Understanding Industrial Processes, Measurement, and Control

FG05, Version 4.5 2006

Course Logistics
Course materials & location
Handouts and textbook Exercises, additional resources, instructional surveys, and progress reviews Tent card

Course attendance & participation

Certificate of course completion Continuing education units (CEU)

Breaks
Lunch Stretch, refreshment, etc.

Personal belongings

ISA Resources
Books Software Videotapes/DVDs Interactive multimedia Standards Journals Training courses Membership services John Shaw (Developer) Jerry Booher Jim Federlein Jack Hausman Fred Meier Wiley Montana Dale Polmateer Larry Thompson
Grover Allen Bill Brown Daniel Evans Eugene King Carl Sossman

Course Contributors

Advisory Group Members:

Introduction of Course Participants

Instructor
Name Background/experience

Classmates

 Name, company, position Background/experience What would you like to get from this course?

General Course Objectives

Be able to communicate with measurement and control professionals Understand the role of measurement and control in industrial processes Be able to differentiate between continuous, batch, and discrete control Be able to apply specific ISA standards to interpret symbols and drawings associated with process control documentation Understand the most common methods and devices used in temperature, pressure, level, and flow measurement

General Course Objectives (contd)

Know how control valves operate in a feedback control loop Understand the operation and tuning of process controllers Be able to differentiate between control system architectures including single loop controllers, Distributed Control System (DCS), and Programmable Logic Controllers (PLC) Know the latest trends in measurement and control technology

Pre-Instructional Survey
Answer the questions to the best of your ability You are not expected to be able to correctly answer all the questions prior to instruction The results will help the instructor emphasize areas required by all class members

Performance Objectives Day 1

List types of industrial processes Define the role of measurement and control in industry Identify and interpret a variety of symbols and documentation used in process measurement and control Describe basic concepts of industrial measurement Describe the operation and use of common pressure and level measurement devices

Section 1: Concepts of Process Control

Industries that use process control Types of processes Process control and the feedback loop

Types of Industries
Process
Most processes involve handling of fluids Use continuous or batch process

Discrete parts manufacturing

Most processes involve making or manipulating parts Use machines and manual assembly

Combinations
Some locations are combinations of continuous and batch processes and discrete parts manufacturing

Typical Industries
Process industries

Petroleum Chemical Power Pulp and paper Food and beverage Textile Pharmaceutical Waste Treatment Water Treatment Automotive Electrical/electronic manufacturing Instrument/parts manufacturing Toys Sporting Goods

Discrete parts

Definition of a Process
A process is a part of a manufacturing plant in which material or energy is converted to other forms of material or energy
Change in pressure, temperature, speed, electrical potential, etc.

Continuous vs. Batch Processing

Continuous
Material is fed and removed from the process at the same time. An individual piece of material cannot be identified

Batch
Material is added to a vessel; some process takes place; A product can be traced to a specific piece of raw material product is removed

Typical Continuous Processes

Steam production Chemical reactions Separations Waste treatment Distillation

Continuous Process Example Typical Batch Processes

Alcoholic beverages Explosives Food products Liquid detergents Pharmaceuticals

Batch Process Example Process Control

The regulation or manipulation of variables influencing the conduct of a process in such a way as to obtain a product of desired quality and quantity in an efficient manner

Room Heating Example The Process Control System (Feedback Loop) Room Heating Example Industrial Process Example Control Loop on P & I Drawings Summary: Concepts of Process Control
Industries that use process control Types of processes Process control and the feedback loop

Section 2: Documentation
Symbols and identification P&IDs Loop diagrams

Loops Instrument Line Symbols Control Loop on a P & I D General Instrument or Function Symbols Control Loop on a P & ID Identification Letters Identification Letters (contd) Typical Letter Combinations Piping & Instrumentation Drawing (P&ID) Loop Diagram Application Exercise 1
Interpreting Simple P&IDs
Using the symbols and other information in your noteset and textbook, interpret some simple P&IDs

Interpreting Simple P&IDs Application Exercise 1 Interpreting Simple P&IDs Application Exercise 1 (contd) Interpreting Simple P&IDs Application Exercise 1 (contd) Other Forms of Documentation
Process flow diagrams Instrument lists Location plans Installation details

Specification forms Logic diagrams Calibration data sheets Wiring diagrams

Summary: Documentation
Symbols and identification P&IDs Loop diagrams

Section 3: Industrial Measurement Systems

Signal transmission Measurement terminology Errors and calibration

Process Measurement
The acquisition of information that establishes the magnitude of process quantities (ISA-51.1) The measurement of process variables for:
Display - Recording - Control

Measurement System Instruments

Sensing element
The element directly responsive to the value of the measured variable

Transducer
An element or device which receives information in the form of one quantity and converts it to information in the form of the same or another quantity

Transmitter
A transducer which responds to a measured variable by means of the sensing element, and converts it to a standardized transmission signal which is a function only of the measured variable

Standard Signals
Pneumatic transmitter
Converts value of measurement to air pressure and sends signal to controller via a tube Range of signal is 3-15 psig (pounds per square inch gage) (-20 -100 kPa gage)

Electronic transmitter
Converts value of measurement to electric signal and sends signal via wire (or radio, microwave) to controller Range of signal is 4-20 mA-dc (milliamperes of direct current)

Digital transmitter
Converts value of measurement to digital signal

Standard Signal Example Instrument Performance Terminology

Resolution
Smallest scale increments

Sensitivity
Smallest detectable change

Hysteresis
Difference in measurement output when measuring input ascending and descending

Dead band
Range in which input signal may change upon reversal of direction without causing measurable change in output

Repeatability and Accuracy Error

The algebraic difference between the indication and the actual value of the measured variable
Span error Zero error Linearization error

Span Error Zero Error Linearity Errors Adjusting for Errors (Calibration)
Calibration is an adjustment or set of adjustments performed on an instrument in order to make the instrument function as accurately (error free) as possible

Calibration Block Diagram Calibration Chart Summary: Industrial Measurement Systems

Signal transmission Measurement terminology Errors and calibration

Section 4: Pressure Measurement

Principles Manometers Pressure elements

Pressure Defined / Pascals Law Pressure Units Absolute and Atmospheric Pressure Relationship Between Pressure & Column of Liquid Hydrostatic Head Pressure U-Tube Manometers U-Tube Manometers (contd) Well Manometers Bourdon Pressure Gage Spiral and Helical Elements Bellows Elements Diaphragm Element Application Exercise 2 (optional)
Pressure Scales
A student exercise to review the various pressure scales

Summary: Pressure Measurement

Principles Manometers Pressure elements

Section 5: Level Measurement

By surface detection By interface detection By hydrostatic pressure By weight

Level / Inventory Measurement Dip Stick Level Measurement Basic Sight Glasses Float & Cable Arrangements Ultrasonic Measurement Capacitance Probe Radiation Point Measurement Continuous Radioactive Measurement Rotating Paddle Radar Level System Interface Measurement with Displacers Hydrostatic Pressure Open Tank Level Zero Suppression in an Open Tank Zero Suppression in a Closed Tank Zero Elevation in a Closed Tank Level Measurement by Weight Air Bubbler System Summary: Level Measurement
By surface detection By interface detection By hydrostatic pressure By weight

Daily Progress Review

Were todays objectives clearly identified and covered? Did todays presentation/activities meet your learning goals? Was level and pace of instruction right for you?

Performance Objectives Day 2

Discuss flow measurement, various flow measuring devices, and operating characteristics Discuss temperature measurement, various temperature measuring devices, and operating characteristics Describe the operation and function of control valves, actuators, and positioners used in industrial process control

Section 6: Flow Measurement

Differential pressure flowmeters Target flowmeters Variable area flowmeters

Open channel measurements Magnetic flowmeters Vortex shedders Turbines Ultrasonic flowmeters Mass flowmeters Positive displacement flowmeters

Classifying Fluid Flow Measurement Types of Flow Reynolds Number

3160 x Qgpm x SG / cP x D
Q = flow SG = specific gravity cP = viscosity in centipoises D = inside diameter of pipe in inches

Liquids can be significantly affected by viscosity Can affect flowmeter performance Indication of flow regime
Laminar (<2000) Transitional (2000-4000) Turbulent ( >4000)

Differential Pressure Flowmeters Orifice Plate Primary Element Concentric Orifice Eccentric Orifice Segmental Orifice Tap Locations in Orifice Plate Orifice Plate Maintenance
Bore wear Build up Transmitter removal/replacement Tap/tubing pluggage Leakage Transmitter failure Verification

Flow Nozzle Elbow Flowmeter Wedge Flow Element Venturi Tube Pitot Tubes V-Cone Target Flowmeter Rotameter or Variable Area Meter Open Channel Flow Measurement

Weir Flume Require level measurement Usually used for large flows
Waste treatment Rivers and streams

Weirs Parshall Flume Methods That Measure Velocity Magnetic Flowmeter Vortex Shedding Phenomenon Vortex Sensing Vortex Flowmeter Turbine Flowmeter Ultrasonic Flowmeter Principles
Principle of operation
Doppler Time of flight

Construction
Clamp-on transducer Wetted transducer

Applications
Large pipes (cost) Flashing fluids Corrosive fluids Hazardous fluids Non-coating service

Doppler Effect Time of Flight Operation Methods That Measure Mass Flow Tube Vibration and Twist Coriolis Mass Flowmeter Coriolis Mass Flowmeter (contd) Thermal Mass Flowmeter Mass Flow Measurement Temperature Method Positive Displacement Flowmeters Rotary Vane Design Oval Gear Design Nutating Disc Design Flowmeter Selection Application Exercise 3 (optional)
Flow Measurement
A student exercise to review the subject of flow

Summary: Flow Measurement

Differential pressure flowmeters Target flowmeters Variable area flowmeters Open channel measurements Magnetic flowmeters Vortex shedders Turbines Ultrasonic flowmeters Mass flowmeters Positive displacement flowmeters Principles Thermometers Bimetallic elements Thermocouples Resistance Temperature Detectors (RTDs) Thermistors Radiation Pyrometers

Section 7: Temperature Measurement

Temperature Scales Liquid-in-Glass Thermometer Types of Liquid-in-Glass Thermometers Filled Bulb Thermometer Comparison of Filled Systems Bimetallic Thermometer Thermocouples (TCs) Reference Junction Compensation Standard Thermocouple Materials Standard Thermocouple Materials (contd) Standard Thermocouple Extension Leads Bare Wire Thermocouple Insulation Types Typical Thermocouple Assembly Immersion & Insertion Lengths Thermowell (TW) Installations RTD - Resistance Temperature Detectors Basic RTD Circuit (2 Wire) 3 Wire Circuit 3 Wire Circuit Redrawn 3 Wire RTD Balanced Condition 3 Wire RTD Unbalanced Condition 4 Wire Circuit RTD Constructions

RTD Thick Film Model Sheathed RTD Smart RTDs Thermistors

Electrical resistance of material varies greatly with temperature Limited spans, low cost High accuracy & stability Limited to low-medium temps Resistance decreases as temperature increases 3% to 5% per F (5% to 9% per C)

Temperature Response Curves Radiation Pyrometers Block Diagram of Modern RT Summary: Temperature Measurement
Principles Thermometers Bimetallic elements Thermocouples RTDs Thermistors Radiation Pyrometers Control valve design Actuators Positioners Transducers Emerging Technologies Other final control elements

Section 8: Control Valves

Final Control Element A Typical Control Valve Valve in Control Globe Valves (Linear Motion) Other Linear Motion Valves Rotary Motion Valves V-Notched Ball Cv Equation for Liquid Flow
Q = Flow (gpm) Gf = Specific gravity P = Inlet pressure - outlet pressure P = P1 - P2

Valve Characteristics (Trim) Inherent Flow Characteristics Actuators

Air to Close Actuator Air to Open Actuator Positioners Typical Motion-Balance Positioner Current to Pneumatic (I/P) Transducer
Used to convert current signal to pressure signal

Emerging Technologies Emerging Technologies Other Final Control Elements Summary: Control Valves Daily Progress Review Performance Objectives Day 3 Section 9: Feedback Control Strategies
Process dynamics Single loop control strategies Controller tuning

Control Hierarchy Process Dynamics First Order Lag Dead Time First Order Lag Plus Dead Time Multiple Lags Multiple Lags Plus Dead Time Control Actions Controllers and Control Strategies Direct Acting Controller Reverse Acting Controller Direct or Reverse Acting - Example On-Off Control of Heating System Temperature Record - PID Controller On-Off Control of Level System Controller Modes
Since all process loops vary in their response to process upsets, each controller must be tuned to the process. Tuning is the process of setting the controller response to a disturbance in three different areas: How Far apart the process variable and the set point are How Long they have been apart How Fast they are moving toward or away from each other

Controller Modes (Contd)

Control Formula
The classic control formula that a controller uses to develop the output signal is:

Where E, Error is the difference between the set point and the process variable.
K1 - amount of proportional action or gain set in the controller, How Far K2 - amount of integral or reset action set in the controller, How Long K3 - amount of derivative or rate action set in the controller, How Fast

Proportional Control Proportional Action

Proportional band
The amount of input change that will produce 100% output change. Always expressed as a percentage

Gain
A unit-less number that defines the ratio of the change in output, due to proportional control action, to the change in input

Proportional Control of a Continuous Process Proportional Action Proportional Control Deficiency

Offset sustained deviation of the controlled variable from set point

Level Control Offset Example Integral Action

Integral (reset):
Control action in which the output is proportional to the time integral of the input Reset action is adjusted in repeats/minutes or minutes/repeat

Minutes/Repeat (Ti) Repeats/Minute (Ri) 2 ------------------------- .5 1 ------------------------- 1 .5 ------------------------- 2

Proportional + Reset Controller Response Derivative Action

Derivative (rate):
Control action in which the output is proportional to the rate of change in the input

Output of Proportional + Derivative Controller Response of Controller Modes Recap Controller Modes Tuning
The adjustment of gain, reset, and rate to achieve good process control

Good Process Control Summary: Feedback Control Strategies

Process dynamics Single loop control strategies Controller tuning

Laboratory Exercise
Basic Tuning Simulation
Demonstrate the characteristics of the proportional, integral (reset) and derivative (rate) control modes in closed loop operation, including trial and error tuning

Section 10: Advanced Control Strategies

Cascade control Ratio control Feedforward control

Control Hierarchy Cascade Control Application: Without Cascade Application: With Cascade Ratio Control Ratio - Both Streams Controlled Ratio - Wild Stream Control Feedforward Control Feedforward Control Example Summary: Advanced Control Strategies
Cascade control Ratio control Feedforward control

Section 11: Control System Hardware

Analog controllers
Pneumatic Electronic

Single loop digital controllers (SLDC) Distributed control systems (DCS) Programmable logic controllers (PLC) Personal computers for operator interface (OI) & control

Control Hardware Pneumatic Controller Electronic Controller Single Loop Controller

Single loop controller, capable of complex calculations on one control loop
has capability of analog and digital inputs (on-off) will display process variable, set point, and control output, as well as alarms set point is adjustable, control can be put into manual with control output manually adjustable

Single Loop Digital Controller (SLDC) Distributed Control System (DCS) Programmable Logic Controller (PLC) Personal Computers for Control Summary: Control System Hardware

 Analog controllers
Pneumatic Electronic

Digital single loop controllers Distributed control systems Programmable logic controllers Personal computers for operator interface (OI) & control

Section 12: Smart Field Devices

Smarter field devices Better field communications (fieldbus)

Current Practice - Field Devices Smart Field Devices Smart Transmitter Bench Hook-up Benefits of Smart Transmitters
Better performance Reliability Ease of repair Remote re-ranging Various outputs and local metering Faster response time Ease of calibration

Smart Devices Available Fieldbus - An Enabling Technology

A new data communications protocol
Allow mounting of measurements and controls in harsh environments of factory floor & field Common link between PLCs and remote I/O Allows common link between distributed process control systems and PLCs

Empower smart devices in field to assume lowest levels

of control

Enable routine primary closed loop control and repetitive on-off control to be done in final control devices

Smart Transmitter Fieldbus Applications

IEC Bus Standard 61158 Type 1 - Fieldbus Foundation H-1 Type 2 ControlNet Type 3 Profibus Type 4 P Net Type 5 Fieldbus Foundation H-2 Type 6 SwiftNet Type 7 WorldFIP Type 8 - Interbus

Smart Transmitter Fieldbus Applications (contd)

IEC Bus Standard 61158 Type 1 - Fieldbus Foundation H-1

Type 2 ControlNet Type 3 Profibus Type 4 P Net Type 5 Fieldbus Foundation H-2 Type 6 SwiftNet Type 7 WorldFIP Type 8 - Interbus

Fieldbus Foundation An Example

Fieldbus is an open (non-proprietary) digital protocol Development started in 1980s A simple method of connecting control system input and output devices using a single cable and reducing installed cost

Fieldbus Foundation - H1 Fieldbus Foundation - H2 How is Fieldbus Different?

DDC - Direct Digital Control DCS - Distributed Control Systems FCS - Fieldbus Control System

Direct Digital Control (DDC) Distributed Control System (DCS) Fieldbus Control System (FCS) Summary: Smart Field Devices
Smarter field devices Better field communications (fieldbus)

Post-Instructional Survey
Answer the questions to the best of your ability This survey can be compared to the pre-instruction survey to determine effectiveness of this course Instructor will review questions and answers to enhance your learning experience

Final Course Evaluation

ISA Course Evaluations are tools that help us maintain the quality of our training programs Please complete the form and return it to your instructor upon completion of the course

Related Courses from ISA

Overview of Measurement and Control Fundamentals (FG05C) Measurement and Control Workbench (FG10) Installing, Maintaining, and Calibrating Electronic Instruments (TI25)
All ISA courses are available any time as on-site training For more information: www.isa.org/training or (919) 549-8411

Other Related Resources from ISA

Measurement and Control Basics by T.A. Hughes from ISA Press The ISA-5.1-1984 (R1992) Instrumentation Symbols and Identification Standard

 ISA Membership and the ISA Process, Measurement and Control Technical Division connect you to people and ideas in automation and control
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