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Principles of Instrumentation & Control

Process control uses instruments to monitor process variables and controllers to maintain variables at set values by adjusting manipulated variables. A typical control loop involves a sensor measuring a process variable, which is fed to a PID controller that calculates any difference from the set value and sends a signal to a final control element to adjust the manipulated variable. Common process variables measured include pressure, level, temperature, and flow. Pressure can be measured using various mechanical and electronic transducers while level, temperature and flow each have multiple measurement methods and devices.

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Anjani Ganti
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259 views

Principles of Instrumentation & Control

Process control uses instruments to monitor process variables and controllers to maintain variables at set values by adjusting manipulated variables. A typical control loop involves a sensor measuring a process variable, which is fed to a PID controller that calculates any difference from the set value and sends a signal to a final control element to adjust the manipulated variable. Common process variables measured include pressure, level, temperature, and flow. Pressure can be measured using various mechanical and electronic transducers while level, temperature and flow each have multiple measurement methods and devices.

Uploaded by

Anjani Ganti
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Process Control & Instrumentation

MEROX Block

Process Control Concepts


Process Control is to maintain certain process

variables (PV) of a process at a desired level (Set


Values)
Instruments are used to obtain information about
the process variables (PVs)
Controller ( a software program resident in DCS)
calculates the difference between SV and PV and
accordingly sends a signal, called Manipulated
Value (MV) to final control elements (Valves,
Vanes etc.).

DESIRED VALUE
OR
SET VALUE

Manipulated variable
(MV)

PID
CONTROLLER

P/I Convreter
I/P Convreter

PROCESS VARIABLE(Pv)
OR
CONTROLLED VARIABLE(CV)
OR
MEASERD VARIABLE

SENSOR

Process
FINAL CONTROL ELEMENT

TYPICAL CONTROL LOOP

Process Control Concepts


Automatic Control: Process Variables are

controlled by DCS resident Controller with out the


intervention of an operator except setting of SV
Controller modes include Auto Mode, Man Mode,
Cascade Mode & Computer Mode
Types of Controllers include Feed Back and Feed
Forward
Controller Tuning parameters include P
(Proportional), Integral (I) and D (Derivative) a

Pressure Measurement
Absolute Pressure: Measured over total

vacuum/zero absolute
Atmospheric/Barometric Pressure: Pressure
exerted by Earths atmosphere
Differential Pressure: Difference between two
pressures
Gauge Pressure: Pressure over the atmospheric
Pressure
Hydrostatic Pressure: Pressure exerted by a liquid
column

Pressure Measurement
Line Pressure/Working Pressure/Static Pressure:

Pressure exerted by a flowing fluid on the pipe


surfaces
Dynamic Pressure: Pressure exerted by a flowing
fluid parallel to the flow direction
Vacuum: Pressure below the atmospheric pressure
Compound Pressure: Measured from a reference
which is neither atmospheric nor total vacuum

Mission Statement
A clear statement of your companys long-

term mission. Try to use words that will


help direct the growth of your company, but
be as concise as possible.

Pressure Measurement
Devices
Pressure is a force applied/distributed over a

surface.
Pressure measurement is used for pressure itself,
flow, level and even temperature
All measurement systems consists of :
Primary Element which indirectly/ indirectly in contact
with fluid and interacts with pressure changes
Secondary Element which translates this interaction
into values for use in indication, recording and control

Pressure Measurement Devices


Secondary Elements
Mechanical Transducers

Bellows
Bourdon Tubes
Diaphrams
Force Balanc

Pressure Measurement Devices


Secondary Elements
Electronic Transducers

Variable Capacitance
Variable Reluctance
Vibrating Wire
Variable Resistance

Mechanical Transducers

Level Measurement
Level measurement is divided into two groups:

Direct Level and Pressure-operated


Direct Level Measurement:
Hook type
Sight Glass
Float Gauging

Pressure-Operated Measurement: Use is made of

the fact that pressure does not depend on the


cross-sectional area of a vessel, in stead it depends
on liquid height and density

Direct Level - Level Gauges

Level Gauges
Directing Level reading device
Types : Transparent and Reflux
Transparent type is used for:

Caustic, Acidic, Heavy HC services, High pressure


Coated with protective Mica
Reflux type is used for light services:
Non-corrosive, non-viscous, Clear HC
It has special optical property for clear demarcation

Level Gauges
While commissioning, open the Jerguson

valve partially till the gage is pressured up /


warmed up.
While in service, jerguson valve shall be
fully in open condition
Quarter turn valves for quick isolation
Have special ball-checks for auto shut-off in
case of glass breakage

Closed Vessels Differential


Pressure Approach
h = P /g
In closed vessles, pressure above the liquid affects

the pressure measured at the bottom


To measure the true level, the vessel pressure must
be subtracted.
Making a pressure tap at the top of the vessel and
connecting this to LP side accomplishes this
Dry Leg: If gas is non-condensable
Wet leg: Condensed Liquid introduces error.
Hence calibrated with a reference liquid.

Level Measurement in Closed


Vessels

Temperature Measurement
Temperature is degree of hotness/coldness

on a definite scale
oC = 5/9 (oF 32)
Most reliable methods of measurement:
Bimetallic
Thermocouples
RTD

Temperature Measurement
All temperature gages uses bimetallic principles
Bimetallic Principles:
Metals change in volume in response to temperature
and different metals respond differently to change in
temperature

Its accuracy is not as good as a glass thermometer

Temperature Measurement
Bimetallic Gage
Bimetallic Principles:
Metals change in volume in response to temperature
and different metals respond differently to change in temperature
All temperature gages uses bimetallic principles
Most reliable methods of measurement:
Bimetallic
Thermocouples
RTD

Thermocouples
Summarize

competition
Outline your
companys
competitive advantage

Thermocouples
It is a thermoelectric temperature measuring

device
It is formed by pressing two dissimilar metals in
series
When the junctions are at different tempertures,
emf is generated
Measuring junction/hot junction is inserted into
the medium of which temperature is inserted
Cold Junction/Reference junction is inserted in the
measuring device

Thermocouples -Types
J type:
Iron-Constantan
Low Range

K Type:
Chromel -Alumel
Clean and oxidizing services

E Type:
Chromel-Constantan
Vacuum, mildly oxidising, inert services

T type:
Copper-Constantan
Sub zero termperatures

Others include: B, R, S, W

Resistance Temperature
Detectors
Uses the change in resistance in response to

change in temperature
Resistance depend on metal size and
resistivity of the metal

Flow Measurement
Most commonly used methods for flow

measurement:
Head type
Area Type
Mass Flow Meters

Flow Measurement
Head Type:
A restriction of known dimension is introduced
in the flow line
Thus, pressure drop created, which is measured
Sub-Type:
Orifice &
Venturi

Flow Measurement
Orifice
Orifice may be concentric or eccentric
Orifice plats constricts the flow to produce a
differential pressure
The result is a high pressure upstream and a
low pressure down stream
Dp is proportional to the flow
Orifice meters are inexpensive

Flow Measurement
Venturi
Low Pressure
Highly accurate
Big Size Pipe

Annubar
Uses Pitot Tube
Principle

Flow is proportional
to pressure drop

Uses multiple ports

Flow Measurement
Area Meters:
In head flow meters, the restriction area kept
constant generating a pressure differential
Where as in area meter, a variable area holds
differential pressure constant
Change in area is a measure of flow rate
Ex.: Rotameter

Rotameter- Suitable for low flows

Valves Valve is a variable


Orifice !
Valve Types:

Plug-in-seat
Rotatable Plug
Rotating Vane
Eccentric Rotation
Cage-guided
Deformable Flow Passage

Globe Valve Plug-in-seat

Ball Valve/Plug Valve


- Rotatable Plug
Plug/ball rotated
Through a quarter

of a turn
The ball has a passage

Butterfly valve/ Dampers


Rotating Vane
Quarter turn operated
Leakage prone

Valve Accessories
Actuators: Translates control signal into

action, eg.:Motors, Diaphrams, solenoids,


cylinders
Transducers and Positioners: Convert
electronic signals into pneumatic/hydraulic
pressures that control actuators/valves
Positioner is used when more accurate
positioning of valve steam is required

There are two basic designs of gate valves, inside


screw stem and outside screw stem.
Seating is perpendicular or at right angles to the line
of flow - meets it head on.
Repeated movement of the wedge near the point of
closure, under high velocity flow, may create a drag on
the seating surfaces and cause galling or scoring on
the downstream side.
A slightly opened wedge may also cause turbulent
flow with vibration and chattering of the wedge.

Globe valve seating is parallel to the line of


flow. All contact between seat and disc ends
when flow begins. These are advantages for
more efficient throttling of flow, with minimum
wire drawing and seat erosion.
Globe valves are generally ideal for throttling,
and preferable for frequent operation.

Butterfly Valves are of the quarter turn


family and are so designed because a 90
degree turn of the operator fully opens or
closes the valve.
. In some cases, they may be used for
non-critical throttling applications. They
are lighter in weight than conventional
valves.

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