Instrumentation Training

Moataz Sherif
I&C Department Manager
Instrumentation Training

● Concept of Process Control

● Process Measurements

● Control Valves

● Introduction to Distributed Control System (DCS) 2

Concept of Process Control

Moataz Sherif
I&C Department Manager
Concept of Process Control

● Introduction

● Process Control Definition

● Basic Elements of Control Loop

● Open Loop and Closed Loop Control

● Sensors and Transducers

● Standard Instrument Signals 4

Introduction

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Industrial Instrumentation

• Instrumentation is the science of automated measurement and

control.

• The first step, naturally, is measurement.

• If we can’t measure something, it is really pointless to try to control it.

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Industrial Instrumentation

Instrument
• Any device for measuring,
indicating, controlling, recording
and adjusting a physical or
chemical property e.g. flow,
pressure, acidity, weight, gas
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concentration, etc.
Industrial Instrumentation

Instrumentation
• A complete set of instruments used to control a process, e.g. refining, oil/gas
production, LNG, LPG, Power Station, etc.
Industrial Instrumentation

Instrumentation Arrangements
• Instrumentation generally includes many arrangements of instruments used to:

➢ Measure

➢ Indicate

➢ Record

➢ Control
Industrial Instrumentation

Process Variables.
• Variable quantities that exist in a process are :
➢ Pressure

➢ Temperature

➢ Flow

➢ Level

➢ Speed

➢ Vibration

➢ Density
Industrial Instrumentation

Instrumentation System
• An instrumentation system may include:

➢ Transmitters ➢ Positioner
➢ Resistance ➢ Switches
Temperature ➢ Control valves.
➢ Detectors (RTD) ➢ Blow down valve
➢ Pressure gauges
➢ Transducers
Industrial Instrumentation

Methods of Measurements
• There are a two basic methods
Direct
➢ Used for local indication only without signal
transmission

➢ For example the Level in a sight Glass.

➢ Pressure Gauges

➢ Temperature Indicators
1
2
Industrial Instrumentation

Methods of Measurements
Indirect
➢ This method of measurement uses various
‘Physical Principles’ of the laws of physics

➢ For example in an RTD, it’s resistance

changes with temperature so by measuring
the resistance of the RTD we can Indirectly
measure the temperature of a process.
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Industrial Instrumentation

• Once we measure the quantity we are interested in, we transmit a signal

representing this quantity to an indicating or computing device where

either human or automated action then takes place.

• If the controlling action is automated, the computer sends a signal to a

final controlling device which then influences the quantity being measured. 14
Instrumentation in oil & gas

• Common applications of oil and gas instrumentation include monitoring

the presence of flammable and combustible gases in production and

storage areas and monitoring emissions for pollution control.

• Instrumentation is also used for monitoring and controlling flow in

delivery systems. 15
Instrumentation Engineer Role

Instrumentation engineer can work in one of the following:

• Maintenance Engineer

• Sales / Sales Service / Technical Sales Engineer

• Project Engineer
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• Design Engineer
Instrument Maintenance Engineer Role

• Maintenance and Troubleshooting Techniques

• Technical Knowledge and Experience
• PO Release & Acceptance
• Spare Parts
• Management of Upgrades
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• On-Job Training
Control System

• A system which responds to input

signals from the process and/or
from an operator and generates
output signals causing the process
to operate in the desired manner.
• The control system include
● Input devices
● Controller
● Final elements Definition from IEC 61511-1 18
Control System

Control system choice depends on

● Purpose.

● Equipment Under Control (EUC).

● Scale.

● Available technology.

● Cost.
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● Technical support.
Control System

Control system can be Control system can used as a

• Pneumatic • Basic Process Control

• Electric System

• Electronic • Safety Instrumented System

• Programmable Electronic • Combined BPCS-SIS

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Basic Process Control System

• Basic Process Control System (BPCS) is a system which responds to

input signals from the process, its associated equipment, other

programmable systems and/or an operator and generates output
signals
• causing the process and its associated equipment to operate in the

desired manner but which does not perform any safety instrumented 21

functions with a claimed SIL ≥ 1

Pneumatic Control System

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Programmable Logic Control (PLC)

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Turbo machinery Control System

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Boiler Control System

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Process Control Definition

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Process Control Definition

• A process is broadly defined

as an operation that uses

resources to transform inputs
into outputs.
• It is the resource that provides

the energy into the process for 27

the transformation to occur.

Process Control Definition

• Each process exhibits a particular dynamic (time varying) behavior that

governs the transformation.
• That is, how do changes in the resource or inputs over time affect the
transformation.
• This dynamic behavior is determined by the physical properties of the
inputs, the resource, and the process itself.
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Process Control Definition

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Terminology:

• The manipulated variable (MV) is a measure of resource being fed

into the process, for instance how much thermal energy.
• A final control element (FCE) is the device that changes the value of
the manipulated variable.
• The controller output (CO) is the signal from the controller to the
final control element. 30
Terminology:

• The process variable (PV) is a measure of the process output that

changes in response to changes in the manipulated variable.

• The set point (SP) is the value at which we wish to maintain the

process variable at.

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Process Control Definition

• Process control is the act of controlling a final control element to change

the manipulated variable to maintain the process variable at a desired set

point.
• A corollary to our definition of process control is a controllable process

must behave in a predictable manner.

• For a given change in the manipulated variable, the process variable must
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respond in a predictable and consistent manner.
Basic Elements of Control Loop

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Basic Elements of Process Control

Controlling a process requires knowledge of four basic elements:

• the process itself

• the sensor that measures the process value

• the final control element that changes the manipulated variable

• the controller. 34
Basic Elements of Process Control

• Input devices used to see what’s

going on in the process

• Control Systems make decisions

based on process inputs, operator

inputs, and control software
• Output devices control the

process
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Basic Elements of Process Control

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Open Loop and Closed Loop Control

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Open Loop Control

• The open-loop control is where output variable does not have any

influence on the input variable.

• In open loop control the controller output is not a function of the

process variable.
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Open Loop Control

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Open Loop Control

• the controller output is fixed at a value until it is changed by an

operator.
• Many processes are stable in an open loop control mode and will
maintain the process variable at a value in the absence of a
disturbances.
• Disturbances are uncontrolled changes in the process inputs or 40

resources.
Example for Open Loop Control

41
Example for Open Loop Control

• A system consists of the "valve" with the output variable "volumetric

flow" and the input variable "control valve setting".
• This system can be controlled by adjusting the control valve. This
allows the desired volumetric flow to be set.
• if the applied pressure fluctuates, the volumetric flow will also
fluctuate. 42

• In this open system, adjustment must be made manually.

Example for Open Loop Control

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Closed Loop Control

• process where the controlled variable is continuously monitored and

compared with the reference variable.

• Depending on the result of this comparison, the input variable for the

system is influenced to adjust the output variable to the desired value

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despite any disturbing influences.
Closed Loop Control

• Closed loop control is also called feedback or regulatory control.

• The output of a closed loop controller is a function of the error.

• Error is the deviation of the process variable from the set point and is
defined as

E = SP - PV
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Example for Closed Loop Control

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Closed Loop Control

• The controller now passes a signal to the manipulating element dependent

on the deviation.
• If there is a large negative deviation, that is the measured value of the

volumetric flow is greater than the desired value the valve is closed further.
• If there is a large positive deviation, that is the measured value is smaller

than the desired value, the valve is opened further.

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Example for Closed Loop Control

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Closed Loop Control

• Setting of the output variable is normally not ideal:

➢ If the intervention is too fast and too great, influence at the input
end of the system is too large. This results in great fluctuations at
the output.
➢ If influence is slow and small, the output variable will only
approximate to the desired value. 49
Sensors and Transducers

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Sensors and Transducers

• A sensor is a device that has a characteristic that changes in a

predictable way when exposed to the stimulus it was designed to

detect.

• A transducer is a device that converts one form of energy into

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another.
Sensors and Transducers

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Sensors and Transducers
Classification of Transducers

• Active and Passive Transducers.

• Primary and Secondary Transducers.

• Analog and Digital Transducers.

• Transducers and Inverse Transducers.

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Active and Passive Transducers

• Doesn’t need external Power Supply.

• Self-generation
• Ex. Solar cells and Thermocouples

• It needs external Power Supply.

• It depends on passive elements
(R,L,C).
• Position Transducer 55
Primary and Secondary Transducers

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Transducer and Inverse Transducer

Physical Electrical
Transducer
Quantity Output

Electrical Inverse Mechanical

Signal Transducer Output

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Sensors and Transducers

• Primary Sensing Element, or PSE: A device directly sensing the

process variable and translating that sensed quantity into an analog
representation (electrical voltage, current, resistance; mechanical
force, motion, etc.).
• Examples: thermocouple, thermistor, bourdon tube, microphone,
potentiometer, electrochemical cell, accelerometer. 58
Sensors and Transducers

• Transmitter: A device translating the signal produced by a primary

sensing element (PSE) into a standardized instrumentation signal

such as 3-15 PSI air pressure, 4-20 mA DC electric current, Fieldbus

digital signal packet, etc., which may then be conveyed to an

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indicating device, a controlling device, or both.
Sensors and Transducers

• Industrial process control rely on the control of many process physical

quantities that are very important to measure accurately. The basic
quantities are:
 Temperature
 Pressure
 Level
 Flow

• There are many other important quantities like Vibration, speed and 60

analyzers.
Standard Instrument Signals

61
Standard Instrument Signals

• Standard instrument signals for controllers to accept as inputs from

instrumentation and outputs to final control elements are:

• pneumatic

• current loop

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• 0 to 10 volt
Pneumatic Signals

3 to 15 psig

• Before 1960, pneumatic signals were used almost exclusively to transmit

measurement and control information.

• Today, it is still common to find 3 to 15 psig used as the final signal to a

modulating valve.

• Most often an I/P (I to P) transducer is used. 63

• This converts a 4-20 mA signal (I) into a pressure signal (P).

Current Loop

4-20 milliamp

• Current loops are the signal workhorses in our processes.

• A DC milliamp current is transmitted through a pair of wires from a sensor

to a controller or from a controller to its final control element.

• Current loops are used because of their immunity to noise and the

distances that the signal can be transmitted. 64

Current Loop

Output Scaling

• Scale outputs for a one-to-one correspondence.

• Controller output is configured for 0% to correspond to a 4mA signal and

100% to correspond to a 20mA signal.

• The final control element is calibrated so that 4mA corresponds to its 0%

position or speed and 20mA corresponds to its 100% position or speed. 65

Current Loop

Input Scaling

• Scale inputs for a one-to-one correspondence as well.

• Example:

• If we were using a pressure transducer with a required operating range of 0 psig to 100
psig we would calibrate the instrument such that 0 psig would correspond to 4mA
output and 100 psig would correspond to a 20mA output.

• At the controller we would configure the input such that 4mA would correspond to an 66

internal value of 0 psig and 10mA would correspond to an internal value of 100 psig.
0 to 10 Volt

• 0 to 10 volt is not commonly used in control systems because this signal is

susceptible to induced noise and the distance of the instrument or final

control element is limited due to voltage drop.

• You may find 0-10 volt signals used in control systems providing the speed

reference to variable speed drives. 67