WEEK 16

ACTIVITY NO. 16

ADVANTAGE/DISADVANTAGE OF

ADVANTAGE DISADVANTAGE
PLC Reliability Limited design
Flexibility in programming and Fixed circuit design
reprogramming
High operational speed
Quick response time
Easy troubleshooting
Low cost
DCS Access a large amount of Expensive
current information from data Needs regular maintenance
highway More prone to cyber security
Past process condition trends threats if not protected
can be monitored properly
Less overloading of the system
Reliability
Good speed
SCADA Easy to maintain Implementation would need
It would provide access to real- special skills
time data It would only process data when
Implementation tools are the system is available
advanced Compatibility with PLCs needs
Reliable to be verified
Continuous operation

LEVEL-FLOW CASCADE CONTROL WITH ASSISTANCE OF AN LV-PROSIM

In single-loop control, the controller’s set point is set by an operator, and its output drives a final control
element. For example: a level controller driving a control valve to keep the level at its set point.

Cascade control is beneficial only if the dynamics of the inner loop are fast compared to those of the
outer loop. Cascade control should generally not be used if the inner loop is not at least three times
faster than the outer loop, because the improved performance may not justify the added complexity.

TYPES OF MAINTENANCE

Corrective maintenance.

Preventive maintenance.

Risk-based maintenance.

Condition-based maintenance.
CMS

A content management system (CMS) is software that enables end users to create and manage content
on a website. They are designed to make content management easy for non-technical users. One of the
key features of a good content management system is that no coding is needed to create or modify
content.

2.6.3.14 – SIGN AND SYMPTOMS OF CONTOLLER FAILURE

2.6.3.15 – CAUSES OF HUNTING IN A CONTROL SYSTEM

2.6.3.19 – MEGGER TEST

MAINTENANCE OF INSTRUMENTS AND CONTROL SYSTEMS

The Instruments Maintenance section is made up of expert technicians able to repair and maintain
laboratory equipment such as Vacuum Pumps, Centrifuges, Incubators, Ice Makers, Film Developers,
Pipettes, Balances Shakers, Glove boxes, Robots and more.

CALIBRATION PROCEDURES FOR VARIOUS TYPES OF INSTRUMENTS AND CONTROL LOOPS

Calibration is the process of configuring an instrument to provide a result for a sample within an
acceptable range. Eliminating or minimizing factors that cause inaccurate measurements is a
fundamental aspect of instrumentation design.

The method is as follows: Apply the lower-range value stimulus to the instrument, wait for it to stabilize.
Move the “zero” adjustment until the instrument registers accurately at this point. Apply the upper-
range value stimulus to the instrument, wait for it to stabilize.

TUNING AND ELECTRONIC CONTROLLER

Controller tuning is the process of determining the controller parameters which produce the desired
output. Controller tuning allows for optimization of a process and minimizes the error between the
variable of the process and its set point.

We should tune a controller so that it can match the characteristics of the control equipment to the
process. So because of the tuning, it would respond quickly to the errors and the system would be stable
too.

WEEK 15

ACTIVITY NO. 15

PNEUMATIC TRANSMITTER AND PID CONTROLLER OPERATION.

 A pneumatic controller is a mechanical device designed to measure temperature or pressure and
transmit a corrective air signal to the final control element. Bourdon tubes, bellows, temperature
elements, or displacers are used as the sensing elements.

The level controller uses a displacer connected to the controller to sense the liquid level. The displacer
sits in the process fluid inside of the separator. When the liquid level increases and the displacer reaches
a high set point, the level controller sends a pneumatic signal to open the control valve.
CONSTRUCTION AND PRINCIPLE OF OPERATION OF VARIOUS TYPES OF CONTROL VALVE BODIES

The most common final control element in the process control industries is the control valve. The
control valve manipulates a flowing fluid, such as gas, steam, water, or chemical compounds, to
compensate for the load disturbance and keep the regulated process variable as close as possible to the
desired set point.

Control valves may be the most important, but sometimes the most neglected, part of a control loop.
The reason is usually the instrument engineer's unfamiliarity with the many facets, terminologies, and
areas of engineering disciplines such as fluid mechanics, metallurgy, noise control, and piping and vessel
design that can be involved depending on the severity of service conditions.

-CMS

2.6.3.17 – FUNCTIONAL PURPOSE OF THE FOLLOWING

 ACTUATOR

An actuator is a device that produces a motion by converting energy and signals going into the system.
The motion it produces can be either rotary or linear. An electric linear actuator is a device that
produces a motion by converting energy and signals going into the system.

CONSTRUCTION AND OPERATION PRINCPLE OF:

 STEPPER MOTOR

Stepper motors are available in three basic types; which are permanent magnet, variable reluctance and
hybrid. Variable-reluctance : Variable-reluctance type stepper motors, that are the simplest type of
steppers, consist of a soft iron multi-toothed rotor and a wound stator.

 SERVO MOTOR

A servo motor is a general term used for a specific kind of linear or rotary actuators. Basically, the name
servo motor is related to the term servomechanism, which means that the motor is constantly
monitored to control its motion.

OPERATION PRINCIPLE OF

 MOTOR DRIVES

A motor drive controls the speed, torque, direction, and resulting horsepower of a motor. Dc drives
typically control a shunt-wound dc motor, which has separate armature and field circuits. Ac drives
control ac-induction motors and, like their dc counterparts, control speed, torque, and horsepower.

 PERISTATITC PUMPS

Peristaltic pumps can run on a continuous basis or they can also be used for precise applications. They
are most often used to move fluids that are sterile or aggressive chemicals. They can also pump IV fluids
or slurries with a high degree of fluid content. They are also used for heart/lung machines during
surgery.

WEEK 14
ACTIVITY NO. 14

PID ON PRESSURE AND LEVEL PROCESS

As the name suggests, this article is going to give a precise idea about the structure and working of the
PID controller. However, going into details, let us get an introduction about PID controllers. PID
controllers are found in a wide range of applications for industrial process control. Approximately 95% of
the closed-loop operations of the industrial automation sector use PID controllers. PID stands for
Proportional-Integral-Derivative. These three controllers are combined in such a way that it produces a
control signal. As a feedback controller, it delivers the control output at desired levels. Before
microprocessors were invented, PID control was implemented by the analog electronic components. But
today all PID controllers are processed by the microprocessors. Programmable logic controllers also
have the inbuilt PID controller instructions. Due to the flexibility and reliability of the PID controllers,
these are traditionally used in process control applications.

PI CONTROL ON TEMPERATURE PROCESS

A PID temperature controller, as its name implies, is an instrument used to control temperature, mainly
without extensive operator involvement. A PID controller in a temperature control system will accept a
temperature sensor such as a thermocouple or RD as input and compare the actual temperature to the
desired control temperature or setpoint. It will then provide an output to a control element.

WEEK 13

ACTIVITY NO. 13

1. VARIOUS TYPES OF RECORDERS AND CONTROLLERS

There are three basic types of controllers: on-off, proportional and PID. Depending upon the
system to be controlled, the operator will be able to use one type or another to control the
process.

On/Off Control
-An on-off pid controller is the simplest form of temperature control device. The output from the device
is either on or off, with no middle state. An on-off controller will switch the output only when the
temperature crosses the setpoint.

Proportional Control
-Proportional controls are designed to eliminate the cycling associated with on-off control. A
proportional controller decreases the average power supplied to the heater as the temperature
approaches setpoint. 

Standard PID Controller

-This standard PID controller combines proportional control with integral and derivative control (PID),
which helps the unit automatically compensate for changes in the system.

2. PRINCIPLES OF AUTOMATIC CONTROL

An automatic control has two process variables associated with it: a controlled variable and a
manipulated variable. A controlled variable is the process variable that is maintained at a specified value
or within a specified range e.g. the tank level in the above example.

CMS

2.6.3.11 – OPERATING PRINCIPLES AND LIMITATIOMS OF THE FOLLOWING CONTROL:

 PROPOTIONAL CONTROL - a control system technology based on a response in proportion to
the difference between what is set as a desired process variable (or set point) and the current
value of the variable.

 PROPOTIONAL-INTEGRAL CONTROL - sometimes also known as proportional plus integral (PI)

controllers. It is a type of controller formed by combining proportional and integral control
action. Thus, it is named as PI controller.

In the proportional-integral controller, the control action of both proportional, as well as the integral
controller, is utilized. This combination of two different controllers produces a more efficient controller
which eliminates the disadvantages associated with each one of them.

PROPOTIONALODERIVATIVE CONTROL - a control system whose output varies in proportion to the

error signal as well as with the derivative of the error signal is known as the proportional derivative
controller. It is also known as a proportional plus derivative controller or PI controllers.

This type of controller provides combined action of both proportional and derivative control action.

2.6.12 – EFFECTS OF INCREASING AND DECREASING OF GAIN IN PROPOTIONAL CONTROL

In over-all, growing the proportional gain will rise the speed of the control system response. However, if
the proportional gain is too large, the process variable will begin to oscillate.

2.6.13 – IMPORTANCE OF MANUAL RESET ON PROPORTIONAL CONTROL

Some newer controls are using manual reset (as a digital user programmable value) in conjunction with
automatic reset. This allows the user to preprogram the approximate output requirement at the
setpoint to allow for quicker settling at setpoint.

2.6.3.18 – ADVATAGES AND DISADVATAGE OF PROPORTIONAL CONTROL

The main advantage of P+I is that it can eliminate the offset in proportional control. The disadvantages
of P+I are that it gives rise to a higher maximum deviation, a longer response time and a longer period of
oscillation than with proportional action alone.
 CALCULATION OF PID

C = 1 Kp + Ki * --- + Kd * s s with Kp = 350, Ki = 300, Kd = 50 Continuous-time PID controller in parallel

form. Now, we have designed a closed-loop system with no overshoot, fast rise time, and no steady-
state error.

WEEK 12

ACTIVITY NO. 12

pH MEASUREMENT

The pH scale is commonly used to represent hydrogen ion activity. On the pH scale, pH values below 7
represent acidic solutions (hydrogen ion activity greater than hydroxide ion activity) while values above
7 represent basic solutions. At pH = 7, hydrogen ion and hydroxide ion activity are equal.

MEASURING DEVICES FOR GAS ANALYSIS

gas meter, device for measuring the quantity or rate of flow of a gas. Types of gas meters (by operating
principles) include displacement, velocity, head, thermal, acoustic, and tracer.

 Measuring instruments.
 Gas moisture meters.
 Gas density meters.
 Testing machines.
 Test chambers.
 Test benches.
 Hardness testers.
 Measuring systems.

CMS

2.6.3.9 – TACHNOMETER

A tachometer refers to any device that produces a signal PANGIT MU proportional to the speed of
rotation of a joint. There are many different types of tachometers, some based on measuring the
frequency of, or the time between, pulses generated by the rotating shaft.

CMS

2.6.3.17 – FUNCTIONAL PURPOSE OF THE FOLLOWING:

  SENSORS - a device that detects and responds to some type of input from the physical
environment. The input can be light, heat, motion, moisture, pressure or any number of other
environmental phenomena.
 TRANSDUCERS - a device that converts energy from one form to another. Usually
a transducer converts a signal in one form of energy to a signal in another.
 CONTROLLER - mechanical, electro-mechanical, or electronic devices which use input signals to
change conditions or values in processes or oversee access to buildings, gated areas, etc.

OPERATIONAL PRINCIPLES OF

 TWO – WIRE TRANSMITTER LOOPS - The 2 – wire transmitter would receive the power and
transmit data signal through the same pair of cables. These two wires are used to power the
transmitter and also to transmit the output signal. These transmitters are energized by loop
current, these transmitters depend upon the loop current from the receiving device. 

 THREE – WIRE TRANSMITTER LOOPS - The 3 -wire transmitter would transmit the data signal
and the power with respect to the common ground. The receiver common is connected to the
transmitter common. In this transmitter, the current loop can also be operated on a measuring
instrument that has high input impedance.

 FOUR-WIRE TRANSMITTER LOOPS - In the case of a 4- wire transmitter, two wires are used for
the data signal and two wires for the power supply. In this arrangement the current signal from
the transmitter would connect the process variable input terminals of the controller to complete
the loop.

WEEK 11

ACTIVITY NO. 11

RELATIONSHIP BETWEEN TEMPERATURE AND VOLTAGE GENERATED BY THERMOCOUPLE

A thermocouple generates a voltage at the junction of two dissimilar metals when irradiation produces a
temperature change. The metals most commonly employed are antimony and bismuth. The generation
of a voltage in this way is known as the Setback effect.

Voltage signal is nonlinear: The slope of a thermocouple response curve changes over temperature. For
example, at 0°C a T-type thermocouple output changes at 39 µV/°C, but at 100°C, the slope increases to
47 µV/°C.

RELATIONSHIP BETWEEN TEMPERATURE AND THE ELECTRICAL RESISTANCE OF RTF

According to the general rule, the dependence of resistance on temperature is that the resistance
increases as the temperature increases in conductors and decreases with the increasing temperature in
insulators. Insulation materials in transformers degrade at higher operating temperature in presence of
oxygen and moisture. When temperature increases water migrates from paper to oil and vice versa.

MEASURING DEVICES FOR LIQUID ANALYSIS

Liquid volume is usually measured using either a graduated cylinder or a buret. As the name implies, a
graduated cylinder is a cylindrical glass or plastic tube sealed at one end, with a calibrated scale etched
(or marked) on the outside wall.

WEEK 10

ACTIVITY NO. 10

EXPLAIN THE ISA CLASSIFICATION OF TEMPERATURE MEASUREMENT

The materials of construction, temperature range, accuracy and control requirements for each type of
temperature-measuring device varies, but the key function remains the same.

In general, however, temperature measurement can be classified into a few categories:

 Thermometers. - are the oldest type of temperature-measurement device. They appeared in the
1500s in the form of an air-thermoscope, the forerunner of the glass thermometer. 
 Probes. - The principles and theory associated with thermoelectric effects were not established
by any one person, but the discovery of thermoelectric behavior generally is attributed to
Thomas Johann Seebeck. 
 Noncontact devices.

STATE THE VARIOUS ELECTRICAL TYPE OF TEMPERATURE MEASUREMENT

The seven basic types of temperature measurement sensors or temperature checking devices discussed
here are thermocouples, resistive temperature devices (RTDs, thermistors), infrared radiators, bimetallic
devices, liquid expansion devices, molecular change-of-state and silicon diodes.

SIMPLE TEMPERATURE PROBLEM SOLVING

 Celsius degrees

The temperature on Monday was 5 celsius. The temperature on Thursday was 7 degrees less than the
temperature on Monday. What was the temperature on Thursday?

Correct answer:

Top of Form

t2 =  -2 °C

Step-by-step explanation:

t1=5 °C  t2=t1−7=5−7=−2°C

 Degrees Fahrenheit
What is the current temperature if the temperature is 12 degrees Fahrenheit and changes by -26
degrees Fahrenheit?

Correct answer:

Top of Form

t2 =  -14 °F

Step-by-step explanation:

t1=12 °F t2=t1−26=12−26=−14°F