Topic covers in Unit - I

Instrumentation - Basics
Role of Instrumentation
Measuring of process parameters
Basics of field Instrumentation
Controlling of Process parameters

PLC Basics
Introduction to PLC
PLC Fundamentals – (PLC Architecture)
PLC Components – Power supply, CPU, I/O and
communication modules
Types of Inputs and Out puts
Introduction to the field devises attached to PLC
Measuring of process parameters
• Measurement:

A set of operation having the object of determine the quantity,

property or condition which is being measured. Sometimes
referred to as the “measurand” .In other way the
measurements in general are made with the objective of
determining the physical characteristics of an item

• Purpose of Measuring and monitoring of process

parameters

Good control requires measurements that are accurate,

reliable, responsive and maintainable. These factors are
influenced by the choice of principle used for the
measurement, the detailed specifications and features of the
instrument selected, how well the installation and
maintenance.
The vast majority of physical measurements are Flow,
Pressure, Temperature, Level, and Weight & Position.
Terminologies use in measurement technique

• Range:-
The region between the limits within which a quantity is measured, received or
transmitted, expressed by stating the lower and upper range values

• Error:-
This is the difference between the measured signal value or actual reading and the
true (ideal) or desired value.

• Span:-
The algebraic difference between the upper and lower range values, expressed in
the same units as the range in other word Span is the difference between
Maximum and minimum values. Input span is Imax - Imin and Output span is
Omax – Omin.

• Accuracy: -
Degree of conformity of a measured value to an accepted standard value (or)
closeness of a reading

• Precision (Repeatability):-
This is the maximum difference between output readings when the same input is
applied consecutively. This is the closeness of agreement among consecutive
measurements of an output for the same value of input under the same operating
conditions, approaching from the same direction. It is usually measured as non-
repeatability and expressed as a percentage of span.
 Calibration
• Calibration
It defined, in general, as the process of determination /
verification by measurement or comparison with a standard of
greater accuracy in order to detect, correlate, report or
eliminate by adjusting any deviation in accuracy; or
determination of the settings of a control device that
correspond to particular values of its characteristics.

Measuring parameters in an
Industry
Pressure
Temperature
Level
Flow
Weight
Vibrations
Quality Parameters
Speed
Position
 Pressure
• It is defined as the force per unit area. Pressure is generally measured in pounds per
square inches (psi) or inches of water column (WC) or in bars or Kg/Cm2

Terminologies used in Pressure

measurements
Static pressure is the pressure of a fluid at rest.
Dynamic Pressure:
If the fluid is in motion, its pressure will depend on its flow velocity and it is termed
as the dynamic pressure.
Absolute pressure: At sea level atmospheric pressure is 14.7 psi (Also expressed
as 1 bar or 100Kpa) but it varies 0.5 psi for every 1000ft elevation. Absolute
pressure is measured with respect to vacuum (Zero pressure). In other words
Absolute pressure is the Pressure referenced to full vacuum ie atmospheric
pressure (1 bar).
Gauge Pressure:-
Pressure indicate in Gauge in other words the indicative pressure with out
atmospheric pressure
Pressure measuring technique and instruments
Variety of pressure measurements methods are used, such as manometers,
bourdon tubes and bellows, and diaphragm
 Pressure Measuring
Instruments

• Pressure Gauge:
• Pressure Switch:
• Pressure transmitter:
Principles of Pressure
Measurement
 Pressure Switch (PS)

Pressure Transmitter (PT)

 Temperature
• Temperature is a degree of hotness or coldness the can be measured using a
thermometer. It's also a measure of how fast the atoms and molecules of a
substance are moving. Temperature is measured in degrees on the Fahrenheit,
Celsius, and Kelvin scales

Terminologies used in Temperature

measurements

Ambient temperature:-
The average or mean temperature of the atmospheric air which is
surrounding a sensor or instrument.

Ambient temperature compensation:-

An automatic correction which prevents the reading of a sensor or
instrument from being affected by variations in ambient temperature

Temperature measuring technique and instruments

In general there are four types of temperature sensors based on the
following physical properties, which are temperature dependent.
 Principles of temperature
Measurement
Expansion of a substance with temperature (TG)

Change in electrical resistance with temperature (RTD)

Change in contact potential between dissimilar metals with

temperature (TC)

Changes in radiated energy with temperature (Radiation Pyrometer)

 Level Measurement
A device that measures the height of material–typically liquid–
inside a tank or other vessel.

Principles of Level Measurement

Float
Ultrasonic and radar
Capacitance
Differential pressure
 Flow
Flow measurement is the quantification of bulk material (fluid)
movement

Principles of FLOW Measurement

Volumetric flow is the commonest and is used to measure the volume
of flow fluid past a given point per unit time.

Mass flow is the mass of fluid past a given point per unit time

Inferential method: - Placing an obstruction in the flow path causes

the velocity to increase and the pressure to drop. This pressure
difference in the pipe can be used to measure the flow rate. An orifice
type is the most common one used in this technique

Velocity methods – Magnetic flow meters depends on this principle

that motion between a conductor (the flowing fluid) and a magnetic
field develops a voltage in the conductor that is proportional to the
velocity of the fluid. Exa: Vortex, Turbine, Ultrasonic
 Sensors
• Limit Switches
Position Sensing
Photo electric sensors

Barcode reader

Proximity sensors
 Actuation technology
Electrical motors Solenoid Valves
(MOV)

Pneumatic actuators
Pneumatic Control
Valves
Basics of field instrumentations &
Terminologies
• Transducer is a device that converts one physical quantity into another, the
second being an analog representation of the physical quantity.
• Sensor: It a device which will sense the presents of physical quantity
(Object, temperature etc...) in other word nothing but a transducer
• Transmitter is a signal processing device which receives signal from a
sensing device (transducer) and converts it to 4 to20mA or 0 to10v for
transmitting to Control or Display devices
• Digital Signals: - The signals from field / to the field have two states as ON
of OFF called Digital signals. Widely used digital signals are 24V DC, 230V
Ac, and 110V Ac
• Analogue signals: - An analog or analogue signal is any continuous
signal for which the time varying feature (variable) of the signal is a
representation of some other time varying quantity. It differs from a digital
signal in that small fluctuations in the signal are meaningful. Most commonly
used analogue signals are 4-20mA and 0-10V
• Protocols: - An agreed-upon format for transmitting data between two
devices. The protocol determines the following:
The type of error checking to be used
Data compression method, if any
How the sending device will indicate that it has finished sending a message
How the receiving device will indicate that it has received a message
Commonly used protocols are RS-232, RS-485, Modbus, profibus, field bus and
Ethernet protocols
Field Instruments connection

Field Digital
ON/OFF
Junction box
Controller
(DJB)

PS Liner
PG PT Controller

Field Analogue
Junction box
(AJB)
 Controlling of Process
parameters
• A control system is a system of integrated elements whose function is to
maintain a process variable at a desired value or within a desired range of
values. The control system monitors a process variable or variables, and
then causes some action to occur to maintain the desired system
parameter.

• A control system is a device or set of devices to manage, command, direct

or regulate the behavior of other devices or systems
 Method of process control
• Manual: It means take necessary action by a man to control the process
parameters. In this case only process indicating instruments will be
available.

• Automatic: By using a control device maintains the process parameters

with in the accepted limit. Automatic process controls are implemented in
four levels as follows Open loop control, Closed loop control,
Sequential Controller and Logic controller

• Open loop controller: By this concepts the process parameters (PV) are
measured / monitored from particular point and based on the set point -
SV (Operation control point) output signal (ON/OFF -Control signal) will be
generated and it will actuate / operate the controlling device

• Closed loop control

If the PV, the objective of control, is used to determine the control action it
is called closed loop control system.
Method of process control Cont..
• Sequential Controller
An automatic sequential control system may trigger a series of equipments in
the correct sequence to perform a task. For example various electric and
pneumatic transducers may fold and glue a cardboard box, fill it with product
and then seal it in an automatic packaging machine.

• Logic controller
Pure logic controls were historically implemented by electricians with
networks of relays, and designed with a notation called ladder logic.
Nowadays, most such systems are constructed with programmable logic
controllers.
Logic controllers may respond to switches, light sensors, pressure switches
etc and cause the machinery to perform some operation. Logic systems are
used to sequence mechanical operations in many applications. Examples
include elevators, washing machines and other systems with interrelated
stop-go operations.
Logic systems are quite easy to design, and can handle very complex
operations. Some aspects of logic system design make use of Boolean logic