Introduction to Instrumentation Basics
Introduction to Instrumentation Basics
• What is Instrumentation?
• Basic Terminologies
• Process & its Control
• Field Instruments & its principles
• Valves & its working
What is Instrumentation?
• Instrumentation is about measurement
and control.
• Transducer(sensor):
Element which converts one form of Energy to Other form.
• Primary Transducer:
Transducerwhich converts the Process parameter to a form
readable by Secondary Transducer.
Eg: Orifice plate
• Secondary Transducer:
Transducer or transmitter which responds to a measured
variable and converts it to a standardized transmission signal which
is a function only of the measurement.
Eg: DP Transmitter
• Signal:
The signal is the event or phenomenon that conveys data from one
point to another.
• Loop:
• Controller:
ANALYSER:
WEIGHFEEDER:
•Controller multiplies the signal from the load cell(belt load,kg/m) with that
from the speed transducer(belt speed,m/s) to get the feed rate.
•The controller then either changes the belt speed or belt load to get the set
feed rate.
CONVEYOR:
Conveyors are used as components in automated distribution and
warehousing. A belt conveyor consists of two or more pulleys, with a
continuous loop of material - the conveyor belt - that rotates about
them. One or both of the pulleys are powered, moving the belt and the
material on the belt forward. The powered pulley is called the drive pulley
while the unpowered pulley is called the idler.
BELTWEIGHER:
•Material flowing over the belt may be weighed in transit using a
beltweigher.A belweigher or belt weigher is a piece of industrial control
equipment used to gauge the mass or flow rate of material travelling over a
conveyor belt.
Process & its Control
• Process Parameters:
- Pressure
- Level
- Temperature
- Flow
Pressure Measurement
• PRESSURE
A force applied to or distributed over a surface. The
pressure (P) of a force (F) distributed over an area(A) is
defined as :
P=F/A
Pg=Pa+Po
where
P g = gauge pressure
Po = atmospheric pressure
Poverpressure = Pgauge
ABSOLUTE PRESSURE
The absolute pressure is measured relative to the absolute zero pressure - the pressure
that would occur at absolute vacuum.
P=Pg+Po
P=absolute pressure,
Pg=gauge pressure,
Po=atmospheric pressure.
D
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F
F
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ATMOSPHERIC PRESSURE
•The atmospheric pressure is the pressure in the surrounding air at or "close" to the surface
of the earth.
•The atmospheric pressure varies with temperature and altitude above sea level.
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Level Measurement
• Some of the most commonly used liquid-level
measurement methods are:
• RF capacitance
• Conductance (conductivity)
• Hydrostatic head/tank gauging
• Radar
• Ultrasonic
Level Measurement
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Flow Measurement
• Principle:
- Flow is measured by measuring velocity through a
known [Link] this indirect method,the flow measured
is the volume flow rate Q.
Q=AxV
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• Service: Clean Liquids, Gases Steam Slurries and Dirty Fluids
• Scale: Square Root
• Accuracy: 1% Full Scale
• Rangability: 3:1
• Permanent Pressure Loss: Low
• Cost: High
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Ultrasonic Flowmeters
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Temperature Measurement
• Temperature:
C = 5/9(F - 32)
F = 9/5 (C ) + 32
K = 273 + C
R = 460 + F
Temperature Measurement
• Types of Temp Measurement:
-R T D
-Thermocouple
-Thermistor
-Thermopile
- Pyrometer
Temperature terminology
Temperature Control Loop
• Temperature Loop Issues:
Fluid response slowly to change in input heat
Requires advanced control strategies
• Feedforward Control
Dis;::!nce Q ◄ - - - --- - - - - - - - - - -
-
--- - - - - - - - - - - - - - - - - -
\
Q TIC
Q j
Cold i)
Water
Steam
Hot
ater
3 5
Temperature Measurement
Technology
Change in RESISTANCE with response to change in
TEMPERATURE
• Example: Thermistors
• RTD (discussed later)
• Thermistors
• Semi-conductors made from specific mixtures of pure oxides of
nickel, manganese, copper, cobalt, and other metals sintered at very
high temperature.
• Used with Wheatstone Bridge which amplifies small change in
resistance - in a simple circuit with a battery and a micro-ammeter.
• Stability
• Linearity Moderate
• Slope of Output Poor (Logarithmic)
Negative
36
Temperature Sensors
RTDs
• What is an RTD ?
- Resistance Temperature Detector
» Operation depends on inherent characteristic of metal
(Platinum usually): electrical resistance to current/low changes
when a metal undergoes a change in temperature.
» If we can measure the resistance in the metal, we know
the temperature!
Platinum
resistance changes
_ with temperature ----1 =====----:::::::=--= -
Series 78,
(Q Series 68 58
Series 65
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38
= 103.90
Temperature Sensors
Thermocouples
What is a Thermocouple ?
- Two dissimilar metals joined at a "Hot" junction
- The wires are connected to an instrument (voltmeter)
that measures the potential created by the
difference between the two ends.
temperature
Process
1irmperatur "40 millivolts!," Tomm
Hot junctionv/ /
'y): e Seebeck yelled in a heat d
e ate.
-
he junction of two dissimilar metals creates
small voltage output proportional to
tem erature!
39
Temperature Sensors
Thermocouples
T2 ► T1
Thermoelectric Voltage 80
vs. T emoerature
c
Chart:
0
Millivolts 40
0 0.000
10 0.591 ->
o
20 1.192 20
-500 .... 500 1000
30 1.801 -20
TYPE E THERMOCOUPLE
Temperature (°C)
40
Temperature Sensors
Thermocouples
Types of Thermocouple
Type J
- Iron/
• White, Red
Constantan
• Oto 760 °C
• Least Expensive TypeT
- Copper/
Constantan
Type K
» Blue, Red
- Chromel /
» -180 to 371 °C
Alumel
» Yellow, Red
» Highly
+ » Oto 1150 °C resistant to
» Most Linear corrosion from
moisture
41
Temperature Sensors
Comparison
Better Stability
- T/C drift is erratic and unpredictable; RTD's drift
predictably
- T/C's cannot be re-calibrated
Greater Flexibility
- Special extension wires not needed
42 - Don't need to be careful with cold junctions
Temperature Sensors
Comparison
43
Temperature Sensors
Comparison
RANGE OFFER
44
Sensor
accessories
Thermowells
• What is a thermowell (T-well)?
- A unit that protects a sensor from
process flow, pressure, vibrations, and
corrosion
- Allows for sensor removal without
process shutdown
- Slows response time (by 5 times)
45
Control
•
Valves
The control valve manipulates a flowing fluid, such as gas, steam, water,
or chemical compounds, to compensate for the load disturbance and
keep the regulated process variable as close as possible to the desired
set point.
• The control valve regulates the rate of fluid flow as the position of the
valve plug or disk is changed by force from the actuator.
• Control valves are valves used within industrial plants and elsewhere to
control operating conditions such as temperature, pressure ,flow, and
liquid level by fully or partially opening or closing in response to signals
received from controllers that compare a "set point" to a "process
variable" whose value is provided by sensors that monitor changes in such
conditions.
• The opening or closing of control valves is done by means of electrical,
hydraulic or pneumatic systems.
CONTROL VALVES:
SUPPLY SUPPLY
AIR AIR
Control Valve Types
LOADING PRESSURE C O N N E C T I O N - . . ._ --r-i
DIAPHRAGM C A S I N G - - -. .. . - 1 c
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CAPABILITY
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Valve Body Types
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Input Output Input Output Input Output Input Output
Module Module Module Module Module Module Module Module
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VNET
VNET VNET
BCV
RLB U S
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MOPL MFCD
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'------1 MAR
•Unlike Personal Computer, PLC does not contain peripherals, such as display or keyboard, that allow
user to directly interact with PLC. In order to facilitate interaction, separate computer is provided,
normally taking form of a standard PC. Through this external computer, operator can re-program PLC,
provide set-points and view trends of process variables that are controlled and manipulated by PLC.
External -
- PLC - Actuator - Process
Computer - l
Sensor
Programmable Logic Controller Architecture
PLC
Power Supply
Microprocessor +
Memory
Operator .
Workstation
-
I Communication Module
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Discrete Output (DO) Module I
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Discrete Actuator
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Analogue Output (AO) Module I
. Analogue Actuator
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Programmable Logic Controller Architecture
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External -
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Computer I
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Actuator -----+ Process
Microprocessor-----+ Output Moduler.-.I
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PLC consists of the following components:
• Microprocessor - This is the brain of PLC. It reads input signals, executes control
program and communicates results (decisions) of control program as action signals to the
outputs.
• Memory - It stores control program that is to be executed at a prescribed
rate.
• Power Supply - This component is used to convert the mains AC voltage to the low DC
voltage (e.g. from 240V AC to 5V DC). This unit powers the processor and the circuits in
the input and output modules.
• Input Module - This component receives information from external devices (sensors). It
contains circuitry that provides electrical isolation and signal conditioning functionalities.
Input module can be analogue input (Al) or discrete input (DI) module. Al module receives
continuously changing signal whose amplitude is proportional to the current value of the
measured process variable. DI module receives discrete/digital (ON/OFF) information from
discrete sensors, for example push button (ON if button is pressed, OFF if button is not
pressed). Note that DI is much more frequently used than Al.
Typical PLCs
PLC Programming
• Collection of data from field devices, which can be sensors, actuators and
controllers.
• Convey any required supervisory control actions back to the field devices.