BASIC INDUSTRIAL INSTRUMENTATION,

PROCESS CONTROL AND AUTOMATION

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INTRODUCTION TO INSTRUMENTATION AND
PROCESS CONTROL
.

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Basic Concept of Instrumentation and Control

Instrumentation and control is the core of industrial

plants, power generation and the majority of

processes, which require a higher level of

intelligence to accomplish producing a variable

product or process. 3
 Basic Concept of Instrumentation and Control
When a process is modified to improve its function, the best and most
economic change of the system is to improve the control and
instrumentation systems.

Quality, quantity and efficiency are directly related to the control and
instrumentation systems.

The efficiency of the controls directly reflects the profitability and

quality of the product and/or service obtained from a process and/or
system. 4
 PROCESS MEASUREMENTS

Fluid pressure

Fluid flow rate

The temperature of an object

The level of fluid stored in a vessel 5

Fluid volume stored in a vessel

Chemical concentration

Machine position, motion, or acceleration

Physical dimension(s) of an object

Count (inventory) of objects

Electrical voltage, current, or resistance 6

PROCESS PLANTS

Petrochemical Plant 7
 Process Control

In the chemical industry, the design of a control system

is essential to ensure:

◦ Good Process Operation

◦ Process Safety

◦ Product Quality

◦ Minimization of Environmental Impact 8

 Process Control
Element of Process Control

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 Process Control
Boiler Water Level Control System

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 INSTRUMENTATION
AND CONTROL
STANDARDS,
DOCUMENTATION AND
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 Instrumentation documentation
Instrument Data Sheet
Instrument Data Sheet is a document containing specification and information of an

instrument device.

It specifies general information of instrument such as tag number identification,

service description, location (line number/equipment number), P&ID number or

drawing number reference, process data (if applicable), calibrated range (if

applicable), material, performance details (such as accuracy, linearity – if

applicable), hazardous certification (for electrical device), accessories required, etc.

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The details of information in data sheet may differ among each types
of instrument such as transmitter, switch, gauge, control valves.

Preparing a data sheet requires some document/drawing references.

The following steps describe the work flow:

P&ID: it provides general information such as instrument tag

number, service description, line number/equipment number, P&ID
number.
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The purpose of instrument data sheet
When the data sheet is completed, it is attached to requisition
which is to be sent to several vendors.

Vendors will offer their quotation with various model and

manufacturer among the offers.

It is an instrument engineer responsibility to evaluate all

quotation and determine which offer is technically acceptable.14
Having been considered its technical and commercial aspects, the instrument is
purchased.

Following the purchase order, vendor will submit supporting document and drawing.

Based on vendor data, instrument data sheet may be updated to accommodate details
to make the data sheet “as-built”.

Finally, data sheet along with its supporting vendor data are stored in library or
document control and will be referred during construction, operation and
maintenance.
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Instrumentation documentation
Specification

ISA FORM 520. 11a

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 Specification

.

ISA FORM 520.17

11a
 Instrument Symbols
.

Instrument Line Symbols 18

 Instrument Symbols
.

General Instrument or Function Symbols 19

 Instrument Symbols
.

Valve body, damper symbols 20

 Instrument Symbols

.

Actuator symbols 21
 Instrument Symbols
.

Symbols for other devices 22

 Instrument Symbols
.

Process symbols 23
 Instrument Tagging

.

Tag number convention 24

 Instrument Tagging

.

Identification letters 25
 Instrument Tagging
.

Typical letter combination 26

Applications of instrument Symbols and Tags

.

Basic neutralizer control system 27

.

Process Flow Diagram 28

Piping and Instrument Diagram 29
 Instrument Hook-up Drawing
Hook-up drawing is a detailed drawing showing typical installation of instrument

in a correct manner so that instrument operates properly (gives accurate indication

and prevent any issued which could potentially affect the measurement such as

liquid trap in gas impulse line).

Hook-up drawing indicates tubing slopes, position of instrument in reference to

process tapping point, scope break between instrument vs piping. Hook-up drawing

also gives information of the requirement of bulk material for each installation. It

also details its specification (size, type and material) and the quantity.

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 INSTRUMENT LOOP DIAGRAM
Loop diagram represents detailed drawing showing a connection from one point to
control system. It could be connection between:
Field instrument to control system (or vice versa)
Signal from Control Panel to control system (or vice versa)

Loop diagram shows instrument and its terminal numbers which are to be
connected, instrument cable number, junction box number, terminal number
assigned for the specified instrument, multi-pair cable and pair number , marshaling
cabinet number, terminal number in marshaling cabinet, control system details. It
also clearly indicates location of each equipment by means of border line as a limit.
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 LOOP DIAGRAM

.

Loop sheet 32
Block diagram

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 INSTRUMENT INDEX
Instrument index is a document containing list of instrument devices

within a plant.

Instrument index shall include tag number of all physical instruments

(e.g. field instrument, physical alarm and indicator) and pseudo

instruments which commonly named “soft tag” (e.g DCS indication,

alarm, controller). 34
 Instrument Index
.

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 CONTROL SYSTEM ARCHITECTURE

Control system architecture depicts the architecture

of the plant control systems and the interface among

the systems required for overall operation of the

process plant.

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 INSTRUMENT TUBING LAYOUT
Instrument Tubing Layout shows routing of instrument tubing according to plant

layout and the location of source and destination points connected by tubing.

In addition, instrument tubing layout shows the details related to instrumentation

tubing such as:

Tubing number/identification

Tubing going up/down

Type of fluid carried inside the tubing 37

 INSTRUMENT CABLE LAYOUT
Instrument Cable Layout shows routing of instrument cables according to plant or

platform layout.

In addition, instrument cable layout shows the details related to instrumentation cable

such as:

Location of field devices to be wired

Location of junction box

Cable number

Cable going up/down 38

 SHUTDOWN LOGIC DIAGRAM
Shutdown logic diagram (also known as ESD logic diagram) shows a

hierarchy of shutdown level within a plant or platform.

Shutdown logic diagram start from telling a big picture of shutdown level,

typically the level starts from 0 continues with the higher number (1, 2, …).

Shutdown logic diagram describes the ‘cause’ that may trigger the shutdown

and the effect that may results once signal is activated.

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 TUBING SCHEDULE
Tubing Schedule is a document containing list of instrument

tubings which serves as impulse line, hydraulic/pneumatic

supply and return line, process tubing such as chemical

injection line, fusible loop.

This document also shows details of tubing required for

connecting between two points. 40

 Cable Schedule
Cable Schedule is a document containing list of instrument cable.

This document shows cable as well as gland required by each instrument or connection.

The information of the cable schedule shall consists:

Cable Number

Cable Type / Specification

Cable Size

Cable Length

Source and destination termination description

Cable gland type and size for each incoming cable 41

 Instrument Schedule

The instrument schedule lists each unit by

mounting position and instrument number.

Also included in the schedule is the control channel,

dimmer, color, and focus.

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PRESSURE MEASUREMENT

Separator pressure control 43

Principle of Pressure Measurement
The Pressure Variable
Pressure in a process is created by liquids or gases pushing out on the sides of Pipelines and vessels.

The pressure of a process can affect the properties of hydrocarbons.

Boiling points will change under different pressures.

Gas-oil separation is affected by pressure.

For this reason, pressure must be accurately measured and controlled.

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Pressure Measurement Devices and
Accessories

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THE ELECTRICAL PRESSURE
TRANSMITTER

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Pressure Switches

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LEVEL MEASUREMENT
.

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 THE DIP STICK

 DATUM LINE

 DIPPING FLANGE

 DIP STICK

 ULLAGE

 WET MARK

 BOTTOM LEVEL

 DATUM LINE

 IN01-029

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SIGHT GLASSES

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Industrial Float Systems

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Radar Transmitter

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Differential Pressure

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TEMPERATURE MEASUREMENT
.

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Concept of temperature measurement
Temperature is a useful measure of the thermodynamic state of an object or

system.

It is a macroscopic description of the aggregate amount of microscopic kinetic

energy in a material.

If two bodies are at the same temperature, they are in thermodynamic

equilibrium with each other; if they were connected to each other, there is no net

flow of heat from one to the other. 55

 Measurement based on resistance
Resistance Temperature
Devices(RTD)
Resistive temperature devices capitalize on

the fact that the electrical resistance of a

material changes as its temperature changes.

Two key types are the metallic devices

(commonly referred to as RTDs), and

thermistors. 56
 Measurement based on radiation
Infrared Temperature Measurement Devices

Pyrometers
Infrared sensors are non-
contacting devices.

They infer temperature by

measuring the thermal
radiation emitted by a material. 57
Bimetallic Temperature Measurement Devices

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 FLOW MEASUREMENT

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PRINCIPLE OF FLOW MEASUREMENT

Flow measurement is critical to determine the amount of material

purchased and sold, and in these applications, very accurate flow

measurement is required.

In addition, flows throughout the process should be regulated near their

desired values with small variability; in these applications, good

reproducibility is usually sufficient. 60

Flowing systems require energy, typically provided
by pumps and compressors, to produce a pressure
difference as the driving force, and flow sensors
should introduce a small flow resistance, increasing
the process energy consumption as little as possible.

Most flow sensors require straight sections of piping

before and after the sensor 61
This requirement places restrictions on acceptable
process designs, which can be partially compensated
by straightening vanes placed in the piping.

The sensors discussed in this subsection are for clean

fluids flowing in a pipe; special considerations are
required for concentrated slurries, flow in an open
conduit, and other process situations. 62
Differential pressure

Orifice Plate 63
Turbine flow meters

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Coriolis meter

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 INTRODUCTION TO CONTROL VALVE
THEORY
CONTROL VALVES

 Control valves are valves used in

pipelines to control operating

conditions such as flow, pressure,

temperature, and liquid level by fully

or partially opening or closing in

response to a process signal.

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Different types of control valves
There are three basic types of three-port valve:

Piston valve type.

Globe plug type.

Rotating shoe type. 67

Piston valves

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Globe type three-port valves (also called
'lift and lay')

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GLOBE VALVES

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Rotating shoe three-port valve

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 INTRODUCTION

 An actuator is a component of
a machine that is responsible
for moving or controlling a
mechanism or system, for
example by actuating (opening
or closing) a valve; in simple
terms, it is a "mover“, a
human, or any other input.
TYPES OF ACTUATORS
 HYDRAULIC ACTUATORS

• Hydraulic systems are used to

control and transmit power. A
pump driven by a prime mover
such as an electric motor
creates a flow of fluid, in
which the pressure, direction
and rate of flow are controlled
by valves.
 PNEUMATIC ACTUATORS

 Pneumatic actuators are the

devices used for converting
pressure energy of
compressed air into the
mechanical energy to
perform useful work.
 Manual Actuators

 Manual Actuators are used in

applications that require a
throttling type of control valve
that can be manually operated and
set. Capable of giving precise
manual throttling control, these
actuators can be used on nearly
all standard globe-style or angle-
style valve body assemblies.
 Electrical Actuators

 Electrical Actuator is an
electromechanical device that
converts electrical energy into
mechanical energy. Most electric
actuators operate through the
interaction of magnetic fields
and current-carrying conductors
to generate force.
Positioner

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Positioner

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 Positioner
A valve positioner relates the input signal and the

valve position, and will provide any output pressure

to the actuator to satisfy this relationship, according

to the requirements of the valve, and within the

limitations of the maximum supply pressure.

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When a positioner is fitted to an 'air-to-open' valve and
actuator arrangement, the spring range may be increased to
increase the closing force, and hence increase the maximum
differential pressure a particular valve can tolerate.

The air pressure will also be adjusted as required to

overcome friction, therby reducing hysteresis effects.

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PROCESS CONTROL

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 INTRODUCTION

 In the chemical industry, the design of a control

system is essential to ensure:

◦ Good Process Operation

◦ Process Safety

◦ Product Quality

◦ Minimization of Environmental Impact 83

What is the purpose of a control system?
 “To maintain important process characteristics at desired targets

despite the effects of external perturbations.”

Processing
Perturbations Plant objectives

Safety
Market
Make $$$
Economy
Environment...
Climate
Upsets...

Control
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What constitutes a control
system? Control

 Combination of process sensors,

actuators and computer systems
designed and tuned to
orchestrate safe and profitable
operation.
Plant

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Process Controllers

The controller consists of:

a measuring unit with an appropriate instrument to measure the state

of process, a temperature transmitter, pressure transmitter or similar.

a input set point device to set the desired value.

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A comparator for comparing the measured value with the set
point, calculating the difference or error between the two.

A control unit to calculate the output magnitude and direction

to compensate the deviation from the desired value.

A output unit converting the output from the controller to

physical action, a control valve, a motor or similar.
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 CALIBRATION

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 INTRODUCTION
Calibration is a comparison between measurements – one of known
magnitude or correctness made or set with one device and another
measurement made in as similar a way as possible with a second device.

The device with the known or assigned correctness is called the standard.

The second device is the unit under test, test instrument, or any of several
other names for the device being calibrated.

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Pressure Gauge Calibration

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Pressure Gauge Parts for Adjustment

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Pressure Transmitter Calibration
 Shownbelow is a Typical Smart Pressure Transmitter. (Rosemount
Model 3051).

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Calibrating the Pressure Transmitter
To calibrate the transmitter follow this procedure :

Isolate the process at the manifold.

Vent the instrument from the manifold (ensuring use of a suitable container to collect any waste

hydrocarbons).

Connect the pressure source (usually a Druck) to the manifold.

Connect the Hart Communicator either at the instrument or in a safe area. Check instrument at

0%,25%,50%,75%,100% rising and falling 93

Make any necessary adjustments using the communicator.

SAFELY reinstate the instrument back online.

Deposit any waste hydrocarbons into the open drain system.

NOTE: If opening any Ex certified enclosures always carry a

calibrated portable gas detector (or as per specific permit
instructions). 94
Pressure Transmitter Calibration

 NOTE: If digital trim is required (due to long term drift) then only a theoretically and practically
experienced technician may perform this with apparatus as shown in the diagram above. 95
TEMPERATURE CALIBRATION

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Electrical Calibration
Electrical Calibration is used for measuring and control instruments which are scaled for
temperature or other parameters.

An electrical signal, precisely generated to match that produced by the appropriate sensor
at various temperatures is applied to the instrument which is then calibrated accordingly.

The sensor is effectively simulated by this means which offers a vary convenient method of
checking or calibration.

However this approach is not applicable to sensor calibration for which various thermal
techniques are used. 97
 CERTIFICATION
Officially recognised (accredited ) calibration laboratories are authorised
to perform certain types of calibration and to issue the appropriate
certificate.

Such calibrations are carried out in accordance with appropriate standards,

for example UKAS in the U.K. and DKD in Germany.

The certificate issued for each sensor will state any calibration error which
is measured at the various test temperatures and also the uncertainties
which exist in the measurement system used for the calibration. 98
Calibration Requirements

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 The Smart Transmitter
.

100
Hart Communicator 375
The 375 Hart Communicator exchanges information
(utilised Frequency Shift Key) with the transmitter
from the C.C.B, the instrument location or at any
intermittent point on the loop (J.Bs etc..).

To facilitate communication the communicator

should be connected in parallel as shown below: 101
Hart Communicator 375

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Flow Calibration

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THANK
YOU 104