Introduction To Process Control System

Unit 1
INSTRUMENTATION
What is Instrumentation?
Instrumentation is the technology of using instruments to measure and control the
physical and chemical properties of materials.
The official definition of instrumentation is a collection of instruments or their
application for the purpose of observation, measurement or control.
Industrial Instruments
According to Japanese Industrial Standard (JIS), “Industrial Instrument” is defined
as “measuring/controlling equipment used in production processes in industry”. Here,
“measuring/controlling equipment” is in turn defined as apparatus which indicate and or
record quantities or physical properties, as well as having computing, controlling or alarm
functions, thus including detectors, transmitters, and the like (Instrumentation System
fundamentals).
Importance of Instrumentation
The application of instrumentation and control is a vital aspect in various industries.
Manufacturing processes, chemical and petroleum refineries, food and beverage,
pharmaceuticals, cosmetics, and other process industries need instrumentation and
control in order to:
1. Maintain product quality
2. Plant safety
3. Coordination in various process variables
4. Research and development
Scope of Instrumentation and Control
Instrumentation covers a very diversified area of various disciplines. ISA has
classified them into several divisions:
1. Communication
2. Aerospace
3. Marine Science
4. Metrology
5. Mechanical Automation/Robotics
6. Process Automation
7. Analytical
8. Biomedical
9. Cryogenics
 10. Nuclear
11. Power
Instrumentation for our specific purpose is more concerned with process
automation. It covers measurement and control of process variables such as pressure,
flow, level, temperature, viscosity, humidity, specific gravity, thickness, weight, pH,
conductivity, combustibles, oxygen, hydrogen and others.
Trend Toward Factory Automation
General process flow of manufacturing operations from raw materials to finished
products is shown in Figure 1.1

Continuous Batch Discrete

Process Process Process

“Process Control Industry”

Large Volume Single Small Volume

Product Multi-Product

PA (Process Automation) FA (Factory Automation)

Figure 1.1 Upstream – Downstream Process

As shown in Figure 1.1, going from upstream to downstream, the objects of control
may change from fluids to solids, and likewise the corresponding production.
Industrial Control Systems (ICS)

An industrial control system (ICS) is integrated hardware and software designed to

monitor and control the operation of machinery and associated devices in industrial
environments.

Industrial control systems monitor, automatically manage and enable human control of
industrial processes such as product distribution, handling and production. ICS are used
in extraction resources like mining, oil, gas and coal, as well as factories, water/waste
water treatment, power plants, pulp and paper and transport industries. The systems have
helped bring about an increase in speed, responsiveness to conditions and reliability.
Technologies used in ICS include distributed control systems (DCS), programmable logic
controllers (PLC) and supervisory control and data acquisition (SCADA). The separation
of these systems is becoming less defined as remote telemetry units used to input change
become more capable of local control and information technologies (IT) are increasingly
integrated with operational technologies (OT).

Historically, ICS hardware was not networked. Many devices for monitoring or adjustment
had no computing resources and those that were computerized typically used proprietary
protocols and programmable logic controllers rather than full computer control. However,
a major focus of the burgeoning Internet of Things (IoT) – and the Industrial IoT in
particular – is networking non-computing devices and making it possible for them to
exchange data over the Internet.

Despite the benefits of OT modernization and IT/OT convergence, there are drawbacks
in terms of security. The modernization efforts often expose older, previously
unconnected and harder- to-update systems to new threats. As a result, previously secure
facilities may be left open to industrial espionage and sabotage. Kaspersky Labs defines
targeted attacks against ICS as the number one threat to critical national infrastructure.

Common Types of Industrial Control Systems Used:

SCADA – An acronym for Supervisory Control And Data Acquisition. is a system for
remote monitoring and control that operates with coded signals over communication
channels (using typically one communication channel per remote station). The control
system may be combined with a data acquisition system by adding the use of coded
signals over communication channels to acquire information about the status of the
remote equipment for display or for recording functions. [1] It is a type of industrial control
system (ICS). Industrial control systems are computer-based systems that monitor and
control industrial processes that exist in the physical world. SCADA systems historically
distinguish themselves from other ICS systems by being large-scale processes that can
include multiple sites, and large distances. These processes include industrial,
infrastructure, and facility-based processes, as described below:

 Industrial processes include those of manufacturing, production, power

generation, fabrication, and refining, and may run in continuous, batch, repetitive,
or discrete modes.
 Infrastructure processes may be public or private, and include water treatment and
distribution, wastewater collection and treatment, oil and gas pipelines, electrical
power transmission and distribution, wind farms, civil defense siren systems, and
large communication systems.
 Facility processes occur both in public facilities and private ones, including
buildings, airports, ships, and space stations. They monitor and control heating,
ventilation, and air conditioning systems (HVAC), access, and energy consumption
 The Evolution of SCADA

In the 1950s, the first mini-computers were first developed and used for industrial
purposes. In the 1960s, what were once mini-computers were now considered
mid-sized and they were used for remote monitoring and supervisory control. The
term “SCADA” was coined in the early 1970s, and the rise of microprocessors and
programmable logic controllers (PLCs) during that decade gave enterprises a
greater ability to monitor and control automated processes than ever before.

In the 1980s and 1990s, SCADA evolved again with the wide use of local area
networks (LAN), which enabled SCADA systems to be connected to other
systems, and the introduction of PC-based HMI software.

In the 1990s and early 2000s, structured query language (SQL) databases became
the standard for IT databases but were not adopted by SCADA developers. This
resulted in a rift between the fields of controls and IT, and SCADA technology
became antiquated over time.

PLC – Stands for Programmable Logic Controller. A microcomputer-based control device

containing programmable software; used to control process variables in an industrial
control system. These are used in many industries such as oil refineries, manufacturing
lines, conveyor systems and so on. Wherever there is a need to control devices the PLC
provides a flexible way to “soft-wire” the components together.

DCS – Refers to Distributed Control System. A computer control system having multiple
microprocessors to distribute the functions performing process control, thereby
distributing the risk from component failure. The distributed components (input/output
devices, control devices, and operator interface devices) are all connected by
communications links and permit the transmission of control, measurement, and
operating information to and from many locations.

P&ID – Piping & Instrumentation Diagram or P&ID is used to create important

documentation for process industry facilities. The shapes in this legend are representative
of the functional relationship between piping, instrumentation, and system equipment
units. These are broken down into seven main groups; equipment, piping, vessels, heat
exchangers, pumps, instruments and valves.

1. Equipment – comprised of miscellaneous P&ID units that don’t fit into the other
categories. This group includes hardware like compressors, conveyors, motors,
turbines, vacuums, and other mechanical devices.

2. Piping – A pipe is a tube that transport fluid substances. Piping can be made of
various materials, including metal and plastic. The piping group is made up of one-
to-many pipes, multi-line pipes, separators, and other types of piping devices.
 3. Vessels – A vessel is a container that is used to store fluid. It may also alter the
characteristics of fluid during storage. The vessels category includes tanks,
cylinders, columns, bags, and other vessels.

4. Heat Exchangers – A heat exchanger is a device that is designed to efficiently

transfer heat from different areas or media. This category includes boilers,
condensers, and other heat exchangers.

5. Pumps – A pump is a device that uses suction or pressure to raise, compress, or

move fluids in and out of other objects. This section is comprised of both pumps
and fans.

6. Instruments – An instrument is a device that measures – and sometimes controls

– quantities such as flow, temperature, angle, or pressure. The instruments group
houses indicators, transmitters, recorders, controllers, and elements.

7. Valves – A valve regulates, directs, or controls the flow of a fluid by opening,

closing, or partially obstructing passageways in a piping system. This category
includes rotameters, orifices, and other types of valves.

Acronyms Used in P&ID

Some commonly used acronyms in P&ID are listed here for reference.

Acronyms of Equipment

AHU -- AIR HANDLING UNIT FE -- FAN EXHAUST

ASV-- AIR SWITCH VALVE FRA -- FAN, RETURN AIR
CA -- AIR COMPRESSOR FRL -- FILTER AIR ROLL
CAE -- COOLER, AIR EVAPORATIVE FA -- FAN SUPPLY
D – DAMPER HEAP -- HIGH EFFICIENCY PARTICULAR AIR FILTER
ADA -- DESICCANT AIR DRYER HX -- HEAT EXCHANGER
DAMD -- DUCT AIR MONITOR DEVICE
ES -- EXHAUST STACK
FAB -- FILTER AIR BOX
FANE -- FAN EVALUATOR
FAR -- FILTER AIR REPLACEABLE
FC -- FAN CIRCULATING
P&ID Identification Letters
Equipment
Piping
Vessels and Tanks
Heat Exchangers
Pumps
Instruments
Valves