PROCESS

CONTROL...
Submitted by :
Gagan Sharma
2017-128
 CONTENTS

Foundation Fieldbus & FF Field

Instruments
Delta-V Control Studio (Software)
Example of Programming (Software)
Function Blocks
Foundation
Fieldbus
 Foundation Fieldbus

 Introduction
 FF Field Instruments :
 Mass Flow Meters
1. Coriolis Meter
2. Direct Mass Flow Meter
 Temperature Transmitters
1. Rosemount 648 Wireless Temp. Transmitter
2. 3144P Temperature Transmitter
3. 3244MV Temperature Transmitter
 Flow Measurement
 Differential Pressure Flow Meter
 INTRODUCTION….

What is 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.
 What is Foundation Fieldbus ?
 H1 (Field Segment) 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 and is therefore the
focus of these courses.
 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.
 What is Foundation Fieldbus ?
• Fieldbus is a network
• Devices sit in parallel between the wires
• Transmission Rate = 31.25 Kbit/s
Fieldbus Segment
Only Digital Communication Signals

Terminator Terminator

Power
Conditioner Monitor/
Control
Fieldbus Power Supply Field Devices
 Theory of Coriolis Mass
Flow Meter
 In a dual-tube meter, a manifold
that connects the two tubes splits
the flow in two and direct it
through each of the two tubes. In
this way, 100% of the flow goes
through the sensor

 The two flow tubes are driven

vibration by a drive coil, thus
rotate around the two fixed end
points. Once there is mass flow
through the tube, there is a Coriolis
effect as shown in the picture.
Theory of Coriolis Mass
Flow Meter Power and Signal
Connection
Drive between sensor
Coil and transmitter

Pick-Off
Coils

Resistance
Thermal
Device (RTD) Transmitter processes
and conditions signals
Flow Tube from pick-off coils.

Process
Connection
 Direct Mass Flow Measurement

No Flow

No Flow Flow
Side View
 Theory of Operations
– Mass Flow
 Three-wire platinum RTD measures
tube temperature on inlet side of
sensor
– Accurate to +/- 1.0oC
– Available as additional process variable

 Flow Calibration factor captures the

proportional relationship between
flow and the measured phase shift
– Same factor for liquid or gas
– Linear over entire range
– Also contains the factor used with the
RTD measurement for temperature
correction
 Density Measurement

Low Density

Time
mV

High Density

Time
mV

As per the theory of spring and mass system, the frequency of vibration is proportional to
the mass. So it is with the flow tube vibration. The higher the combined density (flow tube
and inside fluid), the lower vibration. By detecting the frequency of already known fluid,
we can determine the liner relationship between the frequency and density for any fluids.
 Field bus Temperature
Transmitter

Rosemount 648 Wireless Temperature Transmitter

Rosemount 648 Wireless
Temperature Transmitter
Specifications :
 Electrical Temp. Sensors such as RTDs and
thermocouples produce low-level signals proportional
to their sensed temperatures. The 648 converts the
low –level signal to a wireless enabled signal.
 Operated on 2’c’ size primary lithium/thionyl chloride
batteries.
 Temperature range: -40 to 85º C
 Thermocouple can be directly connected.
 Transmitter will accept a variety of RTD, whether it is
2-wire, 3-wire or 4-wire.
 3144P Temperature Transmitter

 It provides superior accuracy, stability, and reliability. it has

the capability to accept either single sensor or dual sensor
input. Compatible with RTDs and thermocouple.
 Dual sensor input capability allows the transmitter to accept
simultaneous inputs from 2 different sensors, enabling the
measurement of differential temperature, average temperature.
 It is self calibrated.
 Operates on 42 V DC and generates the output 4-20 mA.
3244MV Field bus
Temperature Transmitter
 Provides a robust digital signal
 Reduces wiring costs
 Performs control functions in the field
 Provides temperature measurement diagnostics
 Allows local indication
 Offers user-selectable inputs
o RTDs, Thermocouples, mVs, Ohms
 Offers multivariable capability
 Suitable for Safety and Control applications
 3244MVFF - Best Total
Performance
 Superior Reference Accuracy
 Superior Ambient Temperature Compensation
 Best Long-term Stability
 Reduces sensor interchangeability error
1.50
Sensor Interchangeability Error
1.25
Drift Over Time
1.00
Ambient Temperature Effects
Error (oC)

0.75
0.50
Reference Accuracy
0.25
0.00

Programmable 3244MV with

Transmitter Transmitter-Sensor
Matching
Product Details

Standard Features

 Same Look and Feel as 4-20mA/HART Product

 Same performance as HART 3244MV
 Extra functionality via Fieldbus Electronics
 3 Analog Input (AI) Function Blocks
- 3 of the 4 Transducer Block parameters can be assigned to the AI function blocks
- Transducer Block parameters
- Sensor 1, Sensor 2, Terminal, and Differential Temperatures

 1 Input Selector (ISEL) Function Block

- Used to select any on of the following outputs:
- Hot Backup®, First Good, Average, Minimum, Maximum, or Midpoint Temperature

 Backup Link Active Scheduler (LAS)

- enabled via firmware.
- Can be configured as primary link master
 INTRODUCTION

Measuring Flow is one of the most important aspects

of process control. Infact, it may well be the most
frequently measured process variable in any Process
plant. The Process industries by their very nature deal
constantly with various flowing liquid, gas or vapour.
These Flow are measured, indicated, recorded, totalized
and used for Control and Process Shutdown applications,
per process Needs.

In some operations, the ability to conduct accurate flow

measurements is so important that it can make the
difference between making a profit or taking a loss. In
other cases, inaccurate flow measurements or failure to
take measurements can cause serious (or even disastrous)
results.
 TYPES OF FLOW

Before dealing with the different types of flow meter,

basic characteristics of fluid flow will be considered.

There are three types of flow:

1. Laminar
2. Transient
3. Turbulent
 FORMS OF FLOW

In Laminar flow the fluid particles

travel parallel to the pipe walls and
there is very little radial movement,
the fluid may be considered as
being in concentric layers.

In Transient to turbulent
conditions, light layers are
beginning to break up and layers
have started to intermingle.

In Turbulent flow the layers have

disappeared and there is
considerable radial motion. On
process plant, flow is usually
turbulent.
 Types Of Flow Meter

 Of the many devices available for measuring flow, the type of device
used often depends on the nature of fluid and the process conditions
under which it is measured.
 Numerous types of flow meters are available. In general, the flow
meters
 Can be grouped in to four generic types:

1. INFERENTIAL TYPE FLOW METERS

2. VELOCITY TYPE FLOW METERS
3. VOLUMETRIC TYPE FLOW METERS
4. MASS TYPE FLOW METERS
 Types Of Flow Meter
Inferential flow meters do not measure volume,
velocity or mass, but rather measure flow by inferring
its value from other measured parameters. Examples
of flowmeter technologies that measure inferentially
include differential pressure (also known as Head
meters), Target and Variable area flow meters.

Differential pressure devices uses primary elements

such as Orifices, Venturi tubes, Flow nozzles, Dall
Tubes, Pitot/Annubar tubes for DP Measurement.
 Types Of Flow Meter

 Velocity flow meters utilize techniques that measure the

velocity (v) of the flowing stream to determine the volumetric
flow. Examples of flow meter technologies that measure velocity
include Electromagnetic, Turbine, Ultrasonic, and Vortex
shedding.

 Volumetric flow meters directly measure the volume of fluid

(Q) passing through the flow meter. The only flow meter
technology that measures volume directly is the Positive
displacement flow meter. Positive displacement meters include
Piston, Oval-gear, Nutating-disk, and Rotary-vane types.
 Types Of Flow Meter
 Mass flow meters utilize techniques that
measure the mass flow (W) of the flowing
stream. Examples of flow meter
technologies that measure mass flow include
Coriolis mass and Thermal flow meters.

 Flow computers are often used to

compensate flow measurements for actual
process conditions, such as pressure,
temperature, viscosity, and composition.
INFERENTIAL FLOW METERS

Inferential flow meters include differential

pressure, target and variable area flow meters.
These are the most common types of meter used
to measure flow.

The basic operating principle of differential

pressure flow meters is based on the premise that
the pressure drop across the meter is proportional
to the square of the flow rate. The flow rate is
obtained by measuring the pressure differential
and extracting the square root.
INFERENTIAL FLOW METERS

 Differential pressure flow meters, like most

flow meters, have a primary and secondary
element. The primary element causes a
change in kinetic energy, which creates the
differential pressure in the pipe.
1. Orifice
2. Venturi Tubes
3. The DALL Tubes
4. The Pitot/Annubar Tube
5. Flow Nozzle
 1. ORIFICE
 In practice, the orifice plate is installed in the pipe between
two flanges. Acting as the primary device, the orifice
constricts the flow of liquid to produce a differential
pressure across the plate. Pressure taps on either side of the
plate are used to detect the difference.
 Advantages:

Major advantages of orifices are that they have no moving

parts and their cost does not increase significantly with pipe
size. It is Approved by many standards organizations for the
custody transfer of liquids and gases.
Disadvantages:

 Calls for a process shutdown whenever the plate is to be

removed for maintenance or inspection. Sensitive to a
variety of error-inducing conditions like Precision in the
bore calculations, the quality of the installation, and the
condition of the plate itself determine total performance.
Installation factors include tap location and condition,
condition of the process pipe, adequacy of straight pipe
runs, gasket interference, misalignment of pipe and
orifice bores, and lead line design.

 Other adverse conditions include the dulling of the

sharp edge or nicks caused by corrosion or erosion,
warpage of the plate due to water hammer and dirt, and
grease or secondary phase deposits on either orifice surface
 2. VENTURI TUBES

Principle of operation

 The venturi tube produces a large differential pressure with

smaller permanent pressure loss than the orifice plate. It also has
the advantage of being able to measure flows containing
suspended solids.
 The Venturi lube consists of two conical sections joined by a
short length of parallel pipe. This short pipe is knows as the
throat and the lower of the two pressures is measured here. The
steeper angled cone is the inlet cone and its purpose is to provide
a smooth approach to the throat section. The higher of the two
pressures is measured upstream of this cone.
 Advantages:
i. Venturi tubes have the advantages of being able to handle
large flow volumes at low pressure drops. It can be used
with most fluids, including those having a high solids
content.
ii. Venturis are insensitive to velocity profile effects and
therefore require less straight pipe run than an orifice.
iii. Due to self-scouring action of the flow, the device is
immune to corrosion, erosion, and internal scale build
up.

 Disadvantages:
The initial Cost of venturi tube is very high .
 3. THE DALL TUBE

The Dall tube is a special variation of the venturi designed

to give appreciable pressure differentials with a high
recovery factor, around 95%. At the same time, the overall
length of the Dall tube is very much less than the
equivalent size of the venturi.
The element consists of two cones each of relatively large
included angle, the throat being formed by a slot located
between the smaller diameters of the cones. This
construction has the effect of adding a streamline curvature
head to the normal venturi head. The slot where the lower
pressure is measured, prevents the breakaway of the jet
from the walls of the tube.
 Advantages:

 Greater accuracy.
 Very low head loss
 Decreased physical dimensions and hence less expensive
than venturi.
 Easy to install.

Disadvantages:

 Suitable to clean air gas liquid samples only.

 Cooling chambers needed for steam measurement.
 4. THE PITOT/ANNUBAR
TUBE
Essentially, a pitot tube is a velocity
measuring device . In general, they are
used for investigation work, e.g. to
determine the probable maximum flow for
a permanent metering device, or the
velocity distribution in ventilation ducts,
etc. They are also used for experimental
work.

In suitable circumstances, however, a pitot

tube can be used as a permanent detecting
element.
 Annubar is a Pitot tube, with multiport design,
for improved averaging.
It causes a pressure drop in the pipe as it intrudes
with the process flow.

The flow can be calculated from the differential
pressure reading it produce. Annubars are good
for high flow rate applications, but are not good
for low flow applications due to the small
pressure difference these flows represent. Good
installation, is essential to have good accuracy.
Advantages:

 Pitot/Annubar tubes are low cost, no moving parts,

easy installation, and minimum pressure drop.
 Suited for a variety of environment conditions,
including high temperatures and a wide range of
pressures.

Disadvantages:

 The Pitot tubes are susceptible to plugging by foreign

material in the liquid .
 Accuracy and Rangeability are relatively low.
 Several annubars are required in order to cover a large
flow range as the typical turn down ratio is 10:1. Good
Installation is needed to ensure better accuracy.
 5. FLOW NOZZLE
Flow Nozzles may be thought of as a
variation on the venturi tube. The
Nozzle opening is an elliptical
restriction in the flow but with no
outlet area for pressure recovery.
Pressure taps are located approximately
½ pipe diameter downstream and 1
pipe diameter upstream. The flow
nozzle is a high velocity flow meter
used where turbulence is high.
(Reynolds Numbers above 50,000)
such as in steam flow at high
temperatures.
 Advantages
Flow Nozzles, at High Velocities, can handle
approximately 60% greater flow than orifice
plates having the same pressure drop. Liquid with
suspended solids can be metered.

Disadvantages
Flow Nozzles are not recommended for High
viscous liquids or those containing large amounts
of sticky solids.
 VOLUMETRIC METERS
Volumetric flow meters directly measure the volume of fluid passing
through the flow meter. The only flow meter technology that measures
volume directly is the Positive displacement flow meter.

Positive Displacement Meters

Positive displacement flowmeters operate by repeatedly filling and emptying
compartments of known volume with the liquid or gas from the flowstream.
Flowrate is calculated based on the number of times these compartments
are filled and emptied.

Positive displacement meters include:

Piston, Oval-gear, Nutating-disk, Rotary-vane etc..
Positive-displacement meters are good candidates for measuring the flows of
viscous liquids or for use where a simple mechanical meter system is needed.
 VOLUMETRIC METERS
Oscillating piston flowmeters typically are used in viscous
fluid services such as oil metering on engine test stands.
The measurement chamber is cylindrical with a partition
plate separating its inlet port from its outlet.

The piston is also cylindrical and is punctured by

numerous openings to allow free flow on both sides of the
piston and the post .The piston is guided by a control roller
within the measuring chamber, and the motion of the piston
is transferred to a follower magnet which is external to the
flowstream. The follower magnet can be used to drive
either a transmitter, a register, or both. The rate of flow is
proportional to the rate of oscillation of the piston.
Advantages:
PD meters do not require straight upstream and
downstream pipe runs for their installation . In
clean fluid services, and for gas however, their
precision and wide rangeability make them ideal
for custody transfer and batch charging.

Disadvantages:
The process fluid must be clean. Not
recommended for measuring slurries or abrasive
fluids.
Differential Pressure Flow Meter
 Working principle:

Differential pressure flow meters use Bernoulli's principle to measure the flow of fluid
in pipe. D.P flow-meters introduce a constriction in the pipe that creates a pressure
drop across the flow-meter. When the flow increases, more pressure drop is created.
Impulse piping route the upstream and downstream pressures of the flow-meter to the
transmitter that measures the differential pressure to determine the fluid flow.
 Key benefits
Model 3095MV
 Mass flow rate
 1% of rate accuracy
 8:1 range of measured flow rate
 4 measurements in 1 device (Qm , DP, P, and T)
 Cost savings
 installation
 engineering
 maintenance
 Easy to install and configure with the Engineering Assistant
 Proven technology, low risk
Delta-V Control
Studio
 ABOUT…..

 DeltaV, a distributed control system used in industrial process

control.
 DCS- it is computerised control system for a process or plant
usually with many control loops, in which autonomous controllers
are distributed throughout the system, but there is no central
operator supervisory control.
 The DSC concept increases reliability and reduces installation
costs by localising control functions near the process plant, with
remote monitoring and supervision.
 DCS first emerged in large, high value, safety critical process industries, and were
attractive because the DCS manufacturer would supply both the local control level
and central supervisory equipment as an integrated package, thus reducing design
integration risk. Today the functionality of SCADA and DCS systems are very
similar, but DCS tends to be used on large continuous process plants where high
reliability and security is important, and the control room is not geographically
remote.
 STRUCTURE…

 The key attribute of a DCS is its reliability due to the distribution of control
processing around nodes in the system.
 In this if there is failure of one section the it affects only one section but if the failure
of central computer takes place then the whole processes are being affected.
 This distribution of computing power local to find Input/output connection racks also
ensures fast controller processing times by removing possible network and central
processing delays.
 Typical Applications…
 DCS are dedicated systems used in manufacturing processes that are continuous or
batch-oriented.
• Chemical plants
• Petrochemical industries
• Nuclear power plants
• Water treatment plants
• Automobile manufacturing
• Pharmaceutical manufacturing
• Metal and mines
Example Of
Programming

Configuring Alarms on Option

Bitstring Parameters
 1.With the module open in Control Studio, right-
click in the Alarm View and select Add. The Alarm properties dialog appears.
 2.Select an alarm type.
 3.Enter or browse to the module's MERROR parameter. Because MERROR is a bit
string parameter the Mask button appears next to the Browse button.
 Note -
The Mask button appears only when a bitstring parameter that supports alarming o
n individual bits is selected.
 4.To select the bits that cause the alarm to become active click the Mask... button.
The Alarm Mask dialog opens.
 5.Select the bits you want to activate this alarm. If any of the conditions you select b
ecome active, the alarm becomes active.
 6. Close the Alarm Mask dialog.
 7. Select a Functional classification for this alarm.
 8.If you want operators and other users to have access to alarm help, select the Enab
le alarm help check box.
 This check box adds an Alarm Help tab to the properties dialog. For more informati
on on configuring and using alarm help refer to DeltaV Alarm Help.
 9.On the Advanced tab, enter optional alarm message parameters and set the alarm s
uppression timeout.
 Setting the three alarm suppression timeout fields to zero (0) disables alarm suppres
sion.
 10. Close the Alarm properties dialog.
 The Alarm Mask dialog contains check boxes for all of the
bits of the currently selected parameter.
 The Alarm Mask dialog contains check boxes for all of the bits of the curre
ntly selected parameter.
 FUNCTION
BLOCKS…
The function block is the basic component of a co
ntrol module,
it is the building block of the control module. Each f
unction
block contains standard process control algorithms
(such as PID, Analog Out, and Analog In) and para
meters that customize the algorithm.
o Counter
Generates a discrete output value of True (1) when the count reaches a specified
trip value. The block functions as an increment or decrement counter.
o Off-delay Timer
Delays the transfer of a False (0) discrete input value to the output by a specified
time period.
o On-delay Timer
Delays the transfer of a True (1) discrete input value to the output by a specified
time period.
o Retentive Timer
Generates a True (1) discrete output after the input has been True for a specified
time period. When the reset input is set True, the elapsed time and the output
value are reset.
o Timed Pulse
Generates a True (1) discrete output for specified time duration when the input
makes a positive (False-to-True) transition. The output remains True even when
the input returns to its initial discrete value; it returns to its original False value
only when the output is True longer than the specified time duration.
o Action
Evaluates a single structured text expression when the input value is True. Mathematical functions,
logical operators, constants, parameter references, and I/O reference values may be used in the
expression. Expressions are written using IEC 61131-3 Structured Text. See section 3 for Structured
Text details.

o AND
Generates a discrete output value based on the logical AND of two to sixteen discrete inputs
.

o Bi-directional Edge Trigger

Generates a True (1) discrete pulse output when the discrete input makes a positive (0-to-1, False-to-
True) or a negative (1-to-0, True-to-False) transition since the last execution of the block. If there has
been no transition, the discrete output of the block is False.

o Boolean Fan Input

Generates a discrete output based on the weighted binary sum, binary coded decimal (BCD)
representation, transition state, or logical OR of 1 to 16 discrete inputs.

o Boolean Fan Output

Decodes a binary weighted floating point input to individual bits and generates a discrete output value
for each bit (as many as sixteen outputs).
Thank you