Chapter 7 Introduction to Instrumentation

Control Automtico 3 Curso. Ing. Industrial Escuela Tcnica Superior de Ingenieros Universidad de Sevilla

Summary
Introduction Basic concepts Properties of measurement devices Signals transmission. Process and instrumentation diagrams (P & I). Conventional industrial control schemes

Introduction
Output Controller Reference Act Process Measure

Close-loop operation
3

Components
Manipulated variable Controller Actuator Process Controlled variable

Measurement devices Actuators Communication links Controllers

Measured signals

Sensor/ Transmiter

Summary
Introduction Basic concepts Properties of measurement devices Signals transmission. Process and instrumentation diagrams (P & I). Conventional industrial control schemes

Basic concepts
Measurement of a magnitude: is the estimation of the magnitude of some attribute of an object, such as its length or weight, relative to a unit of measurement. It can be a direct measurement or indirect measurement.
Measurement Measurement

Attribute

Attribute

Ideal

Real

Measurement of a magnitude
Measurement mm V mA

Sensor

Transducer

Transmitter

Primary element (sensor): In contact with process. Transducer: converts one type of energy to another for various purposes including measurement or information transfer. Transmitter: Converts signal Filter and amplification of measurement signal

Summary
Introduction Basic concepts Properties of measurement devices Signals transmission. Process and instrumentation diagrams (P & I). Conventional industrial control schemes

Properties of a measurement instrument

Range: Set of values of the process attribute that can be measured by the sensor. For example 50C-150C. Reach: Difference between the upper and lower limits of the range. For example, 100C. Margin of error: Difference between the measurement obtained from the sensor and the real value of the process attribute. It can be static or dynamic. Accuracy: Maximum margin of error under nominal operating conditions. Absolute value % Reach % Upper range limit % Measured value % Full scale

Properties of a measurement instrument (II)

Dead-zone: Range of variation of the process attribute that
does not produce a change on the measured variable. It is related for example to the static friction. (%Reach).

Repetitivity: The sensor is

able to obtain the same measurement for the same process attribute (%Reach).
Sensitivity
Measurement

Sensitivity: Relation between

the increment of the measured signal and the increment of the process attribute. (slope).

Repetitivity

Process attribute

Properties of measurement instrument (III)

Resolution: Minimum increment in the process attribute that
generates a change in the measurement signal. It is related to the Dead-zone and Sensitivity (Absolute or %Reach) Hysteresis: Maximum value of the difference between the measurements obtained in increasing and decreasing sense. (%Reach) Measurement
Measurement

Linearity Hysteresis

Process attribute

Process attribute

Linearity: Maximum linear approximation error.

Properties of a measurement instrument (IV)

Systematic error: Constant error that affects the
measurement. It can be corrected by calibrating the sensor.

Measuring time: Time needed to obtain a precise

measurement.

Reliability: Mean time between measurement faults. Time of operation: Approximate lifetime of the sensor. Operating conditions: External conditions (temperature,
pressure...) that guarantee a proper functioning of the sensor.

Dynamic properties of the sensor.

How to select a sensor?

Operating conditions
Media: liquid, gas, corrosive, physical properties (viscosity, Reynolds, etc) Temperature, pressure, etc

Range of measurement Measurement errors

Tolerance Dynamic error (Time constant * gradient) Systematic error and drift

Resolution

13

Example
Assume we want to measure the temperature of a liquid that can vary from 200 to 350 C, and we have the following set of sensors:
Sensor A B C D E Range (C) [100 , 400] [100 , 500] [150 , 450] [0 , 400] [100 , 500] Tolerance 2.5 C 1% reach 0.75% upper limit 1% measurement 1.5% full scale

Which one provides the lowest absolute tolerance?

14

Classification of measurement instruments

Energy: Passive: Use the energy from the process. Active: Use of an external energy source. Measurement value: Analog: Measurement takes value on a infinite set of values. Digital: Measurement takes value on a finite set of values. Presentation of the information: Blind: No information is visible. Indicators: The measurement is visible to the operator. Recorders: The measurement is recorded by the instrument. Function: Primary element: In contact with the process. Transmitter: Signal transmission. Transducer: Converts one type of energy to another for various purposes including measurement or information transfer. Controller: Local or remote Actuators

Summary
Introduction Basic concepts Properties of measurement devices Signals transmission. Process and instrumentation diagrams (P & I). Conventional industrial control schemes

16

Signal transmission
Transmission medium:
Pneumatic Electric Radio Optic fiber

Codification:
Analog/Digital Amplitude or frequency modulation Pulse modulation

Pneumatic medium
Physical magnitude: Air pressure Range: 0.2-1 Kg/cm2 (3-15 psig)
Minimum pressure of the link 0.2 Kg/cm2
Allows one to detect link failures Improves transmission speed

Advantages:
Fail-safe link under hard operating conditions Not affected by electromagnetic disturbances Allows to directly control pneumatic actuators (valves)

Pneumatic medium
Disadvantages:
The air is compressible
Slow data transmission. Long delays. Can only be applied to short distance links.

High sensitivity to air conditions

Humidity and dirt Need filters

Need a compressor to operate Hydraulic medium

Physical magnitude: Oil pressure Oil is not compressible: Increases speed and power. More expensive and dangerous (oil is inflammable)

Electric medium
Physical magnitude:
Voltage: 1 5 V, 0 10 V, 0-24 V
Voltage drops in wires may introduce errors in data

Intensity: 4 20 mA
Not affected by voltage drops
mA
Transmisor

Advantages
High speed Low cost Controls electronics devices

Cont

Disadvantages
High sensitivity to electromagnetic disturbances
Interference Protection

Other transmission mediums

Wireless
Long distance radio-links Short distance wireless networks

Optic fiber
Not affected by electromagnetic disturbances High bandwidth Low weight and size High cost

Usual in Process industry

Digital codification
Increases signal to noise ratio

Electric transmission
High amount of electronic components

Pneumatic transmission
Valve actuation

Modern instrumentation and Fieldbus

Modern instrumentation
Include microcontrollers Increased functionality Auto-calibration, auto-diagnosis Network communication Protocols: Hart, RS-232, RS-485

Fieldbus or field bus is an industrial

computer network for real-time distributed control. Advanced protocols (bandwidth, safety,) Profibus, CAN, etc.

DISTRIBUTED CONTROL http://en.wikipedia.org/wiki/Fieldbus

Summary
Introduction Basic concepts Properties of measurement devices Signals transmission. Process and instrumentation diagrams (P & I). Conventional industrial control schemes

23

Process and instrumentation diagrams (PI&D diagrams)

DV

Recalentador
MV

CV

Process and instrumentation diagrams (PI&D diagrams)

Process and instrumentation diagrams are a family of functional one-line diagrams showing hull, mechanical and electrical (HM&E) systems like piping, and cable block diagrams. they show the interconnection of process equipment and the instrumentation used to control the process. They are the primary schematic drawings used for laying out a process control installation in a factory or plant. In the process industry, a standard set of symbols may be used to prepare drawings of processes, for instance the instrument symbols used may be based on Instrumentation, Systems, and Automation Society (ISA) Standard S5.1.

P IT 107 A
Loop First letter Secondar y letters Suffix

Function identifier

Loop identifier

Process and instrumentation diagrams (PI&D diagrams)

1st Letter 2nd Letter Other letters Alarm signal Control signal Differential Primary element Relative High Intensity Time Level Humidity Pressure Radioactivity Speed Temperature Viscosity Weight Math module Position Servo Security Indicator Control station Low Medium Point Register Interrupter Transmission Valve

(ISA) Standard S5.1

A C D E F H

Concentration Conductivity Density Voltage Flow

P IT 107 A
Loop First letter Secondar y letters Suffix

I K L M P R S

Function identifier

Loop identifier

T V W Y Z

Examples of instruments

PDT

LRC

PIC

DT

FY

FFC

ST

TDT

27

Process and instrumentation diagrams (PI&D diagrams)

Pneumatic signal PT LRC 128
014 Connection to process
LR C

Digital instrument

128

PLC

Instrument in process Instrument in control panel Accessible to the operator Not accessible to the operator

Logic controller

Accessible to the operator

SEAL NEUMTICA

Medium

P&I diagrams examples

29

P&I diagrams examples

Cascade Control system

30

P&I diagrams examples

Feed-forward control

31

P&I diagrams examples

32

P&I diagrams examples

33

Esquema de un reactor
Alarma de seguridad por temperatura alta Lazo de Control de Temperatura

Lazo de control de caudal Alarma de seguridad de caudal alto y bajo Lazo de Control de Nivel

Control secuencial de seguridad

Alarma de seguridad por presin alta

Alarma de seguridad por temperatura alta

Lazo de Control de concentracin Lazo de Control de Temperatura

34