CLB 21303

Process
In st r u m e n tation
and Control
 OBJECTIVES
After this lesson, you will able to:

 Explain the basic concept of process control.

 Relate the process instrumentation with process control.
 Define the meaning of process instrumentation
terminologies.
 Apply the concept of instrumentation symbols.
 Describe the important of process instrumentation in
industry.
INTRODUCTION
~ ESSENTIAL SKILL in engineering.
~ basic knowledge for process control.
Process instrumentation is very important for
SAFE and EFFICIENT operation.
~ based on mechanical, optical, chemical principal.
Different measurement for different PROCESS
VARIABLES.
PROCESS VARIABLE or process parameter is
the current status of a process under control. E.g.
pressure, level, temperature
 INTRODUCTION

 BASIC CONCEPTS AND QUALITIES OF

MEASUREMENT
 Basic purpose of instrumentation: – to OBTAIN
REQUISITE INFORMATION pertaining to the
successful completion of the process.
 Instrumentation is the philosophy based on:-
The preposition that the condition of human society
and of industrial processes and operations. i.e. the
force of nature
The principle that, before a condition can be
controlled, it must be measured
INTRODUCTION

The dictum that, in order to measure a condition or

property, it must be segregated, and
The logic, “If you control it manually you should
control it automatically”
 DEFINITION
Control
 Instrument / apparatus to regulate mechanism

Instrument
 Devices for indicating / measuring condition,
performance, position, direction or sometimes
controlling operation

Measurement
 Extent, quantity, size which determined by measuring
 BASIC CONCEPT OF PROCESS
CONTROL

 Process control: automatic control of an output

variables by sensing the amplitude of the output
parameter from the process and comparing it to the
desired or set level and feeding an error signal back to
control an input variable.

 A temperature sensor attached to the outlet pipe

senses the temperature of the water flowing.
 As the demand for hot water increases or decreases, a
change in the water temperature is sensed and converted
to an electrical signal, amplified, and sent to a controller
that evaluates the signal and sends a correction signal to
an actuator.

 The actuator adjusts the flow of steam to the heat

exchanger to keep the temperature of the water at its
predetermined value.
 PRINCIPAL OF PROCESS
INSTRUMENTATION

 Part of process control

 4 basic component for measuring process variables:

sensor: devices to measure the element

controller: intelligent unit to control the process
control element: control valve, pump speed, heating
element
controlled variables: element to control
2 important component to measure value:

Sensor: conduct the process variable

measurement
Transmitter: convert measurement by sensor
to signal
(4-20 ma)

Relation between sensor and transmitter:

- Linear
- Non- linear
TERMINOLOGIES
Accuracy

The amount of error that may occur

when measurements are taken.
It determines how precise or
correct the measurements are to the
actual value and is used to determine
the suitability of the measuring
equipment.
Accuracy can be expressed as
any of the following:

 error in units of the

measured value
 percent of span
 percent of upper range val ue
 percent of scale length
 percent of actual output
value
Range of operation/instrument
The high and low operating limits between
which the device will operate correctly, and at which
the other specifications are guaranteed.

Span of instrument
 The difference between the low and the high
value of process variables measured by the
instrument

Zero of instrument
 The lowest value measured by the instrument
Hysteresis
 This is where the
accuracy of the device
is dependent on the
previous value and
the direction of
variation.
Linearity
 Linearity is how close a
curve is to a
straight line. The
response of an
instrument to changes
in the measured
medium can be
graphed to give a
response curve.
Repeatability
close a second
 Repeatability defines how
measurement is to the first under the same
operating conditions, and for the same input.

Response
 When the output of a device is expressed as a
function of time (due to an applied input) the time
taken to respond can provide critical information
about the suitability of the device.
Calibrate
 To configure a device so that the required output
represents (to a defined degree of accuracy) the
respective input

Controller
 A device which operates automatically to regulate the
control of a process with a control variable.

Ramp
 Defines the delayed and accumulated response of the
output for a sudden change in the input.
Sensitivity
 This defines how much the output changes, for a
specified change in the input to the device.

Set Point
 Used in closed loop control, the set point is the ideal
process variable. It is represented in the units of the
process variable and is used by the controller to
determine the output to the process.
Steady state
 Used in closed loop control where the process no
longer oscillates or changes and settles at some
defined value.
Transducer
 A device that convertsinformation from
physical, (temperature or pressure) and
converts it to electrical, (volts or millivolts or
resistance change).

Transmitter
 A device that converts from one form of
energy to another. Usually from electrical to
electrical for the purpose of signal integrity for
transmission over longer distances and for suitability with
control equipment.

Variable
 The quantity of the system or process.
How you want
to tell people
about the
process in this
chemical
processing
plant?
 P & ID DIAGRAM

P & ID diagram ~ piping and instrumentation diagram

~ schematic drawing illustrates functional relationship
among piping, instrumentation and system
equipment.
P & ID DIAGRAM
Instrumentation Symbols and
Identification

 ISA 5.1 (1984)

 Suitable for use in the chemical, petroleum, power
generation, air conditioning, metal refining, and
numerous other, process industries.
 Certain fields, such as astronomy, navigation, and
medicine, use very specialized instruments that are
different from the conventional industrial process
instruments.
 Each instrument or function to be identified is designated
by an alphanumeric code or tag number as shown
 The loop identification part of the tag number generally is
common to all instruments or functions of the loop. A
suffix or prefix may be added to complete the
identification.
Typical letters
Line Symbols
Function Symbol
Valve Body Symbol
Actuator Symbol
Self-actuated Regulators, Valves and
other Devices
Symbols for Actuator Power Failure
Primary Element Symbols
 SELECTION DEVICES CRITERIA

 Wide operating range

 Fast response
 Good sensitivity
 High accuracy
 High over range protection
 Simple design and maintenance
 Cost
 Repeatability
 Size
 Stable
 Resolution
 Robust
 Self generated signal
 Simple to adjust
 Suitable for various material
 Reliable performance
 Unaffected by density, moisture content and conductvity
APPLICATIONS
HVAC (Heating, ventilation and air conditioning)
Applications
 Heat transfer
 Billing
 Axial fans
 Climate control
 Hot and chilled water flows
 Forced air
 Fumehoods
 System balancing
 Pump operation and efficiency
Petrochemical Applications
 Co-generation
 Light oils
 Petroleum products
 Steam
 Hydrocarbon vapours
 Flare lines, stacks

Natural Gas
 Gas leak detection
 Compressor efficiency
 Fuel gas systems
 Bi-directional flows
 Mainline measurement
 Distribution lines measurement
 Jacket water systems
Power Industry
 Feed water
 Circulating water
 High pressure heaters
 Fuel oil
 Stacks
 Auxiliary steam lines
 Cooling tower measurement
 Low pressure heaters
 Reheat lines
 Combustion air

Emissions Monitoring
 Chemical incinerators
 Trash incinerators
 Refineries
 Stacks and rectangular
IMPORTANT

 Safety concern – within allowable limit

 Production specification –
optimum variables maximize
production
 Environmental regulation – within
specified limits
Operational constrains - equipment
Economics – min operating cost, max profit