Process Instrumentation

Prepared by:
Sangmesh Malge

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Course Outcome
 Ability to analyze the process loops and identify the
characteristics

 Ability to apply various control techniques to Processes

 Ability to design multivariable scheme

Teaching Scheme:
 Lectures 3Hrs/week

Examination Scheme:
 T1 & T2: 20 Marks each
 End-sem Exam: 60 Marks
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Process Definition

Arrangement of
different
processing units,
integrated with one
another in a
systematic manner

Converting
certain raw
materials into
desired products
Process

Available source
of energy & in
most economical
ways
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Instrumentation
Definition

Art & Science of

measurement &
control of process
variables within
production area

Instrumentation

Variables such
as temperature,
pressure, flow,
level, speed
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Why Process Control

Safety

Operation Production
Constraints Specificatio
n

Process
Control

Environmen
Economics tal
Regulations
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Process Control
Definition

Architecture &
algorithms for
maintaining the
output of specific
process with a
desired range

Converting
certain raw
Process
materials into
desired products
Control

Output such as
temperature,
pressure, flow,
level, speed, etc
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Process Control Basics

and
Terminology
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Process Control Basics
and
Terminology

Control Loop

It is a cold winter night. You are sitting in front of a small fire but; you feel
uncomfortable. You start to throw another log on the fire.

This is a simple example of a control loop where:

- Variable is the Temperature
- Set point is your comfort level
- Action bring the process back into desired condition by adding more
fuel to the fire

Measurement

In industry it works the same and it requires Comparison

Adjustment
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Process Control Basics
and
Terminology

Simple Control Loop

-In the Figure a level transmitter

(LT) measures the level in the
tank and transmits a signal
associated with the level reading
to a controller (LIC).
-The controller compares the
reading to a predetermined
value, The controller then sends
a signal to the device that can
bring the tank level back to a
lower level
-The valve at the bottom of the
tank opens to let some liquid out
of the tank.
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Process Control Basics
and
Terminology

Process Variables

Is a condition of the process fluid that; can change the manufacturing process
in some way.

Process variables such as:

 Pressure
 Flow
 Level
 Temperature
 Density
 pH
 Mass
 Conductivity
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Process Control Basics
and
Terminology

Controller
Is a device that receives data from a measurement instrument, compares that data to a
programmed set point, and, if necessary, signals a control element to take corrective
action.
For example A process fluid tank is to be maintained
at a constant temperature 100 °C . The tank is
heated by a helical pipe through which steam flows
through a control valve.
- A sensor to measure the process temperature
- A controller to compare the temperaturereading
from the sensor to the set point
- If temperature reaches 110 °C
- The controller determines that, process
temperature is above the set point
- The controller signals the control valve to close
slightly until process temperature cools to 100
°C
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Process Control Basics
and
Terminology

Set point
Is the value for a process variable desired to be maintained .

Also known as Reference Variable.

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Process Control Basics
and
Terminology

Measured Variables, Process Variables, and Manipulated

Variables
In the previous temperature If we measure the flow into
loop example the measured and out of a storage tank to
variable is temperature which determine tank level
must be near to 100 oC

The measured variable is The measured variable (flow) is

also process variable not process variable (level)
Measured Variable Manipulated Variable
is the condition of the process fluid The factor that is changed to
that must be kept at the keep the process variable at set
designated set point. point. (Flow in this example)
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Process Control Basics
and
Terminology

Error
Is the difference between the measured variable and the set point and can be
either positive or negative

Offset
Is a sustained deviation of the process variable from the set point.

Load Disturbance
Is an undesired change in one of the factors that can affect the process variable.
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Process Control Basics
and
Terminology

Rate of Change
The rate of change is shown by the slope of the error plot.
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Process Control Basics
and
Terminology

Control Algorithm
Is a mathematical expression of a control function.
Using the temperature control
loop example, V in the equation
below is the steam valve
position, and e is the error. The
relationship in a control
algorithm can be expressed as:

V = f(±e)
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Process Control Basics
and
Terminology

Open Control Loop

Exists where the process
variable is not compared, and
action is taken not in response
to feedback on the condition of
the process variable
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Process Control Basics
and
Terminology

Closed Control Loop

Exists where a process

variable is measured,
compared to a set point, and
action is taken to correct any
deviation from set point.
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Components
of
Control Loops
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Components
of
Control Loops

Primary Elements (Sensors)

Devices that cause some change in their property with changes in process fluid
conditions that can then be measured and, they are the first element in the
control loop to measure the process variable

Examples of primary elements include:

-Pressure sensing diaphragms, strain gauges, capacitancecells
-Resistance temperature detectors (RTDs)
-Thermocouples
-Orifice plates
-Pitot tubes
-Venturi tubes
-Magnetic flow tubes
-Coriolis flow tubes
-Radar emitters and receivers
-Ultrasonic emitters and receivers
-Annular flow elements
-Vortex shedder
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Components
of
Control Loops

Transducers
Device that translates a mechanical signal into an electrical signal.

Converters
Device that converts one type of signal into another type of signal.

Transmitters
device that converts a reading from a sensor or transducer into a standard signal
and transmits that signal to a monitor or controller.

Transmitter types include:

-Pressure transmitters -Flow transmitters
-Temperature transmitters -Level transmitters
-Analytic (O2 [oxygen], CO [carbon monoxide], and pH) transmitters
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Components
of
Control Loops

Signals

Divided Into Three Types

Pneumatic Signals Analog Signals Digital Signals

Are signals produced by changing The most common standard electrical Are discrete levels or values that are
the air pressure in a signal pipe in signal is the 4–20 mA current signal. combined in specific ways to
proportion to the measured change represent process variables and also
in a process variable. - 4 mA-------- Represents lowest carry other information,
The common industry standard possible measurement, or zero.
pneumatic signal range is
- 20 mA-------- Represents highest
- 3 psig -------- Corresponds to possible measurement.
Lower Range Value (LRV)

- 15 psig -------- Corresponds to

Higher Range Value (HRV)
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Components
of
Control Loops

Indicators
Is a human-readable device that displays information about the process
like pressure gauge.

Records
Is a device that records the output of a measurement devices.
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Components
of
Control Loops

Controllers

Process variable controller divided Into Two Types

Continuous Action Controller Non Continuous Action

The manipulated variable of the Controller The manipulated
continuous action controller variable of a non- continuous-action
changes continuously dependent on controller can only be changed in
the system deviation set steps.

Centrifugal Thermostat of an
Governor iron
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Components
of
Control Loops

Controller

Controllers always have an ability to receive input, to perform a mathematical

function with the input, and to produce an output signal.

Programmable logic controllers Distributed control

(PLCs) systems (DCSs)
Are usually computers connected Are controllers that, in addition to
to a set of input/output (I/O) performing control functions, provide
devices. readings of the status of the process,
The computers are programmed to maintain databases and advanced
respond to inputs by sending outputs man-machine-interface.
to maintain all processes at set
point.
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Components
of
Control Loops

Correcting Elements (Final Control Elements)

Is the part of the control system that acts to physically change the manipulated
variable. In most cases, the final control element is a valve used to restrict or
cut off fluid flow.

ACTUATORS
Is the part of a final control device that causes a physical change in the final
control device when signaled to do so. The most common example of an
actuator is a valve actuator
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Components
of
Control Loops
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Instrumentation, Systems, and

Automation
(ISA) Symbols
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Instrumentation, Systems, and
Automation
(ISA) Symbols

The figure shows a

control loop using ISA
symbology. Drawings of
this kind are known as
piping and
instrumentation drawings
(P&ID).
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Instrumentation, Systems, and
Automation
(ISA) Symbols
Signal Lines
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Instrumentation, Systems, and
Automation
(ISA) Symbols

Control Room Not accessible Auxiliary

Function
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Instrumentation, Systems, and
Automation
(ISA) Symbols

Actuator Symbols
Control Valves

Self Actuated
Regulators
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Instrumentation, Systems, and
Automation
(ISA) Symbols

 Status of valves (default position) is shown below the valve symbol:

 NO = Normally Open
 NC = Normally Closed
 LO = Locked Open
 LC = Locked Closed
Control Valves

 Status of valves (fail position) is shown below the valve symbol:

 FO = Fail Open
 FC = Fail Closed
 FL = Fail Last or Locked
 FI = Fail Indeterminate
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Instrumentation, Systems, and
Automation
(ISA) Symbols
Tag Number
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Instrumentation, Systems, and
Automation
(ISA) Symbols
Tag Number

EMCS = Electronic Measuring Control System

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Instrumentation & Process

Control Fundamentals
Summary
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Instrumentation & Process
Control Fundamentals
Summary
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Instrumentation & Process
Control Fundamentals

The End of The Session

QUESTIONS??