY 101
located in an inaccessible or behind-the-panel-board location.
The output signal from TY 101
is a pneumatic signal (line with
double forward slash marks)
making TY 101 an I/P (current
to pneumatic transducer)
TT 101 and TIC 101 are
similar to FT 101 and FIC 101
but are measuring,
indicating, and controlling
temperature
TIC 101s output is connected
via an internal software or
data link (line with bubbles) to
the setpoint (SP) of FIC 101
to form a cascade control
strategy
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The ISA code for instrument type
First letter
Measured or initiating variable Modifier
A Analysis
B Burner, combustion
C User's choice
D User's choice Differential
E Voltage
F Flow rate Ration (fraction)
G User's choice
H Hand
I Current (electrical)
J Power Scan
K Time, time schedule Time rate of change
L Level
M User's choice Momentary
N User's choice
O User's choice
P Pressure, vacuum
Q Quantity Integrate, totalizer
R Radiation
S Speed, frequency Safety
T Temperature
U Multivariable
V Vibration, mechanical analysis
W Weight, force
X Unclassified X axis
Y Event, state, or presence Y axis
Z Position, dimension Z axis
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Common connecting lines
Connection to process, or
instrument supply
Pneumatic signal
Electric signal
Capillary tubing (filled system)
Hydraulic signal
Electromagnetic or sonic signal
(guided)
Internal system link
(software or data link)
Source: Control Engineering with data from ISA S5.1 standard
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2.1.7 Protection Classes
2.1 Instrumentation
2.1.1 Market
2.1.2 Binary instruments
2.1.3 Analog Instruments
2.1.4 Actors
2.1.5 Transducers
2.1.6 Instrumentation diagrams
2.1.7 Protection classes
2.2 Control
2.3 Programmable Logic Controllers
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German IP-Protection classes
2nd digit water
0 none
1 vertically falling
2 vertically dropping, 15 from vertical
3 spraying, 60 from vertical
4 spraying, any direction
5 jet, any direction
6 strong jet, any direction
protection against temporary dipping
(30 mn, 1 m)
protection against permanent dipping
9K water in high-pressure steam
washing
1st digit touching objects
0 none
1 large body object > 50 mm
surface
2 finger object >12.5 mm
3 tools, wires object > 2.5 mm
4 covered object >1 mm
5 dust
6 hermetical
for dust
e.g. IP 67 connector
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Explosion protection
Instruments that operate in explosive environments
(e.g. petrochemical, pharmaceutical, coal mines,...) are subject to particular restrictions.
e.g.
They may not contain anything that can produce sparks or high heat,
such as electrolytic capacitors or batteries without current limitation.
Their design or programming may not be altered after their acceptance.
Their price is higher than that of standard devices because they have to undergo
strict testing (Typentest, type test) by a qualified authority (TV in Germany)
Such devices are called Eex - or "intrinsic safety devices" (Eigensichere Gerte, "Ex-Schutz",
protection anti-dflagrante, "Ex" ) and are identified by the following logo:
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European Explosion-Proof Code
Eex-devices are "safe" (certified) to be used in an explosive environment.
They must have passed a type test at TF (Germany), UL (USA),...
Swiss Norm: "Verordnung ber Gerte und Schutzsysteme in explosionsgefhrdeten Bereichen"
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Field Device: faceplate (movie)
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Assessment
How are binary process variables measured ?
How are analogue process variables measured ?
How is temperature measured ?
What is the difference between a thermocouple and a thermoresistance ?
How is position measured (analog and digital) ?
What is a Grey encoder ?
How is speed measured ?
How is force measured ?
What is a P&ID ?
What is a transducer ?
How does a 4..20 mA loop operate ?