Basic Instrumentation

Prepared By:
Scott Craig, Instrument Specialist, QG3&4 Completions / Commissioning Team

July 2008
Reference information provided by: Liptak, B.G (editor in chief), Instrument Engineer’s Handbook: Process Measurement and Analysis;
 Objective
The objective of this presentation is to give operations personnel a general
appreciation of the main elements and devices for process instrumentation and
measurement. We will also look at on site applications and general considerations with
respect to installation requirements on the given equipment.

Within this material we will be looking at the main principles and instrument devices to
accurately measure for:

– Flow
– Level
– Pressure
– Temperature

We will also cover an overview of:

– Distributed Control Systems (DCS)

– Emergency Shutdown Systems (ESD)
– Loop and Function Testing.
– Foundation Fieldbus
 Flow Measurement
Purpose of Flow Measurement
Accurate measurement of flow is essential in many process control applications. These
measurements are used to monitor and control flow rates. The flow measurement, along with
measurements of temperature, pressure, and composition, are used to develop material and
energy balances on processes. Also, in some applications, controlling the feed rate in a particular
upstream process helps to sustain the efficiency and to minimize waste in downstream processing
operations.
Flowmeter Definition
A flowmeter is defined as “A device that measures the rate of flow or quantity of a moving fluid in
an open or closed conduit. It usually consists of a primary device and a secondary device.”
Primary Device Definition – A primary device is defined as “The device mounted internally or externally
to the fluid conduit that produces a signal with a defined relationship to the fluid flow in accordance
with known physical laws relating the interaction of the fluid to the presence of the primary device.
Secondary Device Definition – A secondary device is defined as “The device that responds to the
signal from the primary device and converts it to a display or to an output signal that can be
translated relative to flow rate or quantity. ”

Note: The secondary device may consist of one or more elements as needed to translate the
primary device signal into standardized or nonstandardized display or transmitted.
Flowmeter
 Orifice Plate
Orifice Plate

An orifice plate is the main element within

an orifice meter tube. An orifice plate is the
simplest and most economical type of all
differential pressure flowmeters. An orifice
plate is constructed as a thin, concentric,
flat metal plate. The plate has an opening or
“orifice.” An orifice plate is installed
perpendicular to the fluid flow between the
two flanges of a pipe. As the fluid passes
through the orifice, the restriction causes an
increase in fluid velocity and a decrease in
pressure. The potential energy (static
pressure) is converted into kinetic energy
(velocity). As the fluid leaves the orifice,
fluid velocity decreases and pressure
increases as kinetic energy is converted
back into potential energy (static pressure).
on an orifice plate installation there is a pair
of flanges, upstream and downstream
piping, and a pressure tap. The pressure
taps are located either on orifice flanges or
upstream and downstream of the pipe from
the orifice plate.
 General Considerations
• Orifice plates should be installed in straight runs of pipework 20-25 times the diameter of the pipe
upstream and 5-7 times the diameter of the pipe downstream.

• Orifice plates should be installed with the tagged handle installed in the upstream direction and
the chamfered edge (Bevel) in the downstream direction.

• Orifice plate chamfered edge should be clean, sharp and be at an angle of 45 degrees.

• Orifice plates should be stored / protected accordingly to prevent mechanical damage prior to
installation.

• Orifice plates should be removed from pipework prior to line blowing / flushing to prevent
damage.
 Orifice Tube

HP LP

Flow

HP LP

Flow
 Differential Pressure
Differential Pressure Transmitters

The differential pressure flowmeters output

a nonlinear signal that corresponds to the
square of the flow rate. A change in flow at
a low rate produces a very small signal
change. A change in a large flow rate
produces a much larger signal change. For
example, a small flow rate from 0 to10%
outputs a signal from 0 to 1%; for a large
flow rate, a 90 to 100% flow rate change
outputs an 81 to 100 % signal. A transducer
called a square root extractor is often used
with transmitters. A transducer converts a
square root signal to a linear signal. The
differential pressure transmitter outputs a
signal that is used for control, indication, or
totalization.
 General Considerations
• Transmitters should be mounted in areas which are free from vibration

• The transmitter should be mounted at a convenient height of 4 or 5 feet (1.2 or 1.5 meters)
above grade, platforms or walkways. If this is not possible other permanent
means of access should be provided.

• Impulse lines for remote devices should be as short as possible lines greater than 6 meters
should be avoided.

• For Liquid service impulse lines should slope downward to device (general rule 25cm per
300cm)

• For Gas service impulse lines should slope upwards to device (rule as above)

• Process and manifold valveing should be checked and lined up appropriately before
introduction of process.

• Instrumentation should have appropriate preservation measures attached up to the point of

commissioning
 Level Measurement
Purpose of Level Measurement

The purpose of level measurement is to provide a measured variable representing the height or
material presence within a vessel. Level measurement is essential to the effective control of a
vessel’s process material level. The level control scheme for a vessel requires a level
measurement value. The level measurement value provides the level control scheme either a
quantity, such as a representation of height, or a logical value, such as the on/off condition of a
limit switch that represents the detection of process material presence.

Continuous Level Process Measurements

In continuous level process measurements, a level measurement system can provide a numeric
representation of the current position (height) of the process material’s surface. The numeric
value, sometimes expressed in meters or feet, is based upon a proportion of material currently
sensed by the level measurement system. The level is measured continuously between a lower
reference level and an upper reference level.
 Displacer Level Meter
Torque Tube Displacer

Displacement level measurement is the

most common measurement within the
process industry. A torque tube displacer is
so named because torque due to buoyancy.
Forces acting upon the displacement
element are used to infer a level
measurement. At the top of the torque tube
chamber, the displacer’s buoyancy force is
measured by a torque arm assembly.
As the level in the tank changes, the level in
the external chamber changes. As the level
changes, the buoyant forces placed upon
the displacer changes. Although the small
movement on the displacer appears
insignificant to an observer, the small
movement produces a torque that can be
measured and converted to a level
measurement.
 Level Switch
Level Switch

A Level switch operates on the same

principle as the float in a household flush
toilet tank. Many level switches operate on
this principle. Instead of activating a
mechanical valve, floats activate switches.
The switches, in turn indicate status, control
equipment, such as a pump or control valve.
The control equipment raises or lowers the
level until the switch de-activates, which in
turn causes the control equipment to go to
the desired on or off state.
 General Considerations
• Instrumentation should be mounted in a location free from vibration.

• Items should be installed in location that is accessible.

• For general service, externally mounted level devices housed within a chamber are preferred,
since they permit access for calibration and maintenance.

• Block valves should be located at the vessel connection or on a standpipe so that each
instrument can be isolated.

• Connections between vessels and heavy gauges, controllers, or transmitters should be relieved
of strain by properly supporting such instruments.

• Equipment should only be installed when possibility of mechanical damage is negligable.

• Instrumentation should have appropriate preservation measures attached up to the point of

commissioning
 Pressure Measurement
Purpose of Pressure Measurement

In process measurement, the values of process variables (e.g., pressure, temperature, level, and
flow) in a process operation are continually determined to permit the process operation to be
monitored or, more specifically, to permit the process variables to be controlled (i.e., held at their
setpoints or within their operating ranges).

Effective monitoring depends on accurate measurements of pressure for

the following reasons:

• Pressure values themselves are essential data for monitoring.

• Often, the values of process variables other than pressure are derived from
(inferred from) the values that are measured for pressure.

As an example of inferral from pressure, the value for the level of a liquid in a storage tank can
be derived from the value of the hydrostatic pressure that is exerted by the liquid. As another
example, the value for the rate at which a fluid is flowing through a pipeline can be derived from a
differential pressure value that is produced by an orifice plate.
 Pressure Transmitter
The pressure transmitter has a diaphragm
as pressure receiving part which converts
pressure to strain, and the strain is detected
by semi-conductor strain gage.

The detecting part has full bridge system

which consists of four semi-conductor strain
gages. Electrical signal is obtained from the
bridge circuit that is proportional to the
strain. The signal is converted to direct
current output or DC voltage output by a
signal conversion circuit.

This linear strain is then correlated to the

corresponding pressure.
 Pressure Gauge
Typically, pressure gauges are devices
used for measuring the pressure of a gas or
liquid. The value of pressure is then read
manually at the point location within the
field. This reading is essential from the point
of view that outside operators can
determine if process plant is operating as
intended and providing a visual
representation of the actual pressure in the
system.

The pressure gauge functions by means of

expansion of a Bourdon tube which moves
proportionally to applied pressure.
 General Considerations
• Instrumentation should be mounted in a location free from vibration

• The transmitter should be mounted at a convenient height of 4 or 5 feet (1.2 or 1.5 meters)
above grade, platforms or walkways. If this is not possible other permanent
means of access should be provided.

• Impulse lines for remote devices should be as short as possible lines greater than 6 meters
should be avoided.

• For Liquid service impulse lines should slope downward to device (general rule 25cm per 300cm)

• For Gas service impulse lines should slope upwards to device (rule as above)

• Process and manifold valveing should be checked and lined up appropriately before introduction
of process.

• Pressure gauges should be installed at a stage where mechanical and accidental damage is
negligable.

• Instrumentation should have appropriate preservation measures attached up to the point of

commissioning
 Temperature Measurement
Purpose of Temperature Measurement

Accurate temperature measurement is essential to the process control of distillation,

fractionation, storage, and transportation of intermediate and final products. Additionally,
temperature measurement contributes to greater product yield and better quality processing.
Accurate temperature measurement is essential to maximize the efficiency or throughputs of
processing operations. Measuring and controlling temperature also minimizes the reprocessing of
the product because it does not meet the specification requirements.
 Thermowell
• A thermowell helps protect a temperature
sensor from a process fluid’s pressure,
corrosive or erosive effects, or mechanical
damage from the impact of flowing fluids. A
thermowell is constructed as a sturdy,
metallic, tube-shaped enclosure. Industry
standards, such as ISA S1.2 and ISA S19.3,
define thermowells that permit
interchangeability among bimetallic
thermometers, thermocouples, and RTDs.
The thermowells constructed to these
standards are engineered to give the best
combination of strength and speed of
response. The thermowell is often specified
along with the temperature sensor and
related assemblies to make sure that the
sensor fits within the thermowell.
 Thermocouple

Thermocouples are perhaps one of the

most common devices used in process
control for temperature measurement. A
thermocouple consists of two dissimilar
metal wires fastened together at one end to
form a junction. The junction is called the
“hot” or measuring junction. The opposite
end of the wires can be joined to form a
reference or cold junction.
 Resistance Temperature Detector
RTD
A resistance temperature detector is a
sensor whose electrical resistance change
is a function of temperature change. Certain
materials have been identified that provide a
predictable and stable relationship between
resistance and temperature. Only a few
metals—such as platinum, copper, or nickel
—have those properties necessary to make
an RTD. Platinum is especially suited for
RTD construction.
 General Considerations
• Thermowells are required to be sized accordingly to minimise the effect of damage due to flow
rates (Wake Frequency)

• Thermocouples and RTD’s are required to be fitted inside thermowells.

• Thermocouples / RTD’s should be fully grounded (Touching the bottom) within the thermowell to
ensure correct temperature indication.

• Thermocouple type’s should be selected to match required temperature ranges.

• Cables connected to Thermocouples / RTD’s should be kept clear of process pipework to prevent
damage.

• Instrumentation should have appropriate preservation measures attached up to the point of

commissioning
Typical On-Site Installations
Typical On-Site Installations
Typical On-Site Installations
On-Site Preservation

GOOD
PRESERVATION

BAD
PRESERVATION
 Distributed Control System
Distributed Control Systems (DCSs) are dedicated systems used to control manufacturing
processes that are continuous or batch-oriented, such as LNG production, oil refining and
petrochemicals. DCSs are connected to sensors and actuators and use setpoint control to control
the flow of material through the plant. The most common example is a setpoint control loops
consisting of a pressure sensor, controller, and control valve. Pressure or flow measurements are
transmitted to the controller, usually through the aid of a signal conditioning Input/Output (I/O)
device. When the measured variable reaches a certain point, the controller instructs a valve or
actuation device to open or close until the fluidic flow process reaches the desired setpoint. Large
oil refineries have many thousands of I/O points and employ very large DCSs.

A typical DCS consists of functionally and/or geographically distributed digital controllers and, in
addition to proportional, integral, and derivative (PID) control, can generally perform logic and
sequential control.

DCSs may employ one or several workstations and can be configured at the workstation or by an
off-line personal computer. Local communication is handled by a control network with
transmission over twisted pair, coaxial, or fiber optic cable. A server and/or applications
processor may be included in the system for extra computational, data collection, and reporting
capability.
 Emerson Delta V
Within QG3&4 the DCS system will be Emerson Delta V

DeltaV hardware consists of a variety of input/output modules connected to a digital control

computer located with the I/O modules. This hardware is proprietary. The controllers are attached
to a larger redundant DeltaV plant-wide network which includes the PC-based engineering
workstations and the operator workstations. Redundant hardware at the controller and I/O level is
possible with the DeltaV architecture. Redundant hardware increases overall system availability.
If redundant hardware is used, it is possible to update firmware and while maintaining process
control.

Operator interface
As with all DeltaV applications, the DeltaV operator interfaces run on dedicated DELL PC
hardware and Microsoft Windows XP / Server2003 operating system software. DeltaV Operate is
the application program in the DeltaV suite which presents the interface to the operator and
allows the operator to view and manipulate the process.
DCS Face Plate Displays
 Emergency Shutdown System
Emergency shutdown systems (ESDs) are used to provide for the safe operation of process
plants. Safe operation involves safety of plant personnel and of the community surrounding the
plant as well as plant operation without severe damage to equipment.

ESDs are stand alone systems and provide 1 layer of a multi layer protection system which
provides mitigation of unexpected emergencies in the process plant environment.

ESDs are designed to protect plant equipment . and plant personnel, the environment, and the
community in proximity to plants from potential adverse effects caused by unexpected
emergencies, such as fires, explosions, and hydrocarbon or toxic gas releases. ESDs also
function to isolate hydrocarbon streams entering or exiting plant equipment and facilities, remove
heat input to process heaters and boilers, and de-energize all associated rotating equipment.

ESDs interface with DCS systems via Communication links to all inputs to the ESDs and outputs
from the ESDs can be viewed and manipulated from the DCS.
 TRICONEX
Within QG3&4 the main ESD system will be Triconex

The TRICONEX System is a state-of -the-art fault tolerant controller based on a Triple-Modular Redundant
(TMR) architecture. TMR employs three isolated, parallel control systems and extensive diagnostics
integrated into one system. The system uses two-out-of-three voting to provide high integrity, error-free,
uninterrupted process operation with no single point of failure.
All diagnostic information is stored in system variables and annuniciated with Light Emitting Diode (LED)
indicators. This indication is also re-transmitted back to the DCS system.

Benefits and features of the Triconex.

No single point of failure – The failure of any single component will not affect the correct operation of the
system.

Design flexibility – Applications vary in their design requirements and the system's strength is its ability to be
configured according to the level of safety, availability and system cost required. Simplex and dual I/O
modules allow you to choose between different levels of coverage ranging from simplex to TMR and reducing
overall system cost.

Very high safety integrity – With its TMR architecture and high diagnostic coverage, the TRICON system
achieves Safety Integrity Level 3 as defined in the IEC 61508 Draft Standard on Functional Safety. This
system is also certified by TUV for safety related operation in applications requiring the German Safety
Requirement Class 5.
ESD Face Plate Displays
 Function & Loop Testing
LOOP TESTING

Object:
To prove that the installed instrumentation functions correctly and is operational, ready to hand-over for plant
commissioning
Input Test:
• A simulation of the process variables is applied and read in the control room on the relevant DCS screen.

Output Test:
• The final action e.g CV’s is checked against output settings made at the DCS console for 0,25,50,75 &
100% Output

FUNCTION TESTING

Object:
To prove the functionality of advanced and complex controls, interlocks, IPS Logic, Vendor Control and Overall
System Integrity.

• Function tests consist of simulating the respective systems input’s and then monitoring the resultant
output’s to ensure compliance with the design intent.
 Loop Testing

Input Check:
1. Field technician connects communicator or process simulator to transmitter.
2. Field technician then injects signal appropriate to actual process values.
3. Control room technician monitors and records values on DCS Screen.

Output Check:
1. Control room technician inputs values to DCS (0,25,50,75,100%)
2. Field technician monitors valve movement as inputted by Control room tech.
3. Control room technician monitors feedback, Auxiliaries, etc
Loop Testing by System
 Function Testing

1. Field technician manipulates field device or devices

2. Control room technician monitors Control System / IPS / MARK VI / F&G etc
3. Field Technician witnesses operation of output device or devices
4. Control room technician witnesses feedback and records actions for compliance
with design specification / Cause and Effect etc.
 Function & Loop Testing
Operations Involvement
Testing will take place between field and relevant ITR’s / Control Room

Loop Tests
• 100% Witnessed by Company for Verification and Sign off in Project Completions Database.
• Witnessing by Operations for Appreciation of Loop Testing Process and Familiarisation with DCS
Screens and Actions.

Function Tests
• 100% Witnessed by Company for Verification and Sign off in Project Completions Database.
• Operations included to RFI look ahead for Function Tests to allow the Required Level of
Witnessing and Familiarisation with the Functionality of the Relevant Instrument System.
 Foundation FieldBus
• FOUNDATION fieldbus is an all-digital, serial,
two-way communications system that serves
as the base-level network in a plant or factory
automation environment.
• It's ideal for applications using basic and
advanced regulatory control, and for much of
the discrete control associated with those
functions.
• Two related implementations of FOUNDATION
fieldbus have been introduced to meet
different needs within the process automation
environment. These two implementations use
different physical media and communication
speeds.
• H1 works at 31.25 Kbit/sec and generally
connects to field devices. It provides
communication and power over standard
twisted-pair wiring. H1 is currently the most
common implementation.
• HSE (High-speed Ethernet) works at 100
Mbit/sec and generally connects input/output
subsystems, host systems, linking devices,
gateways, and field devices using standard
Ethernet cabling. It doesn't currently provide
power over the cable, although work is under
way to address this.
 Foundation Fieldbus
Conventional analog and discrete field instruments use point-to-point wiring: one wire pair per device.
They're also limited to carrying only one piece of information -- usually a process variable or control
output -- over those wires. As a digital bus, FOUNDATION fieldbus doesn't have those limitations.

Multidrop wiring. FOUNDATION fieldbus will support up to 32 devices on a single pair of wires (called a
segment) -- more if repeaters are used. In actual practice, considerations such as power, process
modularity, and loop execution speed make 4 to 16 devices per H1 segment more typical. That means if
you have 1000 devices -- which would require 1000 wire pairs with traditional technology -- you only
need 60 to 250 wire pairs with FOUNDATION fieldbus. That's a lot of savings in wiring (and wiring
installation).

Multivariable instruments. That same wire pair can handle multiple variables from one field device. For
example, one temperature transmitter might communicate inputs from as many as eight sensors --
reducing both wiring and instrument costs.

Other benefits of reducing several devices to one can include fewer pipe penetrations (for improved
safety and reduced risk of fugitive emissions) and lower engineering costs.

Two-way communication. In addition, the information flow can now be two-way. A valve controller can
accept a control output from a host system or other source and send back the actual valve position for
more precise control. In an analog world, that would take another pair of wires.

New types of information. Traditional analog and discrete devices have no way to tell you if they're
operating correctly, or if the process information they're sending is valid. As a consequence, technicians
spend a lot of time verifying device operation.
Thanks For Your Time