Instrument Devices

Instrument & Control Devices
Convention
Course Duration Ten days (two hours per day)
Rest 10 min after the 1st hour

Participation and Please participate actively
discussion
Phone Allowed, but silent
Opinions All Respected ☺

TABLE OF CONTENTS
1. Introduction
What is Process Field and Control Room Signal System
Field Devices
Instrumentation? Parameter Control Room Devices Transmission Wiring
2. Process Measurements
Temperature Measurements Pressure Measurements Flow Measurements Level Measurements
3. Control Valves
Valve Self-Actuated Solenoid
Introduction Actuators Valve Body Positioner Characteristics Valve Valve
4. Control Room Devices

Indicators Recorders Controllers Annunciators system HMI
5. Signal Transmission
Pneumatic Signals Electrical Signals Digital Signals Wireless Signals.
TABLE OF CONTENTS
6. Control System
Basic Control Proportional Derivative
Introduction ON/OFF Control Integral Action
Principles Control Action
7. Modern Control System

PLC HMI DCS SCADA
8. Piping and Instrumentation Diagrams (P&ID)

Piping & Connection
Purpose of P&ID P&ID Symbols Equipment Symbols Instruments Symbols
Symbols
9. Wiring Diagram
Introduction Wiring Diagram Parts Wiring Diagram Legend Using Wiring Diagram
10.Safety
Introduction
INTRODUCTION
PART #1
1. INTRODUCTION
Field Devices
Instrumentation :is the science of measurement and control.

1. Measure
• To control a particular variable, it must first be 2. Transmit

measured, and something that cannot be measured
cannot be controlled.
• After measuring the variable, we usually send a signal 3. Controller
representing the measured quantity to an indicator or
controller, after which the human takes over the
control, Manual Operation, or the control is through a
specific device without human intervention Automatic
Operation
• The signal then sent to the Final Controlling Device.

which changes the measured variable.
4. Final controlling
Device
1. INTRODUCTION
Field Devices
The temperature is
now 84.9, it should be
85.0. I have to open
the valve a bit
Manual Operation Automatic Operation

The Operator monitors and compares the The controller compares the measured value
measured value PV with the required value SP PV with the required value SP and changes the
and changes the valve opening to make PV=SP valve opening to make PV=SP
1. INTRODUCTION
Field Devices
In the field of industry, the following variables are mainly measured and called Process
Parameters: Process
❖ Temperature Parameter
❖ Pressure
❖ Flow
❖ Level
There are other variables that are

measured and controlled, such as:
❖ Speed
❖ Vibration & axial
❖ Axial
❖ PH
❖ ETC……
Process (Furnace)
1. INTRODUCTION
Field Devices
Filed or Site : it’s

the place where is all
the equipment Field
or
located like (pipes , Site
tanks ,motors
,Furness , transmitters
and control valves
Control Room : It’s

the place that use to
monitor all the
Control
controllers , Room
Annunciators and
Recorders
1. INTRODUCTION
Field Devices
Field
or
Site
Control Room Field or Site

1. INTRODUCTION
Field Devices
Pressure Measurement Devices

Pressure Gauges Pressure Transmitter Pressure Switch
1. INTRODUCTION
Field Devices
Level Measurement Devices

Level Gauges Level Transmitter Level Switch
1. INTRODUCTION
Field Devices
Temperature Measurement Devices

Temperature Gauges Temperature Transmitter Temperature Switch
1. INTRODUCTION
Field Devices
Flow Measurement Devices

Flow Gauges Flow Transmitter Flow Switch
1. INTRODUCTION
Field Devices
Other Devices
Temperature Sensors Control Valves Solenoid Valve
1. INTRODUCTION
Field Devices
Control Room Devices

Controllers Indicators Recorders
1. INTRODUCTION
Field Devices
Control Room Devices

Annunciators HMI Switches & Lights
1. INTRODUCTION
Field Devices
Signals are transmitted between the Field Devices and the control room in one of the following ways
1. Pneumatic air pressure (3-15 psi) or (0.2-1 kg/cm2)
1. INTRODUCTION
Field Devices
Signals are transmitted between the Field Devices and the control room in one of the following ways :
3. Digital Signal through cables or optical fiber
2. Electrical Signal (4 to 20 mA DC) through cables
(FOUNDATION Fieldbus, Modbus, etc.)
1. INTRODUCTION
Field Devices
Signals are transmitted between the Field Devices and the control room in one of the following ways :
4. Wireless Signal
1. INTRODUCTION
Field Devices
1. INTRODUCTION
Field Devices
1. Junction Box (JB)

The Junction Box is used to reduce the
cables between the field equipment and
the control room.
The cables that connect the Field and JB

devices are called Branch Cable.
A branch cable usually consists of a

single pair of wires.
The cables between the control room

and JB are multi-pair cables.
1. INTRODUCTION
Field Devices
1. Junction Box (JB)

1. INTRODUCTION
Field Devices
2. Cable Tray
Cable Tray: It is used to carry the secondary and main cables, and it comes in different sizes
according to the number and size of the cables.
1. INTRODUCTION
Field Devices
3. Marshalling Cabinet
Marshalling Cabinet: It is used to arrange the cables connected from the field to be distributed to
the control devices or the System Cabinet. It also contains some devices such as Relays and Barriers.
1. INTRODUCTION
Field Devices
4. System Cabinet
System Cabinet: In old systems, it contains control devices such as controllers,
indicators, and alarms. In modern systems, it contains PLC, DCS, or SIS.
Marshalling System Marshalling

Cabinet Cabinet Cabinet
PROCESS PART #2
MEASUREMENTS
2. PROCESS MEASUREMENTS
Temperature Pressure Level Flow
Measurements Measurements Measurements Measurements
1. Resistance Temperature Detectors (RTD)

RTD: A device made of pure metal wire (usually
platinum) whose resistance increases with
temperature.
The approximate equation for increasing the
resistance is:
RT = Rref [1 + α(T − Tref )]
where,
Rt = resistance of rtd at temperature t (ohm):
Rref:resistance of rtd at temperature of Tref
αo = temperature coefficient of resistance

PT100: It is one of the most common types of
RTD in the field of industry, its resistance at zero
degrees Celsius is 100Ώ
An approximate equation for calculating heat

would be:
RT = 100 (1 + αT)
The most commonly used α value is 0.003902

To measure the temperature by RTD, we first
measure the resistance value and use special
tables to find the temperature in terms of
resistance.

The adjacent figure represents the effect of wire
resistance on the temperature reading, as the
accuracy decreases with increasing wire resistance.
The real temperature is zero because the resistance is

Temperature 100Ώ, while the ohmmeter measures 102 because of
Temperatur
e at 100 Ώ is
at 102 Ώ is the resistance of the wires, so the measured
approximately
0 C
ͦ 5 C
ͦ
temperature is approximately 5 degrees Celsius.
ͦ
How to get rid of the difference resulting from the
resistance of the wires?

To get rid of the wire resistance, we use a 3wire RTD, where
the extra wire is used to find the wire resistance that must be
subtracted from the measured resistance.
4wire RTD can be used to obtain a more accurate reading,

but this method is economically expensive, so 3wire RTD is
used more widely in industry.
Some temperature sensors contain

RTD is dual and both can be 2wire
Or 3wire or 4wire.
2. Thermocouples (TC)
When two different metals are connected
from one end, a voltage will be generated at
the other end that is proportional to the
temperature.
The bimetallic piece is called a Thermocouple.
To measure the temperature by TC, we first

measure the voltage value and use special
tables to find the temperature in terms of
voltage.
Note when trying to measure the voltage with a
voltmeter, other TC points will be generated
because the type of voltmeter wires differs from
the original TC wire type.
These points are called Cold Junction because they

are located inside the room and cause an error in
the temperature measurement.
Several methods are used to get rid of this error, Special cables made of different alloys are used
but the basic idea is fixed, as another temperature to transmit the signal between the TC and the
sensor, type RTD, is placed, for example, at the measuring devices. Therefore, TC is one of the
meeting place of the wires, and the temperature expensive options, but it is more durable than
difference is subtracted from the measured RTD.
voltage.
There are several types of TC covering different temperature ranges and suitable for different applications, and
each type has a special connecting wire.
Introduction
Pressure is one of the physical variables necessary to measure other variables such as
Flow, Level, density, and weight.
Pressure is the normal force applied per unit area.
Pressure = Force / Area
Pressure is measured in different units, but pounds per square inch (PSI) or Kg/cm2 are
used in industry.
1 kg/cm2 = 15 psi approximately.

Pressure Scales
There are two pressure scales depending on
the reference value:
Gauge pressure: The reference is atmospheric
pressure. It is marked with a letter (g) after
the unit of measurement, for example psi(g). Absolute Pressure= Gauge Pressure + atmospheric Pressure
Absolute pressure: The reference is absolute

pressure. It is marked with an (a) after the unit
of measurement, for example psi(a).
Any pressure less than atmospheric pressure

is called vacuum pressure
Mechanical pressure elements

Bellows: A piece of metal that expands when
pressure increases.
Diaphragm: It is a metallic disc that flexes when

subjected to pressure.
Bellows
Bourdon Tube: It is a tube made of a metal that
has a springy feature that forms an incomplete
ring when subjected to pressure, trying to return
to its straight shape.
It takes advantage of the mechanical movement

to move an indicator that shows the amount of
pressure.
Introduction
Level measurement methods can be divided into three
types:
Direct Sensing method: where the level is measured

directly.
Indirect Sensing: where a characteristic of the liquid

such as pressure is measured and the level is
calculated in terms of it.
Measuring the level at a specific point: Sometimes it is

necessary to know the presence of a liquid at a certain
level.
Level Gauges Glass (LG)

It is the simplest level measuring device of the direct type
and is usually used to check the validity of the reading of
another level device placed on the same tank.
Glass scales are of two types:

• Transparent Glass: Glass is transparent and used to
monitor liquid properties such as colour and level
between two substances.
Reflux
• Reflux Gauge: The glass is in the form of prisms and is

used for transparent liquids, where the level appears
in a dark colour and the empty area in a silver colour.
Transparent
Magnetic Level Gauges (LG)

The Issue with glass gauges is that it is
difficult to distinguish the liquid level.
Magnetic Level Gauges It consists of a

floating body inside a tube containing the
liquid to be measured called Float. It contains
a magnet that changes the position of a set
of magnetic plates coloured in two colours,
as in the adjacent figure. Thus, the liquid
level can be easily distinguished.
Hydrostatic pressure
The relationship between liquid column height
and pressure is as follows:
P = ρgh
Where
P: pressure
ρ : density of the liquid
H: height of the liquid column
g: ground acceleration
That is, the liquid level is proportional to the

height with constant density.
Open Tank Measurement

Level is calculated in terms of pressure as
follows:
Plow = Patm
Phigh = ρgh + Patm
H ΔP = Phigh - Plow = ρgh
The transmitter can be calibrated so that the
output is 4mA when the level is zero and 20mA
when the height is H
Zero (4 mA when h equal zero) = 0

Span (20 mA when h equal H) = ρgH
Closed Tank Measurement (dry leg)

Level is calculated in terms of
pressure as follows:
Plow = Pgas
Phigh = ρgh + Pgas
H ΔP = Phigh - Plow = ρgh

The transmitter can be calibrated so that the
output is 4mA when the level is zero and
20mA when the height is H
Zero (4 mA when h equal zero) = 0

Span (20 mA when h equal H) = ρgH
Closed Tank Measurement (wet leg)

Level is calculated in terms of pressure as
follows:
Plow = Pgas + ρgH
Phigh = ρgh + Pgas
ΔP = Phigh - Plow = ρg(h – H)

H
The transmitter can be calibrated so that
the output is 4mA when the level is zero
and 20mA when the height is H
Zero (4 mA when h equal zero) = -ρgH

Span (20 mA when h equal H) = 0
Displacer Level Transmitter

The Level is calculated in terms of the weight of
the floating body, as the body loses its weight in
an amount proportional to the submerged part
according to the Archimedes rule.
The inner part is called the Displacer attached to

a spring. If the Displacer is immersed in water, it
rises slightly due to the force of the spring. The
vertical movement is transformed into a
rotational movement and transmitted to the
sensor via a Torque Tube. The sensor converts
the movement into an electrical or pneumatic
signal for the purpose of display or control.
Orifice Plate
Orifice Plate: It is a thin metal plate (1.5 to 6
mm thick) that has a hole in the middle.
The pressure difference across the plate is

proportional to the flow as follows
Qv = C √(ΔP/ρ)
Where
Qv: volumetric flow
C: Constant
ΔP: Differential pressure across the plate
ρ : fluid density
Position of process taps and transmitter in case of GAS

In the case of gases, the position of the plate holes in the top and the transmitter is above the tube.
Position of process taps and transmitter in case of LIQUID

In the case of liquids, the location of the plate holes in the bottom and the level of the transmitter is
below the tube.
Position of process taps and transmitter in case of STEAM

In the case of steam, the location of the plate holes on the side and the level of the transmitter is above
the tube, and two containers are placed to condense the steam called Condensers.
Variable-area flowmeters
Variable-area flowmeters work on the
principle of equalizing the forces between
the weight of a certain body and the
floating force resulting from the speed of
the material. The increase the flow
Proportional to the increase the body
height.
This type of scale is designed depending on

the specifications of the material to be
measured.
Magnetic flowmeters
Magnetic flowmeters work based on
Faraday's principle. Where an electromotive
force is generated in a conductor if it moves
perpendicular to a magnetic field
Magnetic Flowmeter is used for conductive

liquids such as water and cannot be used for
hydrocarbons.
E = B*V*D
Flow = V*A = V*D2/4*π
Flow=C.E
Ultrasonic flowmeters
Ultrasonic flowmeters use ultrasound to measure
flow.
The meter contains an ultrasound transmitter and
receiver. The waves are sent obliquely, so the
wave’s arrival speed in the direction of flow is
more than the wave’s speed against the flow. By
calculating the time difference, the speed of the
material can be measured, as the difference
increases with the increase in speed.
Other companies use the Doppler phenomenon to

calculate speed based on the amount of
frequency change between the transmitted and
received wave
Coriolis flowmeters
Coriolis flowmeters are very accurate counters that
calculate the mass flow of matter and also measure
the material's heat and density.
It depends on the Coriolis phenomenon, where the

tube is designed to vibrate at a certain frequency,
and when the material passes through, the two ends
of the tube are exposed to two opposite forces due
to the passage of the material in two different
directions.
By calculating the change in the vibration frequency

and the phase difference between the two sides of
the tube, the flow and density of the material can be
measured.
CONTROL VALVE
PART #3
3. CONTROL VALVE
Valve Self-Actuated
Introduction Actuators Valve Body Positioner Solenoid Valve
Characteristics Valve
Definition
Control Valve: It is the last control device
(Final Controlling Device) in the control Diaphragm
system, its purpose is to regulate the flow Spring
of fluids. Actuator
Indicator
The control valve consists of the following Stem

parts:
• Actuator
• Valve Valve Plug
Seat
3. CONTROL VALVE
Valve Self-Actuated
Control Valve Types

Linear Motion Valves Rotary motion valves
Globe Valve Butterfly Valve
Diaphragm Valve Ball Vale

3. CONTROL VALVE
Valve Self-Actuated Solenoid
Introduction Actuators Valve Body Positioner
Characteristics Valve Valve
Actuator Types
The purpose of the Actuator is to precisely place the
Valve Plug in proportion to the control signal.
The Actuator receives the signal from the control

system and responds to it either by opening the valve
completely or closing it completely or any value in
between.
The most common types of Actuator are:

• Pneumatic type
• Electric type
• Hydraulic Type
3. CONTROL VALVE
Valve Self-Actuated
Pneumatic Actuators Types

Diaphragm Actuators Piston Actuator
Air-To-Open (ATO) Air-To-Close (ATC)

Fail Closed (FC) Fail Open (FO)
Valve Stock ‫يستخدم عادة اذا كانت المسافة المطلوبة لحركة الصمام‬
Reverse Acting Direct Acting
Normally Close Normally Open Diaphragm Actuator ‫كبيرة نسبيا بحيث ال يمكن ان يحققها‬
3. CONTROL VALVE
Valve Self-Actuated
Valve Body Parts

Stem
Packing Ring
Plug
Cage
Cage Plug
Seat
3. CONTROL VALVE
Valve Self-Actuated
Valve Body Types

Valve Valve Action on
Actuator
Body Action Failure
Air to
Direct Direct FO
Close
Air to
Reverse Reverse FO
Close
Air to
Direct Action Reverse Action Direct Reverse
Open
FC
‫الحركة الى االسفل‬ ‫الحركة الى االسفل‬
Reverse Air to
‫تؤدي الى غلق الصمام‬ ‫تؤدي الى فتح الصمام‬ Direct
Open
FC
3. CONTROL VALVE
Valve Self-Actuated
What is Positioner?
Positioner: It is a device that compares the
position of the valve movement with the
control signal and changes the pressure
applied to the Actuator to correct the
position.
Regulator
The control signal is a pneumatic signal of Positioner
Regulator
3-15 psi or an electrical signal of 4-20 mA, Positioner
and the output of the Positioner is usually
3-15 psi.
The Positioner needs an Air Supply with a

pressure of 20 psi or according to valve
specifications.
3. CONTROL VALVE
Valve Self-Actuated
With or without Positioner?

3. CONTROL VALVE
Valve Self-Actuated
Valve Characteristic: It is the relationship between

the amount of flow rate passing through the valve
and the amount of valve opening.
The shape of the cage determines by the Valve
Characteristic.
Quick Opening Linear Equal Percentage

3. CONTROL VALVE
Valve Self-Actuated
What is Self-Actuated Valve?

Self Actuated Vale: It does not depend on
any external signal to control the pressure
and uses the process line pressure as a
signal to close or open the valve.
The Self Actuated Valve can control the

pressure before the valve and is called the
Backpressure Control Valve, or the
pressure can be controlled after the valve
and is called the Relief Valve.
3. CONTROL VALVE
Valve Self-Actuated
Solenoid Valve Types

2 Ways
Solenoid Valve: It is usually a small electric Solenoid
Valve
valve.
2 Ways
Energized: It means that the electrical power Solenoid
Valve
is connected to the Solenoid Valve.
De-energized: It means that the electrical

power is not connected to the Solenoid Valve. 4 Ways
Solenoid
Valve
There are several types of Solenoid Valves,
divided according to the number of ports.
CONTROL ROOM PART #4
DEVICES
4. CONTROL ROOM DEVICES
Introduction to Indicator
Indicator: It is one of the control devices
whose function is to display the reading of
(field devices) without recording them.
The indicator link circuit is called the Open

Loop because it does not contain the final
control device, such as the valve.
Indicator can contain an Alarm.

Indicator Setup
All modern Indicator devices need programming
(Set up), which is done either through a calculator
or by means of keys in the device itself.
The most important things to be programmed in
the Indicator are:
• Tag
• Input Type: (Voltage, current, TC, RTD, etc.)
• Input Range: (1-5V, 4-20mA, 100mVDC, etc.)
• Low Range
• High Range
• Function: (Linear, Square Root)
• Alarm Value (if exist)
Introduction to Recorder
Recorder: It is one of the control devices whose function
is to display and record (store) readings of field devices.
Old recorders are on paper, meaning that data is

recorded on special paper (Chart) enough for about a
month, after which it is replaced.
Modern devices do not contain paper for recording and

are called (Paperless) or (Video Chart Recorder). The
data is stored in a special memory, and after it is full, the
data can be transferred to the computer and the
memory can be reformatted (Format).
The Recorder can contain an Alarm.

Recorder Setup
The Recorder can contain an Alarm.
All modern Recorder devices need to be programmed (Set up), either via a calculator or by means
of keys in the device itself.
The most important things that must be programmed in the Recorder are the same data in the
Indicator, in addition to matters related to the recording speed (Chart Speed) and the display
method.
Controller Programming
All modern controllers need programming (set up),
which is usually done through a PC , due to the large
number of data that must be entered.
Each software company has its own for programming

controllers, and most of them depend on functions
that are programmed and linked to perform the
required purpose.
Modern controllers can perform various operations,

such as logical and arithmetic operations, and contain
timers, comparisons, and logical inputs and outputs.
Introduction to Annunciator
Annunciator: It is a device that alerts the operator in case a variable
deviates from the normal conditions of operation, such as an
increase or decrease in the level of a tank above the normal
situation.
The Annunciator beeps and a lamp flashes indicating the abnormal

signal. The operator must confirm his knowledge of the signal by
pressing a specific key called Acknowledge and symbolized by its
abbreviation ACK. In this case the beep stops and the lamp flashes.
When the variable returns to its normal position, the lamp goes off.
The previous method is the most common method, but there are
other methods adopted by different companies that depend on the
severity of the process.
Introduction to HMI
Modern control systems that depend on PLC or DCS contain
HMI monitoring screens that compensate for all previous
devices, in addition to providing a graphical interface that
Controller helps the operator to better monitor and control.
Indicator
Alarm
Recorder
(Trend)
SIGNAL PART #5
TRANSMISSION
5. SIGNAL TRANSMISSION
Pneumatic Signals Electrical Signals Digital Signals Wireless Signals
Introduction
Despite the development in the instrument industry,
pneumatic measuring and control devices (operating
with air pressure) are still used so far in certain
applications.
The signal is transmitted by a plastic, copper pipe, or

steel tube called S.St.
In the case of air transmitters, the signal is displayed by

means of special pressure gauges called Receiver Gauge,
as it accepts a signal of 3-15psi or (0.2-1kg/cm2) and
displays it in engineering units or as a percentage.
Please be careful when using this type of scale ☺

Scaling
To find the PV transmitter reading if the output pressure is known in psi units:
𝑃−3
PV=Zero + (Span – Zero)
15−3
To find the transmitter output pressure (in psi units) if its scale is known:
𝑃𝑉−𝑍𝑒𝑟𝑜
P=3+(15-3) *
(𝑆𝑝𝑎𝑛−𝑍𝑒𝑟𝑜)
Pressure Pressure
% of scale
(psi) (kg/cm2)
3 0.2 0
6 0.4 25
9 0.6 50
12 0.8 75
15 1.0 100
Examples
‫مثال صمام‬ ‫مثال مرسلة‬
If the positioner's outlet pressure is 11.2psi, how An air pressure transmitter with a range of 5-15
large should the valve opening be? bar, and the reading of the pressure gauge next
to it was 13 bar, so what is the output pressure?
Answer :
Answer :
For the valve , Zero=0 ‫ و‬Span=100 𝑃𝑉−𝑍𝑒𝑟𝑜
P=3+(15-3) * (𝑆𝑝𝑎𝑛−𝑍𝑒𝑟𝑜)
𝑃−3
PV=Zero + (Span – Zero) 13−5
15−3 P=3+(15-3) * = 12.6 𝑝𝑠𝑖
(15−5)
11.2−3
PV=0 + (100 – 0) = 68.33%
15−3
Fitting
To connect the signal tubes are used
Special connections shown in the
figure
Next door is called Fitting.
Fittings come in different shapes and
sizes depending on the type of use,
the size of the pipe, and the material
it is made of.
Tube sizes commonly used in

precision machinery are:
1/4", 5/16", 3/8", 1/2"
The above measurements represent
the outer thickness
Common Tube Fitting Types

CONNECTORS UNION ELBOW TEE
Used to connect a tube to Used to connect one tube to It is a tube connectors with a Its joins three fluid lines
pipe threads another bend together
Union
Tee
Male Union Male Female
Connector Elbow Elbow
If Union is used to joins Male branch

together different tube sizes tee
its called Reduced Union
Union
Elbow
Female
Reduced Male run
Connector
Union tee
Introduction
4-20mA is the most common way to transmit a
signal.
4mA corresponds to the lowest value of the

transmitter (Zero).
20mA corresponds to the maximum value of the

transmitter (Span).
The 4-20mA current inside the controller is

converted into a voltage of 1-5VDC by
connecting a 250Ω resistor for easy voltage
measurement without opening the transmitter
wires.
Scaling
To find the PV transmitter reading if the current is known : Current
Value
Voltage
Value
% of scale
𝑚𝐴−4
PV=Zero + (Span – Zero) 4 1 0
16
To find the transmitted current if its reading value is known: 8 2 25
𝑃𝑉−𝑍𝑒𝑟𝑜 12 3 50
mA=4+16*
(𝑆𝑝𝑎𝑛−𝑍𝑒𝑟𝑜) 16 4 75
20 5 100
To find the PV transmitter reading if the voltages are known:
𝑉−1
PV=Zero + (Span – Zero)
4
To find the voltage of the transmitter if its reading is known:

𝑃𝑉−𝑍𝑒𝑟𝑜
V=1+4 *
(𝑆𝑝𝑎𝑛−𝑍𝑒𝑟𝑜)
Examples
‫مثال صمام‬ ‫مثال مرسلة‬
PLC system, one of its outputs is connected to a Programmable temperature transmitter from
control valve of the ATO type, so if the current is 300ͦC to 500ͦC. And the output current is 4-20mA.
17.3mA, what is the position of the valve What is the value of the current if the
opening in the location? transmitter has a temperature of 432 Cͦ ?
Answer :
Answer :
𝑚𝐴−4 𝑃𝑉−𝑍𝑒𝑟𝑜
OP=Zero + (Span – Zero) mA=4+16 *
16 (𝑆𝑝𝑎𝑛−𝑍𝑒𝑟𝑜)
17.3−4 432−300
OP=0+ (100 – 0) 16 = 83.128% mA=4+16 * (500−300) = 14.56𝑚𝐴
Current Failure
Modern transmitters are designed to distinguish between failure and saturation.
• Failure: means a problem with the transmitter or sensor.
• Saturated: means that the reading assigned to the transmitter is outside the programming range.
Introduction
Modern devices can measure a large number of variables, for example, the Coriolis meter
can measure flow, density, temperature, etc., and modern Positioner devices can measure
valve opening, air source pressure, output pressure, and device temperature.
More wires can be used to transmit such signals, but it is not the most appropriate option.
Digital communication can transmit a very large number of signals, the only determinant of
the number of signals is the speed of communication.
The HART communication system appeared, which used 4-20mA wires to transmit data,
then several communication protocols appeared that used special wires such as Modbus,
Fieldbus, and others.
Fieldbus Protocols
There are several communication systems (generally called Fieldbus) designed to communicate with industrial
equipment.:
Protocol Icon
HART
Modbus
FOUNDATION Fieldbus
Profibus
HART
HART (Highway Addressable Remote
Transducer): The main purpose of this
protocol is to transmit data using the same
wires used to transmit a 4-20mA signal.
HART can transmit four (or more) variables in

a single message.
HART can communicate with multiple devices

connected in parallel at the same time
(Multidrop), but in this case the current of all
devices is 4mA.
MODBUS
MODBUS appeared for the first time in 1979,
and it is a method used to transfer data
between devices via Serial Communication.
The device requesting the data is called the Master.

The device that gives the data is called Slave.
Master can request data from 247 devices,

each with an address between 1 and 247.
Master can write data to Slave devices.

Foundation Fieldbus
Foundation Fieldbus: It is a protocol that not
only enables devices to communicate with each
other, but also enables them to implement
different types of control such as PID, Ratio,
Cascade, and others.
It is of two types:
Foundation Fieldbus H1: Double wire communication, 31.25Kbps used when high
speed is not required.
Foundation Fieldbus HSE: It uses the Ethernet Protocol, its speed is 100Mbps. An
Ethernet cable or an optical cable can be used.
Profibus
Fieldbus it is a type of digital communication.
There are two types:
• Profibus PA (Process Automation)

Uses the Master/Slave principle
• Profibus DP (Decentralise Peripheral)

It uses the Peer to Peer principle, meaning
that devices communicate with each other without
the need for commands, as they exchange data and
alerts continuously.
Information
The signal can be transmitted wirelessly, thus
reducing the cost of wires and reducing the
implementation time. It is very suitable for devices
located in remote areas such as oil wells.
Each device contains a battery that supplies it with

power, and the devices are designed to be low in
energy consumption.
Battery life depends on the Scan Rate of the

transmitter, so it is not suitable for applications that
require high speeds.
Steel structures are obstacles to communication

signals.
CONTROL SYSTEM
PART #6
6. CONTROL SYSTEM
Basic Control Proportional
Introduction ON/OFF Control Integral Action Derivative Action
Principles Control
Introduction
The controller compares the measured value PV
with the required value SP and changes the valve
orifice to make PV=SP. But how does he do that?
And how can the speed of response be controlled

so that we can have perfect control?
6. CONTROL SYSTEM
Principles Control
Control System Variable

In the adjacent figure, it is required to maintain
a constant level of material height in the tank,
let it be 50%.
First you need to define the variables :
The level is the variable that must be controlled.

1. That is, it is PV (Process Variable)
2. The required level for fluid height is 50% which is SP (Set Point).
3. To control the level, the flow of the fluid entering or leaving the tank must be controlled. Thus,
the flow is MV (Manipulated Variable), or the output is called OP (Output).
6. CONTROL SYSTEM
Principles Control
Control System Variable

If the level is equal to 50%, then there is no need
to take any action. But if it is more or less, the
flow must be changed.
The difference between the true level and the

desired level is called error and is denoted by e
e = SP - PV
Simply the controller tries to set the error value to zero.
Note that the control system takes action after an error occurs, so it is called feedback.
6. CONTROL SYSTEM
Principles Control
Open Loop and Closed Loop Control System

Open Loop: The input is not linked to
the output.
For example, the driver of the vehicle
presses the fuel by a constant amount,
regardless of the speed.
Open Loop
Closed Loop: The input is variable
depending on the output.
For example, the driver of the vehicle
Closed Loop
presses on the fuel so that he tries to
keep the speed constant.
6. CONTROL SYSTEM
Principles Control
ON/OFF Control Properties

ON/OFF Control features:
1. The control signal is always either 0% or 100%.
2. SP cannot be obtained due to hysteresis or

deadband.
3. The error value does not affect the control
signal.
Hysteresis: is the difference between the value at
which the alarm (in the adjacent example PI) is ON
and OFF.
Deadband: It is the state in which the system does
not show any response.
6. CONTROL SYSTEM
Principles Control
Offset in Proportional Control

In Proportional Control, the control signal is proportional to
the error.
ΔOP=K.e Where: K is Gain, e is error
If a disturbance occurs in the flow, the transmitter will change

the valve opening and the system will stabilize after a period
when the amount of the incoming substance is equal to the
amount of the outgoing substance, but the new balance point
may differ from the previous value, this difference is called
Offset.
In control systems we usually use Proportional Band (PB).
PB=100/Gain
A high PB value means a low gain and vice versa.
6. CONTROL SYSTEM
Principles Control
Proportional Band
The neighboring figures show
the response of the system to
different values of PB.
Notice the presence of an

offset if the PB values are
large or medium and
fluctuations occur in the
system if the PB value is very
low because the gain will be
high.
6. CONTROL SYSTEM
Principles Control
PI Control
The problem with Proportional Control is that it
does not handle the Offset and therefore the
value cannot be SP=PV.
Integral Control Works to get rid of the error by

making the output signal affected by the
accumulation of error (error integration with
time).
Usually the effect of Proportional Control (P) is
combined with Integral Control (I) and the
output is called PI Control
I is measured in Repeat Per Minute (RPM)
1
ΔOP=K e +
𝑇𝑖
‫ 𝑡 𝑒 ׬‬. 𝑑𝑡 .
6. CONTROL SYSTEM
Principles Control
PID Control
In systems that are subjected to perturbations that
make the error gradually increase with time,
Proportional Control will change the output gradually
and thus we need a long time to control.
We can reduce the value of the offset and shorten the
time required to return to SP again if we add a
component to the output that is proportional to the
rate of change in the error.
This component is added to P and I to get PID

Td is measured in units of time. 1 𝑑𝑒(𝑡)
ΔOP=K e + ‫׬‬ 𝑒 𝑡 .𝑑𝑡 + 𝑇𝑑.
𝑇𝑖 𝑑𝑡
The presence of Td in the equation leads to large
jumps in the output to speed up the system.
6. CONTROL SYSTEM
Principles Control
PID Control
:‫باختصار‬
P Control: causes an Offset to
occur
I Control: Makes the error zero.
D Control: It leads to faster
system stability.
MODERN CONTROL PART #7
SYSTEM
7. MODERN CONTROL SYSTEM
PLC HMI DCS SCADA
Introduction
The old control systems were based on
relays and timers. These systems suffer
from the following main problems:
1. Difficulty making adjustments to the system.

2. Difficulty tracking faults.
3. Lack of reliability due to mechanical parts.
4. The size of the system is large.
PLC appeared to solve the previous problems.

PLC HMI DCS SCADA
What is PLC
PLC (Programmable Logic Controller): It is an industrial
computer designed to control a system. It reads input
sensors, makes decisions based on the user's program,
and controls output devices.
PLCs were first developed in automotive laboratories

in 1968 to provide flexible, programmable, and highly
reliable control units for replacing relays, timers, and
relays.
Then it was developed to be able to process all kinds

of digital and analog signals (Digital & Analog Signals).
PLC HMI DCS SCADA
What is Inside a PLC

Each PLC consists of the following parts:
1. Input units that are connected to the sensors.

2. Central Processing Unit (CPU) that contains the
Reading user's program and determines its work.
Inputs
3. Output units that change the state of the devices
associated with it.
PLC The PLC (PLC Scan) consists of the following stages:

SCAN 1. Read entries.
Writing Program 2. Program implementation.
Outputs execution
3. change outputs.
PLC HMI DCS SCADA
PLC Programming Languages

Ladder (LD) Function Block Diagram (FBD) Valve
Structured Text (ST) Sequential Function Chart (SFC)

PLC HMI DCS SCADA
Introduction
Despite the capabilities provided by the
PLC, the operator needs to monitor data
and control operational conditions.
HMI (Human Machine Interface): It is a

device used to operate and monitor a
specific device or unit by connecting to a
control device such as a PLC.
HMI can be a computer, touch screen,

tablet or mobile device.
PLC HMI DCS SCADA
Use of HMI
HMI is used for the following purposes:
1. View operational data.

2. Trending data recording.
3. Data History
4. View Alarms.
5. Provide a graphical interface to facilitate
the operator's handling of the
equipment.
ETC ☺
PLC HMI DCS SCADA
Introduction
HMI is used to display the data in the PLC
But the following problems will appear :
1. Both PLC and HMI use different software and there is no

PLC Software
standardized database.
2. We need a communication program between PLC and
Communication HMI
Server
3. All data to be transferred must be prepared in the PLC
program, as well as defined in the HMI program, which
increases the incidence of errors and wastes time.
Therefore, DCS appeared to provide a solution to these

problems, in addition to expanding the volume of data it
HMI Software deals with and providing more diagnosis of problems.
PLC HMI DCS SCADA
What does DCS system consists of?

DCS (Distributed Control System) consists of at least
the following parts:
FCS
1. Field Control Station (FCS): Contains the IO Module,
CPU, and Communication Buses.
2. Operator Station: It is simply an HMI that enables

the operator to check the operational unit, monitor
Output signals alerts, change parameters such as SP, print reports,
to Field and more.
3. Engineering Station: Used to program the DCS and
design graphical interfaces that will be monitored
by the operator.
PLC HMI DCS SCADA
Basic Loop Examples

Indicator Controller Digital Output Digital Input
PLC HMI DCS SCADA
Operation Windows
Operating interfaces may include the
following windows:
Control Group Window

Trend Window
Process Alarm Window
Operator guide Message Window
Graphic Window
Overview Window
Process Report Window
Historical Report Window
Tuning Window
PLC HMI DCS SCADA
What is SCADA?
SCADA (Supervisory Control And Data
Acquisition) is a type of industrial control
system that is very large systems covering
large areas, linked to PLC and DCS control
units and other HMI monitoring systems in
addition to software systems and analytical
tools.
The purpose of SCADA is to collect important
data from various control systems, and it
does not usually focus on operational
conditions, but is concerned with production,
economy, and important operational matters.
PROCESS AND INSTRUMENTATION
DIAGRAMS (P&ID)
PART #8
8. PROCESS AND INSTRUMENTATION DIAGRAMS (P&ID)
Purpose of P&ID P&ID Symbols Equipment Symbols Piping Symbols Instruments Symbols
Process Flow Diagram (PFD)

Process Flow Diagram (PFD): It is a
diagram that shows the flow of
between the main parts of the unit
and the expected operating
conditions (temperature, flow,
pressure) to obtain the final product..
PFD is placed in the initial design

stages of the system by the Process
Engineer, so it does not contain many
details such as pipe sizes and micro-
machining devices.
Piping and Instrumentation Diagrams (P&ID)

Instruments Department selects the
field devices and gives each of them a
tag for the purpose of distinguishing
them.
The selected devices, in addition to the

details of the piping, are drawn on a
diagram called P&ID, which is similar to
the PFD diagram in terms of containing
the basic parts of the unit, but it
contains much more details because it
contains pipes, manual valves, and
precise machinery devices located and
linked to the control
Tag
The Tag is placed in a certain way so that it gives information about the thing assigned to it, for example if the
Tag is FIC 104
FIC 204 : Tag Number
FIC 204 : Loop Number
FIC 204 : Function
FIC 204 : First Letter
FIC 204 : Succeeding-Letters
Sometimes the tag contains other letters or numbers, such as:
30-FIC-204A : Tag Number

30-FIC-204A : Tag Number
30-FIC-204A : Optional Prefix
30-FIC-204A : Optional Suffix
Tag
Information about a specific Tag can be found using a special table as shown below:
P&ID Legend and Symbols
The symbols used in P&ID are

subject to a specific standard.
Nevertheless, companies give all
the symbols used and are placed
on the first page of P&ID and are
called P&ID Legend and Symbols
Piping & Connection
Purpose of P&ID P&ID Symbols Equipment Symbols Instruments Symbols
Symbols
Indicator Symbols
Valve Symbols
Valve Failure mode Symbols

WIRING DIAGRAM
PART #9
9. WIRING DIAGRAM
P&ID vs Wiring Diagram

P&ID diagrams show the signal path and give an overview of all loops in the operational unit.
Wiring Diagrams show in detail how the signals are connected to the Control System.
9. WIRING DIAGRAM
Wiring Diagrams are divided

into two main parts:
1. Field
✓ Process Area
✓ Junction Box
2. Control Room
✓ Marshaling Cabinet
✓ System Cabinet
✓ Sometimes there are other
divisions such as Control
Function and others
9. WIRING DIAGRAM
There are other variations of

Wiring Diagrams, depending
on the company that
designed them, but the main
idea is the same.
9. WIRING DIAGRAM
The meanings of all symbols

to be used in Wiring Diagrams
are given on a special page
called Legend.
Some icons may vary

depending on the designing
company.
9. WIRING DIAGRAM
Dealing With Wiring Diagram

The current and subsequent page
numbers (or the total number of pages)
are placed at the bottom of the layout.
32.1 That is, the At the top and bottom of the paper there
link is on page 32
are divisions that help keep track of the
in the first
section charts more easily.
If the element is linked to another page,

the location of the link is determined by
mentioning the page number followed by
9 That is, the link
is on the same
the division number.
page in the ninth
division If the element is linked on the same page,
the division number is sufficient.
PART #10
SAFETY
10.SAFETY SYSTEM
Introduction
Part of the work of IC is to protect the

equipment and operating units by stopping them
in whole or in part, or in any other way that
prevents harm to people and equipment, and
this process takes place without the intervention
of the operator.
These systems are called Safety Instrumentation

System (SIS) and the most common types are:
✓ ESD (Emergency Shutdown System)
✓ FGS (Fire and Gas System)
✓ BMS (Burner Management System)
ETC.
10.SAFETY SYSTEM
Introduction
The control system represents the first line of

defense as it alerts the operator to abnormal
conditions and takes some measures such as
stopping a pump or controlling a specific valve to
avoid the growing danger.
If conditions get out of control, posing a danger to
people and equipment, the protection system
automatically intervenes to prevent the danger.
There are special organizations to monitor the
leakage of toxic gases and the occurrence of fires,
working to issue alerts and control valves and other
equipment to prevent the exacerbation of the
danger by directing flammable materials to other
places.
10.SAFETY SYSTEM
Introduction
All parts of protection systems

(transmitters, PLCs, valves, etc.) are of high
reliability and must be certified by certain
companies such as TUV.
In modern designs, the elements of the

protection system, such as transmitters
and valves, are separated from the
elements of the control system. For this
reason, you can find two pressure
transmitters, for example, connected to
the same tank, or you can find two valves
located on the same pipe and only a short
distance separates them.
10.SAFETY SYSTEM
Introduction
A special programming method is used for

protection systems.
Protection systems must be of high speed

compared to DCS, so a special PLC is usually used.
Protection systems are usually redundant.
The protection system is usually connected to the

control system via a communication protocol for
the purpose of displaying data on the HMI.
The protection system is synchronized with the

control system.
10.SAFETY SYSTEM
Introduction
All details must be taken into account when dealing

with control and protection devices, for example in the
adjacent figure, the controller increases the valve
opening when the temperature measured by the
transmitter decreases.
But if a problem occurred in the transmitter sensor, for
example, and it was programmed to give zero (3.8mA)
at the time of failure, then the controller will increase
the valve opening because it believes that the
temperature has decreased and must be increased. And
because the transmitter is idle, the valve opening will
continue to increase and may lead to damage to the
oven and people.
Therefore, the transmitter must be programmed to give
an Up-scale in the event of a malfunction.

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Instrument & Control Devices

Course Duration Ten days (two hours per day)

Rest 10 min after the 1st hour

Phone Allowed, but silent

Opinions All Respected ☺

4. Control Room Devices

7. Modern Control System

8. Piping and Instrumentation Diagrams (P&ID)

Instrumentation :is the science of measurement and control.

• To control a particular variable, it must first be 2. Transmit

• The signal then sent to the Final Controlling Device.

Manual Operation Automatic Operation

There are other variables that are

Filed or Site : it’s

Control Room : It’s

Control Room Field or Site

Pressure Measurement Devices

Level Measurement Devices

Temperature Measurement Devices

Flow Measurement Devices

Control Room Devices

Control Room Devices

1. Junction Box (JB)

The cables that connect the Field and JB

A branch cable usually consists of a

The cables between the control room

1. Junction Box (JB)

Marshalling System Marshalling

1. Resistance Temperature Detectors (RTD)

1. Resistance Temperature Detectors (RTD)

An approximate equation for calculating heat

The most commonly used α value is 0.003902

1. Resistance Temperature Detectors (RTD)

The real temperature is zero because the resistance is

1. Resistance Temperature Detectors (RTD)

4wire RTD can be used to obtain a more accurate reading,

Some temperature sensors contain

The bimetallic piece is called a Thermocouple.

To measure the temperature by TC, we first

These points are called Cold Junction because they

Pressure is the normal force applied per unit area.

Pressure = Force / Area

1 kg/cm2 = 15 psi approximately.

Absolute pressure: The reference is absolute

Any pressure less than atmospheric pressure

Mechanical pressure elements

Diaphragm: It is a metallic disc that flexes when

It takes advantage of the mechanical movement

Direct Sensing method: where the level is measured

Indirect Sensing: where a characteristic of the liquid

Measuring the level at a specific point: Sometimes it is

Level Gauges Glass (LG)

Glass scales are of two types:

• Reflux Gauge: The glass is in the form of prisms and is

Magnetic Level Gauges (LG)

Magnetic Level Gauges It consists of a

That is, the liquid level is proportional to the

Open Tank Measurement