LUSAKA BUSINESS AND TECHNICAL COLLEGE MANAGEMENT BOARD

LECTURE NOTES

LECTURER: [Link] Katuta COURSE: Electrical Diploma

College: LBTC Subject: Electrical instrumentation
Topic:Designing Instrumentation and Measuring Systems.

Objective(s) At the end of this lesson, students should be able to:

1. Understand the key steps involved in designing instrumentation and

measuring systems.
2. Identify and explain the purpose of essential design documents.
3. Develop instrument design documents.
3. Learn how to develop instrument data sheets and specifications.
[Link] installation and loop drawings for instrumentation systems..

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1.0 DESIGNING INSTRUMENATIONS AND MESAURING SYSTEMS.
Designing of Instrumentation and measuring systems refers to the process of
selecting, configuring, and integrating instruments to measure and control
physical parameters of variable quantities like current, voltage, pressure,
temperature, flow, level, and humidity in an industrial or scientific [Link]
goal or what we intend to achieve in this system is to ensure accurate data
acquisition, reliable control, and efficient process monitoring. Instrumentation
and measuring systems are critical for process control, automation, and
monitoring in industries like manufacturing, power generation, the mining
sector, pharmaceuticals , and chemical [Link] design process
involves careful planning, documentation, and implementation to ensure
accurate measurements and systems reliability. Designing instrumentation
and measuring systems involves several key documentation and design steps,
which are :
i. Instrument Design Documents.
ii. Design for Instrumentation and Measuring Systems.
iii. Production of Instrument Data Sheets.
iv. Production of Instrument Specifications.
v. Production of Installation and Loop Drawings.

1.1 INSTRUMENT DESIGN DOCUMENTS.

Instrument design documents serve as the foundation for the entire
instrumentation system. These documents provide a structured approach to
selecting, installing, and integrating instruments into the process.
Key Instrument Design Documents:
a) Instrument Index (Instrument List): This comprises of a comprehensive
list of all instruments in the project or an industry, it includes the tag
numbers, location, and function of the instrument. For example
Temperature sensor tagged as TS-101 or Pressure Gauge tagged as PG-
202
b) Process and Instrumentation Diagrams (P&IDs): These are graphical
representation of process flow, including instruments, control valves,
pipelines, and control loops. They show the relationship between

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 instruments and processes.
c) Instrumentation Block Diagrams: These display the hierarchy of
instruments connection, from the field instruments to the control systems
( PLCs, DCS, SCADA).
d) Control Narratives & Functional Design Specification ( FDS): These
define the operational behavior of instruments and control loops by
describing how measurements are taken and how control actions are
performed.
e) I/O List (Input/Output List): These list all inputs and outputs for the
control system, specifying whether they are analog or digital signals.
f) Hook-up Drawings: These outline details on how each instrument is
physically connected to the process, including piping, wiring, and
mounting details.

1.2 DESIGN FOR INSTRUMENATION AND MEASURING SYSTEM.

This phase ensure the proper selection, placement, and integration of
instruments for accurate and reliable process measurement and control.
Key Design Considerations:
a) Selection of Measurement Instruments: This is where appropriate
sensors and instruments are chosen based on the process parameters
( temperature, pressure, flow , current, voltage, level etc) considering their
accuracy, range, response time and environmental conditions.
b) Signal Transmission and Processing: This defines the type of signals
whether they are analog or digital signals ( 4-20mA) and the type of
transmission like HART, Fieldbus, Modubus etc, as well as the type of
signal conditioning ( amplification, filtering, isolation).
c) Communication Protocols: The outlines type of communication system
that are used by the sensors or instruments:
i. Wired protocols : HART, Foundation Fieldbus, Modbus RTU
ii. Wireless protocol: WirelessHART, ISA100.
d) Power Supply and Grounding: This specifies stable power sources for
instruments and proper grounding to minimize electrical noise and
interference.

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e) Environmental and Safety Considerations: They outline the compliance
with hazardous area classification like IECEx and protection of
instruments from extreme temperatures, corrosion, and vibrations.

1.3 PRODUCTION OF INSTRUMENT DATA SHEET.

Instrument data sheets is a document that provides detailed technical
specification and essential information about an instrument which is used in a
process control system.
Key Aspects of an Instrument Data Sheet:
a) General Information:
i. Instrument Tag NUmber (e.g TT-101 for temperature transmitter)
ii. Instrument Type ( e.g , Pressure Transmitter, Flow Meter,
Thermocouple)
iii. Manufacture and Model Number
iv. Application ( e.g., Steam Pressure Measurement, Liquid Flow
Monitoring, Power Consumption Monotoring etc.)
b) Measurement & Performance Parameter:
i. Measurement Range (e.g., 0-100℃, 0-10 bar)
ii. Accuracy (e.g., ±0.1% of full scale)
iii. Response Time ( e.g., < 2 seconds)
iv. Output Signal (e.g., 4.20mA), HART. Modubus, Profibus)
v. Calibration Details ( e.g., Factory Calibrated, Field Adjustable)
c) Operating conditions:
i. Process Temperature Range (e.g., -40℃ to 150℃).
ii. Process Pressure Range (e.g., 0-25bar)
iii. Ambient temperature (e.g., -20℃ to 80℃)
iv. Relative Humidity (e.g., 0-95% non condensing)
d) Power & Communication:
i. Power Supply (e.g., 24V DC, 230V AC)
ii. Communication Protocol (e.g, HART, Foundation Fieldbus,
WirelessHART)
iii. Wiring details ( e.g., 2-wire, 3-wire, 4-wire)

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e) Installation Requirements:
i. Mounting Type (e.g., Wall- mounted, Pipe-mounted)
ii. Cable Entry Size ( e.g., M20, ½" NPT)
iii. Required Accessories (e.g., Brackets, Gaskets, Tubing)
f) Certification & Complance:
i. Explosion Proof Rating (e.g., ATEX, IECEx)
ii. Safety Integrity Level (SIL) (e.g., SIL2, SIL3)

Example of an Instrumentation Data Sheet Format

Parameter Specification

Instrument Tag PT-101

Instrument Type Pressure

Transmitter

Manufacturer Emerson

Model Rosemount 3051

Measurement 0-10 bar

Range

Accuracy ±0.1% of full scale

Ouput Signal 4-20mA with HART

Process ½" NPT, SS316

Connection

Ingress IP67
protection

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Power Supply 24V DC

Installation Type Pipe-Mounted

Certification ATEX, SIL2, IEC
61508

Functions of an Instrument Data Sheet.

1. Specification of Instrument Parameter
The data sheet provides detailed specifications of the instrument which
ensures that the correct instrument is selected for the application, preventing
measurement errors and process inefficiencies.
2. Standardization and Compliance
The data sheet ensures that the instrument meets relevant industry standards
such as ISO, ANSI, IEC, ATEX, SIL. This helps engineers and procurement
teams to select instruments that meet safety and operational standards.
3. Procurement and Vendor Communication
A well documented instrumentation data sheet allows procurement teams to
order the correct instrument from the vendors without ambiguity reducing on
procurement errors and ensuring compatibility with system design.
4. Installation and Integration Guidance
It provides essential installation details ensuring correct installation, reducing
risks of instrument failure or inaccurate readings.
5. Electrical and Communication Configuration
It specifies power requirements, wiring details and communicating protocols
which ensures proper electrical connections and system integration,
preventing wiring mistakes and communication failure.
6. Maintenance and Calibration Support
It provides details on calibration procedures, maintenance schedules, and
diagnostic features which helps the maintenance teams perform accurate
calibrations and keep the instrument functioning correctly over time.
7. Environmental and Safety Considerations
It specifies the instrument’s temperature and pressure limits, material

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compatibility, and hazardous area classifications which ensure that the
instrument operates safely in intended environment without failure.
8. Performance Validation and Quality Assurance
The data sheet includes accuracy, response time, repeatability, and drift
specifications, which are crucial for performance validation which helps
engineers verify instrument performance and reliability before commissioning.
Steps taken in the preparation of an Instrumentation Data Sheet
1. Identify the instrument and its application.
This step involves collecting essential information about the process where
the instrument will be used. This includes factors like the temperature,
pressure, viscosity, operating and design conditions, flow rates or level of
measurements, piping and instrumentation diagram (P&IDs) references. This
information is often obtained from process flow diagrams, heat and material
balance, and line list.
2. Define Measurement and performance specification.
Based on the gathered process data, specific requirement for the instrument
are [Link] includes, the measurement range and accuracy,type of
instrument, the required signal output and the environmental conditions.
3. Specify mechanical or process requirement.
This step is essential because it specifics the physical dimensions and
mounting, the material used in the construction of the instrument,
environmental protection like ingress protection (IP) ratings, vibration and
show resistance, pressure and temperature ratings. It also focuses on the
instruments ability to accurately measure and respond to the process
variables like measurement spans, accuracy and precision, response time and
process fluid compatibility etc.
4. Define electrical and communication specifications.
This step clearly details the instrument’s power requirement and electrical
characteristics ensuring the instrument receives the correct power and
operates safely and it also defines how the instrument communicates with
other devices and systems which enable seamless integration with control
systems and data acquisition systems.
5. Outline environmental and safety considerations.

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This step ensures that materials used in the instrument are compatible with
the process fluids to prevent leaks and spills that could harm the
[Link] also provides guidelines for the proper disposal of the
instrument. It also ensures that the instruments are integrated into emergency
shutdown systems where applicable.
6. Document the data sheet and review for accuracy.
Information is organised into clear sections, such as general information,
process data, electrical specifications, and physical specifications. It also
ensures that data is verified against original sources such as vendor catalogs,
technical manuals and process diagrams. It helps in reviewing the data sheet
by qualified personnel who cross-check information against other relevant
documents like process flow diagrams, and equipment specifications.

1.4 PRODUCTION OF INSTRUMENT SPECIFICATION.

This is the process of defining , documenting and standardizing the technical,
functional, and operational requirement of an instrument to ensure it meets
the needs of a specific application. This ensures that the selected instrument
meets the required process, environmental, and safety conditions for efficient
operation. Instrument sepecifications are more comprehensive than data
sheets. Generally specifications are used to ensure that procured instruments
meets project's exact [Link] define the specific requirement for each
instrument, including:
 Performance criteria
 Testing and Calibration procedures.
 Documentation requirements
 Quality control Standards.
 Specifies project requirements.
Key Aspects of Instrument Specification
1. Purpose of Instrument Specification:
a) Defining Requirements: Specifications clearly outline the desired
characteristic, functionality, and performance of an instrument. They also
provide a basis for evaluating whether an instrument is suitable for a
specific application

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b) Ensuring Quality and Consistency: Specifications help maintain consistent
quality across production runs. They establish quantifiable parameters
that can be used for testing and verification.
c) Facilitating Communication: Specifications serve as a communication
tool between manufacturers, suppliers, and users. They provide a
common understanding of the instrument’s capabilities and limitations.
2. Elements of Instrument Specifications:
a) General Specifications: They indicate the model number, manufacturer
and physical characteristic of the instrument. They include the
measurement range, accuracy, and resolution as well as power
requirements and interface options.
b) Performance Specifications: This outlines the instrument’s response time,
measurement uncertainty, repeatability, linearity, stability, sensitivity and
the operating range of an instrument and other performance
characteristics.
c) Environmental specifications: This details the instrument’s operating
temperature and humidity ranges, the vibration and shock resistance, and
protection against dust and moisture. It addresses safety and regulatory
compliance's.
d) Functional Specification: Describes what the instrument is supposed to
do and includes things like the type of measurement it takes, and what the
output signal is.
e) Material Specifications: This indicates the material that is used in the
construction of the instrument. This is very important in situations where
the instrument will be used in corrosive or harsh environments.
f) Safety Specifications: This outlines the safety ratings, and other relevant
safety information.
3. Process of Producing Instrument Specification:
a) Requirement Gathering: The process begins with a clear understanding of
the instrument’s intended application and performance requirement. This
may involve input from engineers, scientists, and other stakeholders.
b) Specification Development: Manufacturers develop specifications based
on their design, testing, and quality control processes. Specifications are

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 typically based on on statistical analysis of a large sample of instruments.
c) Documentation: Specifications are documented in a clear and concise
format, using standardized terminology and units of measurement.
Specification sheets are often provided to customers and are also used
for internal quality control.
d) Documentation: Creating the documentation that clearly states all of the
specifications.
e) Verification and Validation: Instrument specifications must be verified
and validated. This is done through rigorous testing, to ensure the
instrument performs to the specifications that are published.
f) Revision and Updating: Specifications and updated may be revised and
updated as needed to reflect changes in design, manufacturing processes,
or regulatory requirements.

1.5 PRODUCTION OF INSTRUMENT INSTALLATION AND LOOP DRAWINGS.

1.51 Installation Drawings.
Instrument Installation refers to the physical process of setting up and
connecting instruments within an industrial setting. Installation drawings
provide a detailed layout of how instruments and equipment should be
physically installed in a plant or facility. These Include:
a) Location drawings: Show where instruments, panel, and junction boxes
are [Link] include tags, mounting details, and distances.
b) Mounting details: They show brackets, stands, and support structures for
sensors and transmitters.
c) Wiring and Cable routing: Specifies paths for electrical and signal wiring
and indicates cable tray routes and conduit layouts.
d) Piping and Impulse lines: They indicate the connections between
instruments and the process.
e) Instrument loop and interconnection details: Displays signal flow between
senors, controllers, and actuators. Includes I/O (input & output)
assignments and communication protocols.
f) Power supply & grounding: Indicate power distribution and grounding for
safe operation.

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Installation Drawings.

Steps in production of Installation drawings

1. Collect requirements - Understand the system specifications and required
[Link] P&ID (Piping and Instrumentation Diagram).
2. Create layout plans - Use software like Autocad, EPLAN, or SmartPlant to
draft layouts. Draw instrument locations, cable trays, and impulse lines.
3. Include mounting and wiring details - Show the conduit runs, cable trays,
and instrument [Link] wiring paths, junction boxes and power
sources. Label wire numbers, terminal blocks, and communication signals.
4. Review and Approve - Verify drawing compliance with ISA, IEC, and site-
specific standards. Get approval from project engineers and safety teams.

Functions of Installation Drawings

1. Guide for Accurate Installation:
 These drawings offer detailed visual guidance for technicians and
installers, showing the precise placement and connection of
instruments. They specify how instruments should be mounted,
oriented, and connected to piping and electrical systems.

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  They depict wiring diagrams, tubing layouts, and terminal block details,
minimizing the risk of error during installation. This helps to ensure
that signals are transmitted accurately and that instruments function
as intended.
2. Facilitating Maintenance and Troubleshooting:
 When faults arise, these drawings allow technicians to trace signal
paths and identify potential points of failure. They provide a reference
for verifying connections and checking instrument configurations.
 They assist in routine maintenance tasks by providing information on
instrument locations, access points, and connection details.
3. Promote safety:
 They contribute to the development of safe work procedures by
providing detailed information on instruments location and potential
hazards.
4. Enhances communication and Documentation:
 These drawings serve as a common reference point for engineers,
technicians, and operators, facilitating clear communication and
collaboration.
 They create a permanent record of instrument installation, which is
essential for future maintenance, modification, and audits.

1.52 Loop Drawings

Loop drawings are detailed technical diagrams that illustrate the connections
within a specific control loop. They show the connection of field instruments
to control system like PLCs, DCS, or SCADA. A control loop is a system that
maintains a process variable (like temperature or pressure) at a desired
setpoint. Essentially, they show how instruments are interconnected to form a
functional control system.

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Loop Drawings

Contents of a Loop Drawing:

a) Instrument tag numbers - Unique identifiers for each device.
b) Signal flow Representation- Shows how signals travel between sensors,
controllers, and actuators and the signal type whether it analog or digital.
c) Wire and cable details - Specifies wire numbers, terminal blocks, and
junction boxes.
d) Control panel connections - Indicates how instruments interface with
PLCs, DCS, or SCADA systems.
e) Grounding and Shielding - Proper grounding to prevent signal interference
and shielding for noise-sensitive analog signals.
f) Power supply information - Details of voltage levels and grounding.

i. Steps to create a Loop Drawing:

Step 1. Gather required information
 Review P&ID (Piping & Instrumentation Diagram) to understand
the process.
 Identify the instrument loop components (sensor, control system,

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 output device)
 Obtain the I/O list from the control systems.
Step 2. Draft the Loop Diagram
 Draw or Use CAD software like AutoCAD or SmartPlant to
develop the drawings.
 Represent field instruments, junction boxes, and control panels.
 Indicate wiring, terminals blocks, and I/O assignments.
Step 3. Add Electrical and Signal details
 Specify signal types (4-20mA), HART,Fieldbus, Digital).
 Define power supply connections and voltage levels.
 Label terminal numbers, cable IDs, and shield grounding.
Step 4. Review and Approve
 Validate against the control systems design and wiring standards
(ISA 5.4, IEC 61082)
 Cross-check with installation drawings to ensure consistency
 Obtain approval from the engineering team before field
implementation.

Functions of Loop Drawings

1. Detailed Wiring and Connection Information:
 Loop drawings provide detailed wiring diagrams that show the exact
connections between the field instruments ( senors, transmitters,
actuators) and control systems components (PLCs, DCS). They
specify wire type, sizes, color codes, and terminal block locations.
 They clearly indicate the terminal block numbers and connections,
ensuring accurate wiring and minimizing errors.
 They identify signal types (analog, digital, communication protocols)
and signal levels (e.g, 4-20mA, 24VDC).
2. Supporting Installation and Commissioning:
 Loop drawings serve as a guide for electricians and technicians during
the installations phase, ensuring correct wiring and connections.
 They are used to verify the proper functioning of control loops during
commissioning , checking signal flow and instrument calibration.

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3. Facilitating Maintenance and Troubleshooting:
 When problems arise, loop drawings allow technicians to trace signal
paths, identify potential points of failure, and quickly diagnose issues.
 They provide essential information for routine maintenance tasks,
such as calibration checks and component replacements.
 They are sued to determine which wires to test, and where to test
them, when trying to find a problem or fault within a control loop.
4. Documentation and Record Keeping:
 Loop drawings provide a permanent record of control system’s
configuration, which is essential for future maintenance, modification
and audits.
 They facilitate revision control, ensuring that all changes to the control
system are accurately documented.
5. Enhancing Communication:
 Loop drawings serve as a common reference point for engineers,
technicians, and operators, promoting clear communication and
collaboration.

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