Introduction to

Instrumentation and
Control Engineering
INSTRUMENTATION
In general definition this can be defined as
the art and science of measurement and/or
control.

Instrumentation is achieved by using an

“Instrument”.
 Instrumentation based on
industrial application:
“It is the application of instrument for the
purpose of measuring, observing, transmitting,
indicating, recording, monitoring, and controlling
of any industrial process variable.”
Instrumentation - as defined in ISA-5.2, is a
collection of instruments, devices, hardware or
functions or their applications for the purpose of
measuring, monitoring or controlling an
industrial process or machine or any
combination of these.
What is an instrument?
An “Instrument” is any device used directly
or indirectly in order to accomplish an
objective or task.
In instrumentation, an instrument is any
sensing, measuring, transmitting,
indicating, or controlling device associated
with a process or system.
Instrument - device that measures,
monitors and control process variables.
Instrument Examples:
Classification of Instruments
Critical
An instrument which, if not conforming to specification,
could potentially compromise product or process quality
and safety.
Non-critical
An instrument whose function is not critical to product or
process quality, but whose function is more of an
operational significance.
Reference Only
An instrument whose function is not critical to product
quality, not significant to equipment operation, and not used
for making quality decisions.
PROCESS
As used in the term process control and
process industry, refers to the methods of
changing or refining raw materials to create
end products.

This is the physical system we wish to

monitor and control.
PROCESS CONTROL
Refers to the methods that are used to
control process variables when
manufacturing a product.
Manufacturers control the production
process for three reasons:
• Reduce Variability
• Increase Efficiency
• Ensure Safety
SYSTEM
An arrangement, set or collection of physical
components connected or related in such a
manner as to form and/or act as an entire unit.

CONTROL SYSTEM
An arrangement of physical components
connected or related in such a manner as to
command, direct or regulate itself or another
system.
Control System Example:
INSTRUMENTATION SYSTEM
An arrangement of two or more instruments
connected together to perform a unified task.

Each instrument operates independently

according to its specific task. Failure of one
member instrument, means failure of the entire
instrumentation system.

The simplest form of instrumentation system is

a Control Loop.
CONTROL LOOP
Is a group of instruments that work together
to keep a process variable at its desired
value, referred to as set point.
Four Basic Element of a
Control Loop
1. Primary Element/Sensor
2. Secondary Element/Signal-generating
Element/Transmitter
3. Controlling Element/Controller
4. Final Control Element
BLOCK DIAGRAM OF
THE CONTROL LOOP
Disturbances

MV PV
Process Variable

Final Control Sensing/Measuring

Element SP Element

CO PV
Receiving Element
Process Variable (PV)- any variable property of a
process
*A process variable, process
value or process parameter is the current
measured value of a particular part of a
process which is being monitored or
controlled.
Set point (SP)- any input variable that seats the
desired value of the measured variable.
Controller Output (CO)- outputs signal generated
in response to a change of a process variable.
Manipulated Variable (MV)- a process variable
linked to the controller output that is used to
influence the measured variable.
Process Variable
Common process variable includes:
Basic Process Measurement:
Process Level
Flow Temperature
Advance Process Measurement:
Density pH (acidity or alkalinity)
Mass Conductivity
Four Basic Element
of a Control Loop
1. Primary Element/Sensor
2. Secondary Element/Tansmitter
3. Controlling Element/Controller
4. Final Control Element
1. SENSOR
Integral part of loop that first senses the
value of a process variable that assumes a
corresponding, predetermined, and
intelligible state or output and generates an
output signal indictive of or proportional to
the process variable.
Measurement vs Detection
Measurement:
The determination of the magnitude of a variable
(VALUE)

Detection:
The determination of the existence or the presence
of a variable.
Classification of Sensors
• Active or Passive Sensors
• By means of detection used - Electric,
Biological, Chemical, Radioactive, etc.
• By conversion phenomenon (input and
output) - Photoelectric, Thermoelectric,
Electrochemical, Electromagnetic,
Thermooptic, etc.
• Analog or Digital Sensors
Types of Sensors
The following is a list of different types of sensors
that are commonly used in various applications. All
these sensors are used for measuring one of the
physical properties like Temperature, Resistance,
Capacitance, Conduction, Heat Transfer etc.

Temperature Sensor Proximity Sensor

Accelerometer Infrared Sensor (IR)
Pressure Sensor Light Sensor
Ultrasonic Sensor Touch Sensor
Color Sensor Humidity Sensor
Tilt Sensor Flow and Level Sensor
Smoke, Gas, and Alcohol Sensor
2. TRANSMITTER
A device that converts a reading from one sensor or
transducer into a standard and transmits that signal to a
monitor or controller.
.

*Transducer A general form of a device that receives

information in the form of one or more physical quantities,
modifies the information and/or its form, if required, and
produces a resultant output signal.
Types of Signal
Standardized Signals
1. Analog Signal - a signal that has no discrete positions
or states and changes value.
Pneumatic and Electrical Signals
Pneumatic : 3-15 psi
Electrical : 4-20 mA (Current)
: 1-5 VDC (Voltage)

2. Digital Signal - a signal that generates or uses binary

digit signals to represent continuous values or discrete
states.
RANGE:
The limit or extent of variation. The lower limit is
called LRV & the upper limit is called URV.

0 to 400°C

SPAN( of a range):
The number of units between two limits, the
LRV and URV.

(Span = URV-LRV)
 Conversion of a PV into SIGNAL

Measuring Range = 0 to 8 Bars

PV
0 Bars 8 Bars

Measuring
Element

PV Signal

Current Std. = 4mA 20mA

Pressure Std. (English)= 3psig 15psig
Pressure Std. (Metric)+ 0.2 Bars 1.0 Bars
Output Range
Relating 4 to 20 mA signals to
instrument variables
To calculate the equivalent milliamp value for any
given percentage of signal range, the equation
takes the form of the standard slope-intercept
line equation y=mx + b.
y = equivalent current in milliamps
m = the span of the output range
x = the desired percentage of signal
b = LRV of the output range
Range, Input/Output
Calculations
1. Given the PV Input to a Transmitter,
determine the equivalent output signal.
PV Input Signal Output = ?
Measuring Element

a) PV Range = 0 to 100 psi, Output Range=

4 to 20mA. If PV =50psi, What is the
output?
Range, Input/Output
Calculations
1. Given an output signal of a transmitter,
determine the equivalent input PV.
PV Input = ? Signal Output
Measuring Element

a) PV Range = 0 to 100 psi, Output Range=

4 to 20mA. If the output signal is 10mA,
what is the PV?
Range, Input/Output
Calculations
1. PV range = 0 to 100 psi, Output range = 4 to
20mA. If PV = 69 psi, what is the output?
2. PV range = 0 to 100 psi, Output range = 4 to
20mA. If PV = 60 psi, what is the output?
3. PV range = 20 to 100 ℃, Output range = 4 to
20mA. If PV = 50℃, what is the output?
4. PV range = 0 to 100 ℃, Output range = 4 to
20mA. If PV = 38.5℃, what is the output?
Range, Input/Output
Calculations
1. PV range = 0 to 100 psi, Output range = 4 to
20mA. If output signal is 6.9mA, what is the PV?
1. PV range = 0 to 100 psi, Output range = 4 to
20mA. If output signal is 18.8mA, what is the PV?
3. PV range = 20 to 100 ℃, Output range = 4 to
20mA. If output signal is 10mA, what is the PV?
3. PV range = 10 to 100 ℃, Output range = 4 to
20mA. If output signal is 7.8mA, what is the PV?
3. CONTROLLER
a device that receives data from a
measurement instrument , compares
that data to a programmed setpoint,
and, if necessary, signals a control
element to take corrective action.
Types of Controllers:
1. According to the capacity - Single-loop,
Multi-loop
2. According to display - Analog, Digital,
Recording, Blind
3. According to size - 1/4 DIN, 1/2 DIN, etc.
4. According to technology - Pneumatic,
Electric, Electronic, Digital, Microprocessor-
based
Pneumatic Controllers
Multi-loop Controllers
• Programmable Logic Controller (PLC) – usually
computers connected to a set of input/output (I/O)
devices. The computers are programmed to respond to
inputs by sending outputs to maintain all processes at
setpoint.
Distributed Control System (DCS) – are controllers
that, in addition to performing control functions , provide
readings of the status of the process, maintain databases
amd advance man-machine-interface.
4. FINAL CONTROL ELEMENT
The part of the control system that acts to
physically change the manipulated variable.

The final control element may be

Actuator
Control Valve
Electrical motors
Pumps
Dampers
Actuator
The part of a final control device that causes a
physical change in the final control device when
signalled to do so.

An actuator requires a control signal and a source of

energy. The control signal is relatively low energy and
may be electric voltage or current, pneumatic or
hydraulic pressure, or even human power. Its main
energy source may be an electric current, hydraulic
fluid pressure, or pneumatic pressure. When it
receives a control signal, an actuator responds by
converting the signal's energy into mechanical motion.
Actuator
Control Valves
A valve used to control fluid flow by varying
the size of the flow passage as directed by a
signal from a controller.This enables the
direct control of flow rate and the
consequential control of process quantities
such as pressure, temperature, and liquid
level.
Control Valves
 Control
Classification
• Closed and Open Control Loop
• Automatic and Manual Control
Open Control Loop (Feedforward)

An 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, but
is instead taken without regard to process
variable conditions.
Open control loop
Closed Control Loop (Feedback)
A 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.
Closed control loop

TE
Feedforward + Feedback Control

TE
Manual Control
Automatic Control
Other common instruments
on a control loop:

Indicators
Recorders
Converters
Indicators
ISA Definition:
A measuring instrument in which only the
present value of the measured variable is
visibly indicated.
Indicators:
A receiving element that receives the PV
signal from the measuring element and
shows a display or reading of the variable in
actual engineering units.
Types of Indicators:
1. According to the display - Analog, Digital,
Bargraph
2. According to the inputs - Scanning, Multi-
channel
3. According to the scale - horizontal,
vertical, semi-circle, quarter-circle, deviation
4. According to mounting - control room
mounted, field mounted
Conventional Indicators

Vertical-Scale Indicators
Multi-Channel Indicators

Field-Mounted Indicators
Recorders
ISA Definition:
A measuring instrument in which the values
of the measured variables are recorded.
Recorders:
A receiving element that receives the PV
signal from the measuring element and
stores the historical values of the variable in
a graphical and/or tabulated manner, on
paper or a memory media, and may have a
display showing the measured values.
Types of Recorders:
1. According to the recording format - Trend,
Log
2. According to the inputs - Multi-channel,
Multi-point, n-point
3. According to the construction - circular-
chart, strip-chart, paperless, data logger
Importance of the Recording:
1. As a guide to the operation of a process
by observation of the trend of variables.
2. As a troubleshooting function by analyzing
or locating the possible source of the
problem.
3. As a source of management information
in measuring past performance
Circular Chart Recorders

Strip Chart Recorders

Paperless Recorders

Data Loggers
Converter (I/P, P/I, E/P, etc.)
An I/P Converter is also known as a “current to pressure
transducer” as it provides flow/speed controls and
directional control functions in a single valve. Otherwise
known as an I/P Transducer, an I/P Converter eliminates
the need for any external power supply by translating
electric currents into pneumatic output.
Instrument applications:
Factory automation instruments
Plant safety or safeguarding instruments
Product Quality monitoring/control
instruments
Environmental condition monitoring /control
instruments.
Process variable measurement and control
instruments.