E3-Module 2

Package E3: Automation and instrumentation
Instrumentation for
Monitoring, Action and
Protection
Based on the implemented process Control systems
Module 02: Plant instrumentation, surveillance, protection measurement

Copyright©: This training material is licensed by FLSmidth to Lafarge Asia Technical Center and must be used
only for training of staff and personnel employed at Lafarge plants in ATC (Asia, ASEAN and China) regions.
• What is instrumentation?
• A wide variety of instruments, sensors and switches are installed at the

cement plant. They ensure that material flow and storage as well as all
machinery and equipment are protected by lubrication oil, cooling water
levels and speed limits, and that material reservoirs are kept filled, and
that other minimum and maximum levels are maintained. These
instruments are fully (can be accessed from the CCR) or semi- (can be
monitored via the CCR) incorporated into the plant process control
system.
•
Nowadays, many of these instruments have built-in, intelligent electronic
circuits (PLC) which allow the PCS to communicate directly or through
Profibus DP (remote I/O) with these instruments. Certain operating
programmes are stored in the instrument memory. Process values will be
transmitted to the PCS, and set-points, ranges, limits and programmes
can then be altered/modified by the CCR operator or on local control
panels by the maintenance personnel.

Fig. 2.1: The basic control loop (PID)

Fig. 2.2: A block diagram for a “closed loop system”

Toggle switches
Slide switches
Push buttons
Key pad
Microswitches
A microswitch detects very small movements, hence the
term “micro”.
Table 2.3: Input switches.

Magnetic reed switches
Normally used for detecting moving objects such as
doors or hydraulic cylinders.
Temperature
Resistance in a thermistor varies as the temperature
changes.
Capacitance
Eg, is something there? Capacitance sensors will detect
metal, plastic, wood, etc.
Level switches
Is the bath full?
Tilt switch
Has it moved?
Inductive
Eg, has a ferrous piece of material passed by?
Light
Eg, a Light Dependant Resistor (LDR).
Light beam
How many parts have passed by?
Sound
Eg, a microphone.
Variable resistance

Motor
AC or DC.
Stepper motor
Moves in very small but accurate steps or degrees.
Valve
Operating the actuator below.
Actuator
Sometimes called a ram or cylinder.
Solenoid
Pushes things along.
Relay
Used for turning on or off high voltages or currents.
Table 2.5: Output monitors.

Heating elements
LED
Is it turned on?
Bar graph
What level is it at?
Seven-segment display
Counting up or down.
Lamp
Is it on?
LCD display
Can be used for showing a variety of information.
Sound
Could also be a siren or a bell.
Table 2.5: Output monitors.

Fig. 2.6: Typical PLC field installation.

Fig. 2.7: A block diagram for a PLC.

Fig. 2.8: Various inputs and outputs connected to a PLC.

Fig. 2.9: A sample connection for PLC programming with laptop PC, desktop PC or
a programming device from the PLC manufacturer.

Fig. 2.10: “System-on-a-Chip” (SoC) embedded in a credit card.

Fig. 2.11: Basic layout of the auxiliary power control centre.

Fig. 2.12: Basic diagram for the production and distribution of auxiliary power
for a department.

Fig. 2.13 A transmitter for a PT100 temperature sensor (works with 2-, 3- and 4-
wire probes and is incorporated into the sensor’s connection box).

Fig. 2.14: Interconnection between sensor, transmitter and measuring cable.

Fig. 2.15: Serial transmission.

Specification of digits
No special protection of persons against accidental or inadvertent contact with
0 live or moving parts. No protection of machine against entry of solid, foreign
bodies.
Protection against accidental or inadvertent contact with live and moving parts
inside the enclosure by a large part of the human body, ie a hand, but no
1
protection against deliberate access of such parts. Protection against entry of
large, solid, foreign objects (diameter greater than 50 mm).
Protection against contact of fingers with live or moving parts inside the
2 enclosure. Protection against entry of small, solid, foreign objects (diameter
greater than 12 mm).
Protection against contact with live or moving parts inside the enclosure of
tools, wires or such objects of a thickness greater than 1 mm. Protection against
4 entry of small, solid, foreign objects (diameter > 1 mm) excluding the
ventilation openings (intake and discharge of external fans) and the drain hole
of enclosed machine, which may have degree 2 protection.
Complete protection against contact with live or moving parts inside the
enclosure. Protection against harmful deposits of dust. The entry of dust is not
5
totally prevented, but dust cannot enter in an amount sufficient to interfere with
the satisfactory operation of the machine.
Table 2.16: Standard IP ratings.

The first digit concerns protection against contact and entry of object

0 No special protection.
1 Dripping water (vertically falling drops) will have no harmful effect.
Drops of water falling at any angle up to 15 degrees from the vertical will have
2
no harmful effect.
Water falling as a spray at an angle equal to or smaller than 60 degrees from the
3
vertical will have no harmful effect.
Water splashed against the machine from any direction will not harm the
4
machinery.
Water projected by a nozzle against the machine from any direction will not
5
harm the machinery.
6 Water from heavy seas will not enter the machine in any harmful quantity.
Even if immersed in water under the stated conditions of pressure and time,
7
water in a harmful quantity will not enter the machine.
Water in a harmful quantity will not enter the machine, even if this is immersed
8
in water under a specified pressure but for an indefinite time.
Table 2.17: Standard IP ratings.

Table 2.18: Comparing 2-and 3-wire connections.

Fig. 2.19: The 2-wire connection.

Fig. 2.20: The 4-wire connection to RTD.

Table 2.21: Labels of

measuring points.

Table 2.22: Flowsheet codes: Nature and function of measurements.

Table 2.23: Flowsheet codes: Letters.

Fig. 2.24: The signals sent to the central control room.

Fig. 2.25: Flowsheet.

Fig. 2.26: Unloaded cantilever beam spring.

Fig. 2.27: Loaded cantilever beam spring.

Fig. 2.28: Displacement of loaded cantilever beam spring.

Fig. 2.29: Force/displacement chart for a typical spring.

Fig. 2.30: Steel cantilever beam with four strain gauges.

Fig. 2.31: Steel cantilever beam with four strain gauges

Fig. 2.32: Force influencing steel cantilever beam and strain gauges.

Fig. 2.33: Typical load cell schematic diagram.

Fig. 2.34: The belt weighing principle.

Fig. 2.35: Typical weigh feeder (clinker).

Fig. 2.36: Typical set-up of a weigh feeder.

Fig. 2.37: Open-view screw conveyor.

Fig. 2.38: Stand-alone screw feeder.

Fig. 2.39: The weighing principle.

Fig. 2.40: Impact weighing application.

Fig. 2.41: A commonly used coal rotary feeder.

Fig. 2.42: Road weighing bridge with weighing system.

Fig. 2.43: Silo with three load cells.

Fig. 2.44: Suspension of weighing bin

Fig. 2.45: A rotary mass flowmeter to illustrate the operating principle

of the vibrating mass flowmeter. Double-sized version.

Fig. 2.46: When fluid is flowing through the tubes, the tubes
twist slightly. Double-sized version.

Fig. 2.47: The principle design of a curved tube mass flowmeter.

The vibration pattern during no-flow.

Fig. 2.48: Vibration pattern of the tubes when there is mass flow.
Double-sized version.

Fig. 2.49: A coriolis flow meter

Fig. 2.50: Manometer for oil pressure measurement.

Fig. 2.51: Bearing inlet.

Fig. 2.52: Mill outlet.

Fig. 2.53: Slide shoe bearing.

Fig. 2.54: Mill bearing.

Fig. 2.55: Pressure build-up and levelling out at start-up.

Fig. 2.56: Set-up for starting of high-pressure pumps.

Fig. 2.57: Pressure switch.

Fig. 2.58: Pressure transducer.

Fig. 2.59: Pressure sensor with 3 taps for simple pressure measurement.

Fig. 2.60: Pressure sensor for differential pressure measurement.

Fig. 2.61: Pressure measuring, standard layout.

Fig. 2.62: A pressure sensor with 4-20 mA output used for a wide range of
applications.

Fig. 2.63: Differential pressure, standard layout.

Fig. 2.64: Resistance-temperature curve for a 100 Ω platinum RTD, a = 0.00385.

Table: 2.65 Thermocouple elements

Fig. 2.66: Basic thermocouple set-up.

Fig. 2.67: Thermocouple Law of Intermediate Metals.

Fig. 2.68: Inserting an extra lead in the isothermal region.

Fig. 2.69: PT100 sensor for monitoring of bearing temperatures.

Fig. 2.70: Slide shoe bearing for mill.

Fig. 2.71: Design of a cable for temperature measurements.

Table 2.72: Coding of cables for temperature measurements.

Fig. 2.73: Typical sensors.

Fig. 2.74: Pitot tubes in a pipe (small diameter)

Fig. 2.75: Pitot tubes in an Annubar (larger diameter) provided that the gas is not
dusty.

Fig. 2.76: Vortex flowmeter, especially for compressed air.

Fig. 2.77: Oil reservoir.

Fig. 2.78: Safety and measurement equipment for the Symetro gear unit.

Fig. 2.79: Oil level indicator.

Fig. 2.80: Oil level sensor.

Fig. 2.81: Oscillating fork module.

Fig. 2.82: Liquiphant specifications.

Fig. 2.83: Power supply set-up for Liquiphant.

Fig. 2.84: Mounting of piezoelectric crystals in Liquiphant.

Fig. 2.85: Vibration sensor.

Fig. 2.86: Nivector oil level indicator.

Fig. 2.87: Nivector FTC sensor.

Fig. 2.88: Protector.

Fig. 2.89: Capacitive level sensor.

Fig. 2.90: Principle of a capacitor.

Fig. 2.91: A paddle level sensing switch (fluxo slide).

Fig. 2.92: The level paddle switch type.

Fig. 2.93: Oil level indicator with reed switch.

Fig. 2.94: Dispersion of material in a silo.

Fig. 2.95: The silo pilot is the most commonly used silo level sensor at cement
plants.
Fig. 2.96: Measuring principle.

Fig. 2.97: A variety of ultrasonic sensors

with a field controller

Fig. 2.98: The radar measuring principle.

Fig. 2.99: Radar level sensors with typical (antenna) cones.

Fig. 2.100: Screw conveyor.

Fig. 2.101: Drag chain conveyor.

Fig. 2.102: Bucket elevator.

Fig. 2.103: Principle for output signal used for machine supervision

Fig. 2.104: Conveyor belt alignment switch.

Fig. 2.105: Industrial limit switches.

Fig. 2.106: An inductive proximity sensor (used for many applications, eg

speed and position)

Fig. 2.107: TEDS basic application for smart instruments.

Fig. 2.108: On Mill Unit (sensor)

Fig. 2.109: The signal display of the sonic ear and its influence into cement mill feed PID

Fig. 2.110: The Folaphone system.

Fig. 2.111: Cement mill PID control loop with the Folaphone system incorporated.

Fig. 2.112: Measuring principle.

Fig. 2.113: Typical industrial vibration sensor

Fig. 2.114: Open view of the vibration sensor

Fig. 2.115: An actuator
Fig. 2.115: An motor actuator

Table 2.116: Example of troubleshooting.

Fig. 2.117: High-quality measuring instrument with scope function

Fig. 2.118: Digital multimeter.

Fig. 2.119: High-precision instrument calibrator can

be used for a variety of automation instruments.

Fig. 2.120: A multimeter (analogue) with a built-in clamp facility. (good for
fluctuating values V/A

Fig. 2.121: Output from a function/signal generator.

Fig. 2.122: Two-channel 100 MHz oscilloscope with memory.

Fig. 2.123: Oscilloscope with a 90 degrees phase shift difference between x and y
inputs.

Fig. 2.124: Example of personnal protection equipment

Fault finding work sheet

Table 2.125: Fault finding check list.
Machine / Equipment
Type:
Data:
User’s explanation of the fault:
What is the fault?
Cause of the fault:
If spare parts are needed, state necessary

data:

Fig. 2.126: A double, screened instrument cable (2 x 2 x 0.4).

Fig. 2.127: Unscreened power supply cable for instruments.

Cable Max. Table 2.128: Network access

type length protocol.
Network access
protocol
Ethernet 10Base2 Coaxial 185 m
10Base5 Coaxial 500 m
10Base-T TP 100 m
10Base-FL multi-
FO 2 km
mode
10Base-FL
FO 5 km
single-mode
Fast Ethernet 100Base-TX TP 100 m
100Base-FX FO 412 m
FDDI Multi-mode FO 2 km
Single-mode FO 60 km
CDDI TP 100 m

Fig. 2.129: A twisted-pair, multi-core cable for field signalling.

Fig. 2.130: Capacitive coupling between the noise source and signal circuit
modelled by the capacitor Cef in the equivalent circuit.

Fig. 2.131: Inductive coupling between the noise source and signal circuit
modelled by the mutual inductance M in the equivalent circuit.
Fig. 2.132: Improper shield termination. Ground currents are carried in the
shield.

Fig. 2.133: Proper shield termination. No ground or signal current flows through the
shield.

Fig. 2.134: Junction box

Fig. 2.135: General Earthing arrangement for field instruments.

Fig. 2.136: Transmitter, sensor, control system set-ups.

Fig. 2.137: Recommended

earthing methods for signal
cables.

Fig. 2.138: Pyrometric camera.

Fig. 2.139: Kiln shell temperature image.

Fig. 2.140: The scanner window of a kiln scanner

(the scanner sees the kiln shell through this window).

Fig. 2.141: Automatic gas sampling system

Fig. 2.142: Gas analyzer (unit) for all the plants gas analyzing tasks

Fig. 2.143: Sampling probe and sample processing

Fig. 2.144: Analyser cells

Fig. 2.145: A zirconia oxygen analyser

Fig. 2.146: Diagram for gas flow in measuring unit.

Measurement CO to CCS 4 - 20 mA analogue signal

Commands from CCS Selection of measuring point
Selection of measuring range
Indication to CCS Measuring point selected

Measuring range 1 selected
Measuring range 2 selected
Table 2.147: Signals from a measuring point to the central control system.

Alarm to CCS Pre-warning

Unit alarm
Test
Commands from CCS Alarm cancellation
Table 2.148: Common signals between analyzer unit and central control system.

1 - 4 silos 15 min. for each measuring point

1 silo plus 1 filter 4 - 5 min. for the silo and 15 min. for the filter
2 silos plus one filter 4 - 5 min. for the silos and 15 min. for the filter
3 silos plus one filter 2 - 3 min. for the silos and 15 min. for the filter
1 or more filters 2 - 3 min. for each measuring point
Table 2.149: Recommended monitoring time for individual measuring points.

Fig. 2.150: CO gas measurement on top of the silo.

Fig. 2.151: System for scanning coal dust hoppers.

Fig. 2.152: Arrangement of coal safety (Lafarge standard display).

Zone 20 Dust cloud likely to be present continuously or for long periods

Zone 21 Dust cloud likely to be present occasionally during normal operation
Dust cloud unlikely to occur during normal operation, but if it does, it
Zone 22
will only exist for a short period
Table 2.153: Hazardous dust zones.

T-Class Hazards which will not ignite at temperatures below:

T1 450°C
T2 300°C
T3 200°C
T4 135°C
T5 100°C
T6 85°C
Table 2.154: Auto-ignition temperature classes.

Equipment code Description Suitable for zones
Ex ia Intrinsic safety 'ia' 0, 1, 2
Ex ib Intrinsic safety 'ib' 1, 2
Ex ic Intrinsic safety 'ic' 2
Ex d Flame-proof protection 1, 2
Ex p Purge/pressurized protection 1, 2
Ex px Purge/pressurized protection 'px' 1, 2
Ex py Purge/pressurized protection 'py' 1, 2
Ex pz Purge/pressurized protection 'pz' 2
Ex e Increased safety 1, 2
Ex m Encapsulation 1, 2
Ex ma Encapsulation 0, 1, 2
Ex mb Encapsulation 1, 2
Ex o Oil immersion 1, 2
Ex q Sand / powder (quartz) filling 1, 2
Ex n Type n protection 2
Ex s Special protection Normally 1 and 2
Table 2.155: Equipment code for hazardous areas.

Equipment code Description EPL

Ex ia Intrinsic safety 'ia' Ga Table 2.156:
Ex ib Intrinsic safety 'ib' Gb Protection code
and EPL
Ex ic Intrinsic safety 'ic' Gc
(Equipment
Ex d Flame-proof protection Gb Protection
Ex p Purge/pressurized protection Gb Level).
Ex px Purge/pressurized protection 'px' Gb
Ex py Purge/pressurized protection 'py' Gb
Ex pz Purge/pressurized protection 'pz' Gc
Ex e Increased safety Gb
Ex m Encapsulation Gb
Ex ma Encapsulation Ga
Ex mb Encapsulation Gb
Ex o Oil immersion Gb
Ex q Sand / powder (quartz) filling Gb
Ex n Type n protection Gc
Refer to equipment
Ex s Special protection marking and
documentation

P P P S S S E E N N C C N N
Plant
Process
SHOP
Line
BREAKDOWN
Sub-Process
Equipment
and Systems
Equipment
Components
Table 2.157:
Lafarge codification system.

SSS Shop description
Central control room 731 Central control room and computer room
Electrical - Common 800 Electrical commons
Plant power supply 810 Commons
811 Incoming substation No. 1
818 Captive power plant
MV power distribution 820 Commons
821 MV power distribution No. 1
822 MV power distribution No. 2
828 MV emergency generator
LV power distribution 830 Commons
831 LV power distribution No. 1
832 LV power distribution No. 2
838 LV emergency generator
Table 2.158: Allocation of SSS-code.

Lighting and power outlets 840 Commons

841 Supply for lighting and power outlets
842 Lighting and power outlets
Power monitoring control 850 Commons
system 851 Power monitoring control system 1 (levels 1, 2,
(HV, MV, LV) 859 3)
Production and distribution of auxiliary
voltages
Process control system 860 Plant process control system (levels 1 and 2)
861 Line 1 process control system (levels 1 and 2)
862 Line 2 process control system (levels 1 and 2)
867 Plant optimisation data processing level 3
868 (production management, expert system, quality
869 assurance, etc.)
Plant control system level 4 (plant management)
Production and distribution of auxiliary
voltages

Communication systems 870 Commons

871 Telephone, radio, paging systems
872 Video surveillance
Electrical protection systems 880 Commons
881 Grounding system (earthing system)
882 Lightning protection system
Security and fire protection 890 Commons
systems 891 Fire alarms, intruder alarms, fire extinction
equipment

EE EQUIPMENT TYPE DESCRIPTION

AG Analyzer, gas
AM Analogue marshalling board
AU Air conditioning system
AX X-ray, gammametrics analyzer
AY Auxiliary control centre (ACC)
AZ Analyzer, material
BY Battery charger
CO Process control system data server, host computer
CP Capacitor, power factor correction unit
Table 2.159: Allocation of equipment code.

CT Communication tool (radio, receiver, cabling, etc.)

DH Medium-voltage switchgear
DM Digital marshalling board
EC Electrical cabinet (control, protection, metering, lighting, etc.)
ER Cable reel
ET Elevator for material but can lift people
EX Fire and intrusion detection system, fire extinguishing system
EZ Electrical, miscellaneous
GN Power generator
GS Grounding system
HS Electrical heating system
HV High-voltage switchgear
IM Dead human watch system
IN Data network system (electronic device, modem, cabling, hub, bridge)
IT Information technology system for offices
JA Analogue junction box

JD Digital junction box

JX Power junction box, valves control box
LI Lift, passenger elevator (for people mainly)
LP Lightning protection system
LT Lighting and power outlets system
MA Magnet (electrical, permanent), metal detector, iron remover
MC Motor control centre (MCC), power control centre (PCC)
MN Human-machine interface (operator station)
PB Pager, beeper
PE Phone system, interphone
PL PLC, satellite, DCS controller, electronic module
SM Material flowmeter
SU Substation (including electrical room and transformer room)
TE Scanner
TF Power transformer (HV, MV, LV)
TQ Portable electrical tool, instrument

TR Opacity meter
UP Uninterruptible power supply
VD Video monitoring
XY Measuring device for process


SU Substation (including electrical room and transformer room)
TE Scanner
TF Power transformer (HV, MV, LV)
TQ Portable electrical tool, instrument
TR Opacity meter
UP Uninterruptible power supply
VD Video monitoring
XY Measuring device for process
Table 2.160: Allocation of codes for minor equipment.

CC COMPONENT TYPE DESCRIPTION

MT Motor, electric (brake, DC, induction, synchronous)
MY Metal detector
PC Personal computer, office computer, data server
PG Pantograph pick-up assembly
PJ Control panel indicator
PL Local PLC, electronic module
PO Power outlet, power outlets box
PT Office printer, desktop scanner, bag printer
QC Circuit breaker
QI Isolator
QS Power switch
QV Visible cut-off switch (ICV)
Table 2.161: Allocation of codes for minor components.

RB Badge reader, various readers

RG Regulator
RU Resistor (for braking, etc.)
SQ Sequencer
SR Starter, graduator
SV Servomotor, actuator
SX Surge and lightning arrester

SY Selector switch, push button, manipulator
Table 2.161:
TF Power transformer (LV, lighting, auxiliary) Allocation of codes
TQ Portable electrical tool, instrument for minor
TX Measuring transformer (PT, CT)
components.
TY On-load tap changer

VA Valve, solenoid valve
VP Vibrator (electric, pneumatic)
VS Variable-speed drive
WC Cable, control
WH Cable, high/medium voltage
WL Cable, low-voltage power
XB Terminal strip
XE Voltage digital sensor
XF Flow digital sensor
XH Hand digital sensor (emergency shutdown, pull rope switch, etc.)
XI Current digital sensor
XJ Power digital sensor

XL Level digital sensor

XP Pressure digital sensor
XR Radioactive source
XS Speed digital sensor
XT Temperature digital sensor
XV Vibration digital sensor
XW Weight digital sensor
XX Miscellaneous digital sensor
XZ Position digital sensor
YE Voltage analogue sensor
YF Flow analogue sensor
CC COMPONENT TYPE DESCRIPTION
YH Hand analogue sensor (potentiometer, etc.)
YI Current analogue sensor
YJ Power analogue sensor
YL Level analogue sensor

YM Moisture analogue sensor

YP Pressure analogue sensor
YS Speed analogue sensor
YT Temperature analogue sensor
YV Vibration analogue sensor
YW Weight analogue sensor
YX Miscellaneous analogue sensor
YY Measuring converter
YZ Position analogue sensor

CC CABLE CATEGORY
WC Control cable (digital and analogue)
WL LV power cable, lighting and power outlet cable
WH High-voltage, medium-voltage cable
Table 2.162: Definition of component code for cables.

VVV VARIABLE DESCRIPTION

HSn Emergency shutdown of a department
Lnn Selection
Rnn Regulation
Snn Sequence
Table 2.163: Variables connected to a shop.

VVV VARIABLE DESCRIPTION

Rnn Regulation
Lnn Selection
Table 2.164: Variables connected to a piece of equipment

VVV INPUT VARIABLE DESCRIPTION
AVn Available Table 2.165:
Variables connected
B1n Feedback direction 1(forward, up, left, open)
to a component
B2n Feedback direction 2(reverse, down, right, closed)
BP Process feedback (speed monitor, etc.)
DIn Internal digital input
DLOC Drive / Package local control
Fn Failure (miscellaneous)
FT Failure causing a trip alarm
FW Failure causing a warning alarm
HS Emergency shutdown
L1n Local start command from VCS, direction 1 (forward, up, left, open)
L2n Local start command from VCS, direction 2 (reverse, down, right,
closed)
LD Local speed down command from VCS
LS Local stop command from VCS
LU Local speed up command from VCS
RS Ready to start
TA Tare in progress (or scaling)
XIn Other input

VVV OUTPUT VARIABLE DESCRIPTION

CAn Authorisation
C1n Start command direction 1(forward, up, left, open)
C2n Start command direction 2(reverse, down, right, closed)
CKn Failure acknowledgement
CPn Stop command
CXn Unclassified command
ECn Voltage control (set-point)
FCn Flow control (set-point)
LOC Drive / package to be controlled locally
PCn Pressure control (set-point)
SCn Speed control (set-point)
TCn Temperature control (set-point)
WCn Weight control (set-point)
XOn Other output
ZCn Position control (set-point)
Table 2.166: Output variables.

VVV INTERNAL VARIABLE DESCRIPTION

H High level warning
HH Very high level trip (high-high)
Hn Other high level
L Low level warning
LL Very low level trip (low-low)
Ln Other low level
SLn Selection of the component
Table 2.167: Internal variables


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Package E3: Automation and instrumentation

Based on the implemented process Control systems

Module 02: Plant instrumentation, surveillance, protection measurement

• A wide variety of instruments, sensors and switches are installed at the

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.1: The basic control loop (PID)

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.2: A block diagram for a “closed loop system”

Module 02: Plant instrumentation, surveillance, protection measurement

Table 2.3: Input switches.

Module 02: Plant instrumentation, surveillance, protection measurement

Module 02: Plant instrumentation, surveillance, protection measurement

Table 2.5: Output monitors.

Table 2.5: Output monitors.

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.6: Typical PLC field installation.

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.7: A block diagram for a PLC.

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.8: Various inputs and outputs connected to a PLC.

Module 02: Plant instrumentation, surveillance, protection measurement

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.10: “System-on-a-Chip” (SoC) embedded in a credit card.

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.11: Basic layout of the auxiliary power control centre.

Module 02: Plant instrumentation, surveillance, protection measurement

Module 02: Plant instrumentation, surveillance, protection measurement

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.14: Interconnection between sensor, transmitter and measuring cable.

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.15: Serial transmission.

Module 02: Plant instrumentation, surveillance, protection measurement

Table 2.16: Standard IP ratings.

Module 02: Plant instrumentation, surveillance, protection measurement

Table 2.17: Standard IP ratings.

Module 02: Plant instrumentation, surveillance, protection measurement

Table 2.18: Comparing 2-and 3-wire connections.

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.19: The 2-wire connection.

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.20: The 4-wire connection to RTD.

Module 02: Plant instrumentation, surveillance, protection measurement

Table 2.21: Labels of

Module 02: Plant instrumentation, surveillance, protection measurement

Table 2.22: Flowsheet codes: Nature and function of measurements.

Table 2.23: Flowsheet codes: Letters.

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.24: The signals sent to the central control room.

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.25: Flowsheet.

Fig. 2.26: Unloaded cantilever beam spring.

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.27: Loaded cantilever beam spring.

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.28: Displacement of loaded cantilever beam spring.

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.29: Force/displacement chart for a typical spring.

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.30: Steel cantilever beam with four strain gauges.

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.31: Steel cantilever beam with four strain gauges

Module 02: Plant instrumentation, surveillance, protection measurement

Module 02: Plant instrumentation, surveillance, protection measurement

Fig. 2.33: Typical load cell schematic diagram.