Basic Elements of a Control Loop

Instrumentation (Figure: Bausbacher and Hunt)

• Controller – Signal to Setpoint = Error => New Signal

• Transducer
– Action to
• Transmitter –
Action =
Action to Signal
Signal to
Action
• Primary element
or sensors – • Final
Physical Action control
Copyright ©, 2010, Representing element –
William G. Beazley, PhD Measured Action to
All Rights Reserved Variable Process
Other Copyrights Apply as Noted Parameter

Instrumentation Senses Process Variables

Signal Changes in Control Loop (Franklen Equipment)
(US DOE)

http://www.franklen.com/index.php
http://hss.energy.gov/NuclearSafety/techstds/standard/standard.
html

Transmitter
(Source:
Bausbacher and
Hunt) Pressure Measurement

1
 PSIA vs PSIG Bourdon Tube Designs
(GO Regulator ) (Source: Omega Engineering Inc.)
Absolute pressure = observed
gage pressure plus local
atmospheric pressure

bar =100
kilopascals and
roughly equal to
the atmospheric
pressure on Earth
at sea level.
standard atmosphere =
101325 Pa = 101.325 kPa =
1013.25 hPa. http://www.omega.com/literature/transactions/volume3/pressure.html

http://www.goreg.com/index.htm

Pressure Sensor Diaphragm Designs

(Source: Omega Engineering Inc.)
Pressure Gauge
• Can be filled with
fluid to avoid
contaminates &
corrosion
• Rear or bottom pipe
connection
• Pipe connection is
std NPS
http://www.omega.com/literature/transactions/volume3/pressure.html

Refilling Elevated Pressure Tap Lines Elevated Pressure

(Don Casada) Gauge with Loop Seal
• If pump is drained and (Don Casada)
vented, will pressure • Potential for instrument line
tap lines refill? draining problems can be
• Pressure readings may minimized by a loop seal or
be off if tap line not "pig tail" between the
filled with process fluid pressure gauge and the
(i.e. column of air) pipe connection
• Fix: Vent tap lines with • Pig tails can also buffer the
petcock at the gauge pressure gauge from high
process temperatures.
http://apps1.eere.energy.gov/industry/bestpractices/energymatters/full_issue.cfm/volume=6 http://apps1.eere.energy.gov/industry/bestpractices/energymatters/full_issue.cfm/volume=6

2
 Flow
Instruments
(Source:
Bausbacher and
Hunt)

Flow Measurement • Annubars are

Pitot averaging
or separate
sampling
devices

Sectional View of Orifice Meter Sectional View of Venturi Meter

(US Bureau of Reclamation) (US Bureau of Reclamation)
• Simple - Calibration based on geometry • Smoothly varying flow boundaries
• Standardized Tap Locations
• Useful for measuring sewage and
flow carrying other materials.

http://www.usbr.gov/pmts/hydraulics_lab/pubs/wmm/chap14_03.html http://www.usbr.gov/pmts/hydraulics_lab/pubs/wmm/chap14_03.html

Variable Area Flowmeter

Orifice Flowmeter
(Source: Omega Engineering Inc.)
(Source: Emerson
Process Management)
• Conditioning Orifice Plate
Delivers ±0.5% accuracy
with only two diameters of
straight pipe-run
• For: Retrofit installations
with poor results caused by
limited straight-run
http://www.omega.com/
http://www.emersonprocess.com/home/news/resources/index.html#rosemount-8800cd

3
 Coriolis Flowmeters
Rotameters (Source: Emerson Process Management)
(Source: Omega
Engineering Inc.)

http://www.omega.com/
http://www.emersonprocess.com/home/news/resources/index.html#rosemount-8800cd

Coriolis Flowmeters Turbine Flowmeters

(Source: Emerson Process Management) (NC Department of Transportation)
• High Accuracy
and Reliability
for low-volume
applications
• Example: fuel
blending

http://www.emersonprocess.com/home/news/resources/index.html#rosemount-8800cd

Turbine Flowmeter for Flanged Pipe

(Source: Emerson Process Management) Liquid Turbine
Flowmeter with
Male NPT Ports
(Source: Omega
Engineering Inc.)

http://www.omega.com/

http://www.emersonprocess.com/home/news/resources/index.html#rosemount-8800cd

4
 Sectional View of Magnetic Meter Installed Magnetic Flowmeter
(US Bureau of Reclamation) (Source: Lawrence Berkeley National Laboratory)
• Voltage induced in electrical conductor
moving through magnetic field.
• Conductor is flowing fluid being measured
• For a given field strength, induced voltage is
proportional to velocity of conductor.

(Photo: James F.
Steffe, Ph.D., P.E.)

http://www.usbr.gov/pmts/hydraulics_lab/pubs/wmm/chap14_03.html http://www.egr.msu.edu/~steffe/dairyplant/dairy.htm http://poet.lbl.gov/tour/sac/flow.html

Transit-Time Vortex Shedding Flow Meter

Acoustic (Cancoppas Limited)
• Flow path obstructed by a bluff body (or strut)
Flowmeters • Creates vortex swirl. (Photo: James F. Steffe, Ph.D., P.E.)
(US Bureau of
Reclamation)

http://www.usbr.gov/pmts/hydraulics_lab/pubs/wmm/chap14_03.html http://www.cancoppas.com/flow_vortex_flow_technology.htm http://www.egr.msu.edu/~steffe/dairyplant/dairy.htm

Doppler-type
Vortex Acoustic
Flowmeter Flowmeter and
(Source: Lawrence Cross-
Berkeley National correlation
Laboratory) Acoustic
Flowmeter.

http://poet.lbl.gov/tour/sac/flow.html
http://www.usbr.gov/pmts/hydraulics_lab/pubs/wmm/

5
Two Transducer Doppler Flowmeter Clamp on Doppler Flowmeter
(Dynasonics) (EESIFLO)

http://www.dynasonics.com/ http://www.eesiflo.com/index.html

Temperature Measurement Instruments

(Source: Bausbacher and Hunt)
• Gauge indicator:
– Metallic probe for insertion into the pipe or
vessel,
– Must show required temperature range.
– Fixed or swivel-headed for readout angles.
• Thermocouples:
– For DCS or remote reading
– Metallic probe, with a thermowell if required
– Terminal head houses conduit connection

Temperature Measurement • Both generally flanged or screwed, 1/2 in to

2 in.

Chilled Water Thermistor Assembly Duct with Thermistor

(Source: Lawrence Berkeley National Laboratory) (Source: Lawrence Berkeley National Laboratory)

http://poet.lbl.gov/tour/sac/ctower.html

http://poet.lbl.gov/tour/sac/wtemp.html

6
 Thread Mounted Thermowell Weld Mounted Thermowell
(Source: H. O. Trerice Co.) (Source: Conax Buffalo Technologies)

• Allows Thermocouple to: • Allows Thermocouple to:

– Not Contact Process – Not Contact Process
– Remove & Replace during – Remove & Replace during
Operations Operations

• Threaded, flanged, etc. • Flange can be ASME 16.5

http://www.hotrerice.com/ http://www.conaxbuffalo.com/

Resistance Temperature Detectors Industrial RTD Probe with Cast Iron

(Source: RTD Company) Protection Head
• Principle: Resistance Function of Temperature (Source: Omega Engineering Inc.)

http://www.omega.com/

http://www.rtdcompany.com/index.cfm

New way to install thermo- Skin Temperature Attachment

wells…Checks ambient temp. (Source: Bausbacher and Hunt)

• When I asked our Project engineer what was wrong

with the above thermowell installation, he thought for a
few minutes and then said… “are the bolts too long?”

7
 Liquid Level Sensing Technologies
(Delta Controls Corporation)

Level Measurement

http://www.deltacnt.com/

Solid Level Sensing Technologies Level Gauge Glass Operation

(Delta Controls Corporation) (US DOE)

http://www.deltacnt.com/
http://hss.energy.gov/NuclearSafety/techstds/standard/standard.
html

Ball Float Level Gauge Operation

(US DOE) Chain Float
Level
Gauge
Operation
(US DOE)

http://hss.energy.gov/NuclearSafety/techstds/standard/standard. http://hss.energy.gov/NuclearSafety/techstds/standard/standard.
html html

8
 External-Cage Level Controller and Transmitter External-Cage Level Switch
(Delta Controls. Magnatrol )
• Float or displacer in a (Source: Magnatrol)
chamber operates the
sensing device.
• Connected to
– Control valve actuator
directly for local control
– Control room for remote
recording and control.
• Two flanged or screwed
connections on vessel’s
side or top and bottom
(or both).
• Connections usually
ranges from 1 in to 2 in;
• Block valve installed
between vessel and
chamber to suit
maintenance
requirements.
http://www.magnetrol.com/us/

http://www.deltacnt.com/
http://www.magnetrol.com/us/

Side-Mounted Internal Level Switch

and Transmitter
(Source: Magnatrol)
SIDE INSERTED Operation: A shaft supports a float, which
FLOAT SENSOR rides on the liquid level. Two switch actions
ALARM OR PUMP occur as the level varies.
CONTROL

Top-Mounted
SIDE INSERTED Operation: A heavy duty sensing element is
POINT SWITCH
FLOAT OR
supported by a counterweight acting through a
support shaft. Switching occurs as the liquid
Internal Level
DISPLACER
SENSOR
surface passes the elevation of the body.
Switching is accomplished by two magnetic fields,
is positive in both directions, and is vibration proof.
Transmitter
(Emerson/Mobrey)
EXTERNAL Operation: A counterweighted horizontal
CAGE - HIGH pivoting type element operates an output alarm
TEMPERATURE switch as the liquid level or interface crosses the
AND PRESSURE body centerline.
http://www.magnetrol.com/us/ http://www.mobrey.com/downloads/manuals/ip2020.pdf

Differential Pressure Transducers and Point Level Switches

Transmitters (Source: Emerson Process Management)
Source: Honeywell Sensotec)

Rosemount 2110 level switch Rosemount 2120 level switch

http://www.sensotec.com/diffpressure.asp
http://www.emersonprocess.com/home/news/resources/index.html#rosemount-8800cd

9
 Magnetic Bond Level
Radar Level Gauge Operation
Transmitter (US DOE)

(Source: Emerson
Process Management)

http://www.emersonprocess.com/home/news/resources/index.html#rosemount-8800cd
http://hss.energy.gov/NuclearSafety/techstds/standard/standard.
html

Non-Contact Level Gauge

(K-TEK)

Mounting Details

http://www.ktekcorp.com/dnn20/default.htm

Measurement Typical Components of an Orifice

Instrument Mountings Metering Assembly
(Source: Bausbacher and Hunt) (Primary Flow Signal)
• Piping and vessels
tapped and furnished
with a ¾-in threaded or
flanged connection and
a block valve.
• Dial indicator is screwed
into the block valve;
– if a remote readout
system is required, the
valve becomes the
sensing connection.
– dial can be either fixed or
swivel-headed to facilitate
readout.
– A dual local indicator and
transmitter system needs http://www.primaryflowsignal.com/PDF%20Files/PDF%20Files/2001-Orifice%20Plates.pdf
only one tapping point.

10
 Orifice Flange Unions and Holding ASME Venturi Piping
Blocks (Primary Flow Signal)
(Primary Flow Signal)

http://www.primaryflowsignal.com/PDF%20Files/PDF%20Files/2001-Orifice%20Plates.pdf

http://www.primaryflowsignal.com/PDF%20Files/PDF%20Files/TDS-1500-PFS-CV-R0.pdf

Flange Mounted
Below
(Emerson Process
Management)

Flange Mounted
Above
(Emerson Process
Management)

Level Gauge Assemblies Standpipe

(Source: Bausbacher and Hunt) Level Isolation
in Tall, Hot
• Level gauges Vessels
– At vessels to check liquid level
visually. (Omega)
– ½-in threaded end connections.
– ¾-in-by-½-in threaded angle valve is
used for the connection between the
gauge glass assembly and the
vessel.
– Generally, a ¾ block valve is required
between the angle valve an the
vessel;
– vessel connection is threaded or
flanged.
• If reflective glass is specified, it
can only be viewed from one side.
http://www.omega.com/literature/transactions/volume4/T9904-12-PRESS.html#press_4

11
 Distorted Flow can Alter Flow Readings
(Global Water Instrumentation, Inc.)

Standpipe Elimination with

Magnetic Level Indicators
(Magnatrol)
http://www.magnetrol.com/us/html/view_pdf.asp?pdf=mii\tech\papers\199 http://www.globalw.com/support/strtflow.html

Typical Flow Meter

Straight Run Requirements
(Global Water Instrumentation, Inc.)

Straight Run Requirements

(Source: Bausbacher and Hunt)

http://www.globalw.com/support/strtflow.html

Stream Intersection Upstream and Downstream

(Source: Bausbacher and Hunt) Dimensional Requirements
(Source: Bausbacher and Hunt)
• Point: Allow space for these instrument access requirements during
equipment and pipe layout

12
 Typical
Pressure Tap Locations
(Source: Bausbacher and Hunt) Pressure
Gauge
Detail
(University of
Michigan)

http://www.aec.bf.umich.edu/for.archs/StandardDetails.html

Internal Clearance Check Cross-Section of Pipe w/thermistor

(Source: Bausbacher and Hunt) (Source: Lawrence Berkeley National Laboratory)

http://poet.lbl.gov/tour/sac/wtemp.html

Recommended P&ID Simplifications -

Alternative Instrument Details Mountings
(Source: Bausbacher and Hunt) (PIP PIC001)

13
 Recommended P&ID Simplifications - Recommended P&ID Simplifications -
Loops Other
(PIP PIC001) (PIP PIC001)

Digital Bus Technology

(Source: Emerson Process Management)
• Provides many measurements from each
device through a single cable
Before: After:

Explosion
Proof
Electrical
Junction Box
(Sweco Fab,
Inc.)
http://www.pipingtech.com/news/arc_pw_2004/asme2004_02.htm http://www.emersonprocess.com/home/news/resources/index.html#rosemount-8800cd

Wireless Control Networks Analyzer House

(Emerson Process Management) (Source: Bausbacher and Hunt)
• Has portable sampling devices, washing facilities, and sophisticated mass
spectrometers.
• Often controlled environment containing blowers and air-conditioning units.
• Normally occupied or unoccupied (makes difference)

http://www.emersonprocess.com/home/news/resources/morephotos.html

14