OGIM Formation

PROCESS INSTRUMENTATION

Training Coordinator: Faouzi BEN SALAH

Monastir, Tunisia May 2014
OGIM Formation
Module Instrumentation _Package 1
PROCESS INSTRUMENTATION

This is a vast subject and hence covered in 6 packages. Each package consists
of 30 to 35 slides and may take 2 to 3 hrs to explain.

Package 1 : Process control.

Package 2 : Pressure & Temperature measurements.
Package 3 : Level measuring instruments, flow measuring instruments.
Package 4 : Final control elements, control valves, air fail-open/close
valves, shut down matrix.
Package 5 : Types of Automatic Controls. On-off control, gap control, split
range control, proportional control, cascade control, ratio control. PLC
Package 6:Troubleshooting.
 Module Instrumentation _Package 1
PROCESS CONTROL

Objectives:
♦ To understand the basic theory of design and principles of
operation of all manual and automatic Process Controllers.
♦ To understand the Loop Diagram of Process Control.
♦ To understand the working of Flow, Pressure, Level and
Temperature Controllers in particular locations .
 Expected Learning Outcomes

1. Awareness:-

♦ Correct and specific reporting of instrumentation problems.

♦ Process troubleshooting with the best help of instrumentation.

2. Underpinning knowledge:-

♦ Basic knowledge of controllers.

3. Developing practical skills:-

♦ Provide support to Instrument Technicians.

Terminology
♦PV ( Process variable) : PV is the process parameter like, flow,
level, pressure, temperature, speed, etc that we measure from a
process( field).
♦SP ( Setpoint) : SP is the desired value of a process parameter set
by the operator to control a process .
♦ Deviation : Also called OFFSET is the difference between the PV
and SP.
♦Output: Normally called for the output signal from a controller
♦Controlled variable : The Process variable that we control In a
process is the controlled variable.
♦Manipulated variable : The variable that we adjust to
control another variable, e.g. controlling the flow of hot water
through a heater to control the temperature of the gas passing
through it. Here the controlled variable is temperature and
manipulated variable is the flow of hot water.
♦Transducers: are used to convert signals from one form to
another form.
♦I / P converter: is a transducer converting the current input
to equivalent air output.
♦P / I converter: is converting air input to equivalent current
output.
Parameters Normally Measured and Controlled in
the Process Industry.
♦ Pressure
♦ Temperature
♦ Flow
♦ Level
♦ Speed
♦ pH, conductivity
♦ Composition, density, BS&W
♦ Dew point
♦ Oxygen content ( injection water)
 Requirements of a Process Control System
♦ To receive information about a process.
♦ To control parameters like flow, temperature,
pressure, level, etc.
♦ To maintain the quality of products.
♦ To operate a process plant safely.
♦ To protect the asset, personnel & environment.
 Sources of Information About a Process

Gauges

Recorders

Indicators

Sight glasses

Audible alarms

Visible alarms (flashing lights)

Types of Process Controls
Manual

♦ With controller

♦ Without controller

Automatic Control System

♦ ON-OFF control system

♦ Gap control system

♦ PID control system

♦ Cascade control system

♦ PLC based control system

Requirements of a Control System

LT

LI
 Requirements of a Control System

♦ Level (process variable) is controlled by opening and closing valves.

♦ When inlet flow to the tank varies, the level varies.
♦ When outlet flow from the tank varies, the level varies.
♦ To maintain the proper level the valve must be adjusted.
♦ It can be done either by an operator or by an instrument.
♦ In modern installations the control is by instruments.
♦ The controller goes into action when there is a process change.
 Need of Automatic Process Control
♦ Manual control is possible only in simple process.
♦ Manual control needs full-time attention of the operator.

♦ Critical control systems cannot be controlled manually.

♦ Manual control is not possible when stations are far away.

♦ Manual control needs more manpower.

♦ On manual control, process will not be steady.

♦ On manual control, the process will not be safe.

♦ It is difficult to maintain product quality on manual control.

 Manual Control (Without a Controller)

This is done by opening and closing the valve manually.

This needs the full-time attention of an operator. Control
will not be steady.
 Manual Control (Without a Controller)

♦ The operator sees the level.

♦ He compares the level with the desired level.

♦ He goes to the valve and adjusts it.

♦ Again he watches the level to see the action is correct or not.

♦ If required again he adjusts the valve.

♦ This is a typical manual control(with out a controller).

♦ Here the operator is the controller.

 Control Loop
A Control loop is the combination of all
the instruments in a particular order to
achieve the monitoring and control of a
process variable.

A Control loop Can Be Either

♦open loop, or
♦closed loop
 Automatic Process Control
A closed loop
Main elements of closed loop

Process
1. Measuring element
4. Final control
element 2. Transmitting element

3. Controller element

Process variable = Manipulated variable + Controlled variable

Control Loop (Automatic Control System)

PV SP

A M
3
1. Primary element
2 2. Transmitter
3. Controller
4. Final control element
4
1
 Working of a Control Loop

♦Primary elements senses the process parameter

fluctuations and supply this signal to the transmitter.
♦The transmitter sends this signal to the controller
normally in the form of current. ( 4 - 20 mA)
♦ Controller then compares the desired ( set point) and
actual values ( PV) and re-adjusts the output as per the
deviation. The out put from the controller also will be
current (4 - 20 mA). This current is converted into
equivalent pneumatic output in the I / P converter
(transducer)
♦This signal is sent to the final control element for final
adjustment of the process parameter.
 Transmitters : These instruments pick up the signal
from the primary element and transmits to the following

Supply 24 volt

Controller

Recorder
4-20 mA current
Indicator

Alarms
Primary element Transmitter
Interlocks

(Note: more details in the next packages).

 Open Loop

Indicator/recorder

♦In the open loop system, control of the process variable

is not done. There is no automatic feedback from the
controller to the process or from the process to the
controller, only we can monitor the process variable and
do the control manually.
FRC (Flow Recorder FRC
Controller)
PV SP

A M

FT

Orifice plate

FCV
 FRC (Flow Recorder Controller)

♦ Flow is measured by a primary element,e.g. Orifice plate, Venturi tube, d/p

cell, turbine meter etc.
♦The measured value is transmitted by a transmitter. This can be either
electrical or pneumatic signal.
♦ The controller receives the measured value (PV). The controller has a setpoint
(desired value). It compares the PV with the setpoint and the output is
readjusted according to the deviation. This can be either electrical or pneumatic
signal.
♦ The signal reaches the flow control valve and adjusts it.
PRC (Pressure PRC
Recorder Controller)

SP PV

A M

PT

Pressure element

PCV
 PRC (Pressure Recorder Controller)

♦ Pressure is measured by a primary element, e.g. Bourdon tube, diaphragm

type, bellows type etc.
♦ The measured value is transmitted to the controller by a transmitter. This can
be either electrical or pneumatic signal.
♦ The controller receives the measured value (PV). The controller has a set
point (desired value). It compares the PV with the setpoint and the output is
readjusted according to the deviation. This can be either electrical or pneumatic
signal.
♦ The signal reaches the pressure control valve and adjusts it.
TRC (Temperature Recorder
TRC
Controller)
SP PV

The TCV is called also

thermostatic valve
A M

TCV
TT

cooler

Thermocouple
 TRC (Temperature Recorder Controller)

♦ Temperature is measured by a primary element, e.g. bimetallic,

RTD, thermocouple etc.
♦The measured value is transmitted to the controller by a
transmitter. This can be either an electrical or pneumatic signal.
♦ The controller receives the measured value (PV). The controller
has a set point (desired value). It compares the PV with the
setpoint and the output is re-adjusted according to the deviation.
This can be either electrical or pneumatic signal.
♦The signal reaches the TCV and adjusts it. This TCV is a 3 way
valve. It will not restrict the flow. It only bypasses the process flow
to control the temperature.
TRC (Temperature Recorder TRC
Controller)
SP PV

A M

Hot medium

TT
TCV
cooler
Cooling medium

Thermocouple
 TRC (Temperature Recorder Controller)

♦ Temperature is measured by a primary element, e.g. bimetallic, RTD,

thermocouple etc.
♦ The measured value is transmitted to the controller by a transmitter. This can
be either electrical or pneumatic signal.
♦ The controller receives the measured value (PV). The controller is having a
set point (desired value). It compares the PV with the setpoint and the output is
readjusted according to the deviation. This can be either electrical or pneumatic
signal.
♦ The signal reaches the TCV and adjusts it. This TCV is a 2 way valve in the
cooling medium.
♦ Temperature of the main process variable is controlled by adjusting the flow
of the manipulated variable.
LRC (Level Recorder Controller) LRC

LT

A M

LI

LCV
 LRC (Level Recorder Controller)

♦ Level is measured by a primary element, e.g. displacer, d/p cell,

capacitance device etc.
♦ The measured value is transmitted by a transmitter. This can be either
electrical or pneumatic signal.
♦ The controller receives the measured value (PV). The controller is has a
setpoint (desired value). It compares the PV with the setpoint and the output
is readjusted according to the deviation. This can be either electrical or
pneumatic signal.
♦ The signal reaches the LCV and adjusts it.
 Gas to flare
Plant shutdown

Surge tank-1 HH Surge tank-2

H
SURGE TANK LEVEL CONTROL LOGIC
N
L
LL

PumpsStandby
shutdown
Pump Start/Stop logic

Pump 1
LCV

Pump2
 Surge Tank Level Control Logic
♦ Two identical tanks connected together.
♦ Both tanks receive liquid.
♦ Gas phase is connected to the flare.
♦ The stand pipe is connected to both tanks.
♦ Both the tank levels will be equal.
♦ When it is around 50% (normal level) the LCV controls the level.
♦ High(H) level initiate alarm & starts the s/b pump.
♦ Low(L) level initiate alarm & stops the s/b pump.
♦ Low low(LL) level initiate alarm & stops both pumps.
♦ High high(HH) level shuts down the entire station.