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What is Instrumentation?
Basic Terminologies
Process & its Control
Field Instruments & its principles
Valves & its working
What is Instrumentation?
Instrumentation is about measurement and
control.
Instrumentation engineering is the
engineering specialization focused on the
design and configuration of process systems.
Instruments are devices which are used in
measuring attributes of process systems.
Basic Terminologies
Process:
Series of continuous or regularly recurring steps or actions
intended to achieve a predetermined result, as in heat treating
metal, or manufacturing acid.
Transducer(sensor):
Element which converts one form of Energy to Other form.
Primary Transducer:
Transducer which converts the Process parameter to a form
readable by Secondary Transducer.
Eg: Orifice plate
Secondary Transducer:
Transducer or transmitter which responds to a measured
variable and converts it to a standardized transmission signal which
is a function only of the measurement.
Eg: DP Transmitter
Signal:
The signal is the event or phenomenon that conveys data from one
point to another.
Loop:
Controller:
ANALYSER:
WEIGHFEEDER:
Controller multiplies the signal from the load cell(belt load,kg/m) with that
from the speed transducer(belt speed,m/s) to get the feed rate.
The controller then either changes the belt speed or belt load to get the set
feed rate.
CONVEYOR:
Conveyors are used as components in automated distribution and
warehousing. A belt conveyor consists of two or more pulleys, with a
continuous loop of material - the conveyor belt - that rotates about them.
One or both of the pulleys are powered, moving the belt and the material on
the belt forward. The powered pulley is called the drive pulley while the
unpowered pulley is called the idler.
BELTWEIGHER:
Material flowing over the belt may be weighed in transit using a beltweigher.A
belweigher or belt weigher is a piece of industrial control equipment used to
gauge the mass or flow rate of material travelling over a conveyor belt.
Process & its Control
Process Parameters:
Pressure
Level
Temperature
Flow
Pressure Measurement
PRESSURE
A force applied to or distributed over a surface. The
pressure (P) of a force (F) distributed over an area(A) is
defined as :
P=F/A
Standard Unit of Pressure is Pascal
Other units of pressure are psi
kg/cm2
bar
atmosphere
torr
1 Pa = 1 N/m2
Pressure Measurement
Primary Pressure Measuring Devices:
Diaphragm
Bellows
Manometer
Pressure measurements can be divided into three
different categories:
absolute pressure
gauge pressure and
differential pressure
GAUGE PRESSURE
Gauge pressure is the pressure relative to the local atmospheric or ambient pressure.
In measurements a gauge is used to record the pressure difference between the system
and the atmospheric pressure. This is called gauge pressure and can be stated by the
following equation:
Pg=Pa+Po
where
Pg= gauge pressure
Po = atmospheric pressure
When pressure is measured by a gauge, the quantity obtained usually excludes the
ambient atmospheric pressure and is therefore called overpressure,
Poverpressure = Pgauge
ABSOLUTE PRESSURE
The absolute pressure is measured relative to the absolute zero pressure - the pressure
that would occur at absolute vacuum.
P=Pg+Po
P=absolute pressure,
Pg=gauge pressure,
Po=atmospheric pressure.
DIFFERENTIAL PRESSURE
The atmospheric pressure is the pressure in the surrounding air at or "close" to the surface of
the earth.
The atmospheric pressure varies with temperature and altitude above sea level.
1 atmosphere on Earth = 760 millimeters of mercury (760 Torr) and 101,325 Pascals.
The Standard Atmospheric Pressure (atm) is used as a reference for gas densities and
volumes.
The Standard Atmospheric Pressure is defined at sea-level at 273oK (0oC) and is 1.01325
bar or 101325 Pa (absolute). The temperature of 293 oK (20oC) is also used.
Types of Pressure Measuring Devices
Capacitive LVDT
Level Measurement
Some of the most commonly used liquid-level
measurement methods are:
RF capacitance
Conductance (conductivity)
Hydrostatic head/tank gauging
Radar
Ultrasonic
Level Measurement
P = gh
Open Tank Closed Tank
RF Capacitance
Conductive Type
Hydrostatic Head
Ultrasonic Type
RADAR Type
Flow Measurement
Principle:
Flow is measured by measuring velocity through a known
area.with this indirect method,the flow measured is the
volume flow rate Q .
Q=AxV
Hot
Water
35
Temperature Measurement
Technology
Change in RESISTANCE with response to change in
TEMPERATURE
Example: Thermistors
RTD (discussed later)
Thermistors
Semi-conductors made from specific mixtures of pure oxides of
nickel, manganese, copper, cobalt, and other metals sintered at very
high temperature.
Used with Wheatstone Bridge which amplifies small change in
resistance - in a simple circuit with a battery and a micro-ammeter.
Stability -
Linearity - Moderate
Slope of Output - Poor (Logarithmic)
Negative
36
Temperature Sensors
RTDs
What is an RTD ?
Resistance Temperature Detector
Operation depends on inherent characteristic of metal
(Platinum usually): electrical resistance to current flow
changes when a metal undergoes a change in
temperature.
If we can measure the resistance in the metal, we know
the temperature!
Platinum
resistance changes
with temperature
Resistance (Ohms)
350
International Resistance 300
IEC
vs. Temperature Chart:
oC
250
751
Ohms 200
0 100.00 150
10 103.90 100
20 107.79 50
30 111.67 0
-400 -200 0 200 400 600 800
What is a Thermocouple ?
Two dissimilar metals joined at a Hot junction
The wires are connected to an instrument (voltmeter) that
measures the potential created by the temperature
difference between the two ends.
Process
Temperature 40 millivolts!, Tommy
Seebeck yelled in a heated
Hot junction Cold junction
+ debate.
DT MV
-
39
Temperature Sensors
Thermocouples
Voltage (mV)
vs. Temperature Chart:
60
oC Millivolts IEC
0 0.000 40 584
10 0.591 20
20 1.192
0
30 1.801
-500 0 500 1000
TYPE E THERMOCOUPLE -20
Temperature (oC)
40
Temperature Sensors
Thermocouples
Types of Thermocouple
Type J
Iron / Constantan
White, Red
0 to 760 C
+ - Least Expensive Type T
Copper /
Constantan
Type K
Blue, Red
Chromel / Alumel + - -180 to 371 C
Yellow, Red
Highly resistant to
+ - 0 to 1150 C corrosion from
Most Linear moisture
41
Temperature Sensors
Comparison
42
Temperature Sensors
Comparison
Why choose thermocouple over RTD ?
43
Temperature Sensors
Comparison
RANGE OFFER
44
Sensor accessories
Thermowells
45
Control Valves
The control valve manipulates a flowing fluid, such as gas, steam, water, or
chemical compounds, to compensate for the load disturbance and keep
the regulated process variable as close as possible to the desired set point.
The control valve regulates the rate of fluid flow as the position of the
valve plug or disk is changed by force from the actuator.
Control valves are valves used within industrial plants and elsewhere to
control operating conditions such as temperature, pressure ,flow, and
liquid level by fully or partially opening or closing in response to signals
received from controllers that compare a "set point" to a "process
variable" whose value is provided by sensors that monitor changes in such
conditions.
The opening or closing of control valves is done by means of electrical,
hydraulic or pneumatic systems.
CONTROL VALVES:
Pneumatic signal
I / P Converter POSITIONER CONTROL VALVE
CURRENT
V NET
V NET V NET
BCV
FCS FCS
RL BUS
RIO BUS
MOPL MFCD
NIU NIU
MAR
JB 2
JB 1 JB 3
BASIC TERMINOLOGIES OF DCS
HIS: Human Interface Station
The HIS is mainly used for operation and monitoring-it displays process variables,control parameters and
alarms necessary for users to quickly grasp the operating status of the plant.
Unlike Personal Computer, PLC does not contain peripherals, such as display or keyboard, that allow
user to directly interact with PLC. In order to facilitate interaction, separate computer is provided, normally
taking form of a standard PC. Through this external computer, operator can re-program PLC, provide set-
points and view trends of process variables that are controlled and manipulated by PLC.
External
PLC Actuator Process
Computer
Sensor
Programmable Logic Controller Architecture
PLC
Power Supply
Microprocessor + Memory
Operator
Workstation Communication Module
Microprocessor This is the brain of PLC. It reads input signals, executes control program
and communicates results (decisions) of control program as action signals to the outputs.
Power Supply This component is used to convert the mains AC voltage to the low DC
voltage (e.g. from 240V AC to 5V DC). This unit powers the processor and the circuits in the
input and output modules.
Input Module This component receives information from external devices (sensors). It
contains circuitry that provides electrical isolation and signal conditioning functionalities.
Input module can be analogue input (AI) or discrete input (DI) module. AI module receives
continuously changing signal whose amplitude is proportional to the current value of the
measured process variable. DI module receives discrete/digital (ON/OFF) information from
discrete sensors, for example push button (ON if button is pressed, OFF if button is not
pressed). Note that DI is much more frequently used than AI.
Output Module This module communicates control actions to external devices (actuators).
It contains circuitry required to interface PLC with actuators (e.g. digital-to-analogue
converter and power amplifier). Like input module, output module can be analogue output
(AO) or discrete output (DO) module depending on the type of actuator used.
Collection of data from field devices, which can be sensors, actuators and
controllers.
Convey any required supervisory control actions back to the field devices.