Chapter 15: Industrial Process Techniques and Instrumentation

Chapter 15: Industrial Process Techniques and
Instrumentation
Chapter 15: Industrial Process Techniques and Instrumentation
Batch Processes
Continuous
Processes
Instrumentation
Measurement Devices (Sensors)

Feedback Loop Interface Instruments
Controllers
Monitoring Instruments
Manipulation Devices
Introduction
Batch Processes
Continuous
Processes
Reporter: Hitoshi Libungan (slides 4-11)

Batch Processes
Batch Processes
CONTROL REQUIREMENTS
DETERMINING THE WEIGHT OF

THE INGREDIENTS WITH A
PRESSURE SENSOR.
USING A LEVEL SENSOR TO

READ THE HEIGHT OF
INGREDIENTS IN THE VESSEL.
CALCULATING THE
VOLUMETRIC FLOW RATE OF A
RADIO MATERIAL BEING FED
INTO THE REACTOR BY USING A
FLOW METER
Batch Processes
TYPES OF BATCH
PROCESSES
MIXING/BLENDING CHEMICAL REACTION SEPARATION POLYMERIZATION
It Is an operation Is the process of Opposite to Is a process in which a

combining two or combining two or more mixing/blending. During large number of molecules
more ingredients materials or reactants to a separation process, are combined to form a
together. form a product. an ingredient is remove product for polymerization
to a mixture. to take place.
Continuous Processes
A LARGE VARIETY OF
PRODUCTS, SUCH AS
PETROLEUM,
CHEMICALS, PAPER,
PLASTIC GARBAGE
BAGS, AND SO FORTH
ARE PRODUCED BY
THE CONTINUOUS
PROCESS METHOD OF
MANUFACTURING
CONTROL REQUIREMENTS
CONTROLLING THE CONTROLLING OPERATING

QUANTITY OF RAW PARAMETERS DURING THE PROCESS
MATERIALS
TEMPERATUR PRESSURE LEVEL FLOW PRODUCT

E COMPOSITION
Figure 15-3: Heat exchanger Figure 15-4 Heat blending process

Figure 15-5: Continuous-process heat exchanger

Instrumentation
Measurement Devices
(Sensors)
Reporter: Jennifer Jumaquio (slides 11-19)

Instrumentation
Instrumentation Devices.
Performs functions of
elements in a closed-loop
automated system.
A separate control loop is

used for each one of several
different variables that must
be controlled.
Instrumentation
MANUAL AUTOMATION
ERROR- REDUCED
PRONE ERRORS
NO DATABASE RE-USE DATA
FOR FUTURE
ACTIONS REDUCES
TIME-CONSUMING MANUAL EFFORT
Instrumentation
BLOCK DIAGRAM OF A CLOSED-LOOP AUTOMATED SYSTEM
Instrumentation
MEASUREMEN CONTROL MANIPULATION

T
PROVIDES INFORMATION MANIPULATION OF
(VARIABLE “BRAIN” OF THE CRITICAL STAGES OF
MEASUREMENT) FOR THE LOOP THE PROCESS TO
HUMAN OPERATOR ACHIEVE DESIRED
OUTCOME
An industrial process loop ..
begins with measuring

variable
needs a reliable sensor


DYNAMIC STATIC
RESPONSE TIME
Amount of time the
sensor needs to
respond to a change
refers to transient of measured
refers to condition of
response of the variable.
instrument when it is
instrument Determined by stable
factors:
design of
sensor
type of variable

LINEARITY
STATIC
ACCURACY
HYSTERESIS
refers to condition of
instrument when it is
PRECISION
stable
SENSITIVITY
∆𝑂𝑈𝑇𝑃𝑈𝑇
=
∆𝐼𝑁𝑃𝑈𝑇
Feedback Loop
Interface Instruments
Controller
Reporter: Aeron Axle Lopez (slides 20-27)

FEEDBACK LOOP INTERFACE INSTRUMENTS
TRANSMITTER TRANSDUCER
CONVERTS SIGNAL FROM USED TO PERFORM SIGNAL-
THE SENSOR INTO A CONVERSION FUNCTION
STANDARDIZED SIGNAL USED WITHOUT REQUIRING LONG
IN PROCESS SYSTEMS. DISTANCE APPLICATION.

ELECTRONIC SIGNALS
A SIGNAL GENERATED BY
ELECTRONIC MEANS.
E.G. VOLTAGE SIGNALS
CURRENT SIGNALS
PNEUMATIC SIGNALS
TRANSMITTER
A SIGNAL GENERATED BY
CONVERTS SIGNAL FROM THE USE OF PRESSSURIZED
THE SENSOR INTO A GAS AND COMPRESSION
STANDARDIZED SIGNAL USED OF AIR.
IN PROCESS SYSTEMS.

I/P
TRANSDUCER
P/I
TRANSDUCER
TRANSDUCER
A DEVICE THAT RECEIVES A
SIGNAL IN THE FORM OF ONE
TYPE OF ENERGY AND CONVERTS
IT TO A SIGNAL IN ANOTHER
FORM.

ANALOG-TO-DIGITAL
I/E
TRANSDUCER
SQUAREROOT DIGITAL-TO-ANALOG
EXTRACTOR
CONTROLLER
Is the element in
closed-loop system that
performs the decision
making function.
Performs as a
Simple On-Off Control
CONTROLLER
TYPES OF CONTROLLERS
PNEUMATIC PANEL-MOUNTED PERSONAL
CONTROLLERS CONTROLLERS COMPUTERS
CONTROLLER
TYPES OF CONTROLLERS
PROGRAMMABLE DISTRIBUTED
LOGIC CONTROLLERS CONTROL SYSTEMS
Monitoring Instruments
Reporter: Jones Macapinlac (slides 28-32)

MONITORING INSTRUMENTS
Indicators are used to display

information for the operator or
technician
Alarms. Their purpose is to warn
the operator or initiate an action if
an undesirable process condition
develops.
Recorders. Information is often

recorded to be read and analyze
at a later date.
INDICATORS
are used to display
information for the
operator or technician.
They show data such as
set point adjustments,
the amplitude and
polarity of an error
signal.
The most modern
method of indication is
the display on a
computer monitor.
ALARMS
Their purpose is to warn

the operator or initiate
an action if an
undesirable process
condition develops.
When a condition falls
outside parameters that
are programmedinto a
controller, it activates
an alarm.
RECORDERS
Information is often
recorded to be read
and analyze at a later
date
sometimes, a large
number of variables
must be continuously
monitored and
controlled.
Manipulation Devices
Reporter: Andrea Manalili (slides 33-41)

MANIPULATION DEVICES
SOLENOID VALVES ELECTRICAL MOTORS CONTROL VALVES
AN ELECTRONIC DEVICE THAT THE MOST WIDELY USED

THE ACTUATING DEVICE
CONVERTS ON-OFF ELECTRICAL
SIGNALS TO ON-OFF FLOW THAT POWERS THE FINAL CONTROL ELEMENT
CONTROL. MECHANICAL LOAD. FOR PROCESS SYSTEMS.
SOLENOID
VALVES
Consists of a coil and a flow
valve through which fluid
passes
Primarily supplied by
programmable logic
controllers or microcontrollers
Typically used in applications
that provide On-Off control.
ELECTRICAL
MOTORS
DC motors are often used in
applications that requires
precise variable speeds with
high-torque capabilities
AC motors are used to power

the majority of machines in
the process industry
CONTROL VALVE
Valve body. The housing that

is a part of the main process
line
Plug. Its position controls the
flow rate by changing the size
of the passage at seat
Valve actuator. Provides the
force needed to overcome
pressure
CONTROL VALVE CLASSIFICATIONS
Sliding-Stem Globe Valves Rotary-Motion Valves
Sliding-Stem Valves
Single- Double- Butterfly Ball

seated seated valve
Knife Sliding
Gate Gate
CONTROL VALVE
CLASSIFICATIONS
Figure 15-23: Single-seated valve Figure 15-27: Knife-gate valve
Figure 15-24: Double-seated valve Figure 25-38: Sliding gate valve

CONTROL VALVE
CLASSIFICATIONS
Figure 15-29: Typical water-type Figure 15-30 Flow diagram for a

butterfly valve ball valve
SELECTING A
CONTROL VALVE
Valve Capacity. Refers to the

amount of material that a
valve is capable of allowing to
pass.
Valve Characteristics. The
relationship of the change in
the valve opening to the
change of flow through the
valve.
Chapter 15: Industrial Process Techniques and
Instrumentation

Chapter 15: Industrial Process Techniques and Instrumentation

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Chapter 15: Industrial Process Techniques and Instrumentation

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Chapter 15: Industrial Process Techniques and

Measurement Devices (Sensors)

Feedback Loop Interface Instruments

Reporter: Hitoshi Libungan (slides 4-11)

DETERMINING THE WEIGHT OF

USING A LEVEL SENSOR TO

It Is an operation Is the process of Opposite to Is a process in which a

CONTROLLING THE CONTROLLING OPERATING

TEMPERATUR PRESSURE LEVEL FLOW PRODUCT

Figure 15-3: Heat exchanger Figure 15-4 Heat blending process

Figure 15-5: Continuous-process heat exchanger

Reporter: Jennifer Jumaquio (slides 11-19)

A separate control loop is

MEASUREMEN CONTROL MANIPULATION

Measurement Devices (Sensors)

An industrial process loop ..

begins with measuring

needs a reliable sensor

Measurement Devices (Sensors)

Measurement Devices (Sensors)

Reporter: Aeron Axle Lopez (slides 20-27)

FEEDBACK LOOP INTERFACE INSTRUMENTS

FEEDBACK LOOP INTERFACE INSTRUMENTS

FEEDBACK LOOP INTERFACE INSTRUMENTS

FEEDBACK LOOP INTERFACE INSTRUMENTS

Reporter: Jones Macapinlac (slides 28-32)

Indicators are used to display

Recorders. Information is often

Their purpose is to warn

Reporter: Andrea Manalili (slides 33-41)

SOLENOID VALVES ELECTRICAL MOTORS CONTROL VALVES

AN ELECTRONIC DEVICE THAT THE MOST WIDELY USED

AC motors are used to power

Valve body. The housing that

Sliding-Stem Globe Valves Rotary-Motion Valves

Single- Double- Butterfly Ball

Figure 15-23: Single-seated valve Figure 15-27: Knife-gate valve

Figure 15-24: Double-seated valve Figure 25-38: Sliding gate valve

Figure 15-29: Typical water-type Figure 15-30 Flow diagram for a

Valve Capacity. Refers to the

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