DURBAN UNIVERSITY OF TECHNOLOGY

DEPARTMENT OF ELECTRONIC ENGINEERING

STUDY GUIDE TO PROCESS INSTRUMENTATION 2

Latest Revision: 2010

SUBJECT: SAPSE CODE:

PROCESS INSTRUMENTATION 2 0808133220 PRSI201

PRE-REQUISITES: ELECTRONICS 2 ELECTRICAL ENGINEERING 2 CAMPUS: STEVE BIKO CAMPUS

1.

METHOD OF ASSESSMENT:

Progress will be monitored by means of two class tests each of one hour duration, practical reports, one assignment, and one three hour final examination. The two class tests and assignment will make up the course mark for which a sub-minimum of 40% will be required for permission to write the final examination. The final mark will then be made up as follows: Course mark Theory Test 1 40% Theory Test 2 40% Practical 10% Assignment 10% ________________________________ Total 40% Examination mark 60% _______________________________________________ Final mark 100%

2.

COURSE PURPOSE:

This second course in process instrumentation serves to introduce the student to the field of instrumentation not covered in the first course. Some of the plant variables are covered. It must be remembered that the first two courses form the basis for all further study towards the diploma in instrumentation and control. This course is descriptive in nature and some sections are coupled with calculations. Where possible, practical work is used to backup the theory. Students are expected to make use of the extensive library facilities as many books in the field of instrumentation and control are available.

3.

LECTURER:

The lecturer for this course is Mr. Trevor Pillay. Office S8 414, Phone (031) 373 2888

4.

COURSE DURATION:

The course extends over one semester of study and is presented as three theory lectures per week and two practical periods per week.

5.

PRACTICAL ATTENDANCE:

90% practical attendance is compulsory and practicals are treated the same as a test or exam .A learner who for any reason is absent from a particular test, assessment, or scheduled laboratory period, must provide acceptable proof of his/her reason for absence to the lecturer concerned within two (2) days of his/her return to classes. Failure to provide proof of acceptable reasons for absence shall result in a zero mark for the practical component of the course mark as per rule BT5 (Departmental Rules: General handbook.) A sub-minimum of 50% shall apply to the practical component as per rule BT8 (Departmental Rules: General handbook.) 5.1 1. 2. 3. 4. 5. Lab Rules No eating or drinking in the laboratories (including the chewing of gum). Closed shoes are to worn at all times (slip-slops, bare feet and open shoes are not allowed). No cell phones may be used while in the laboratories. No unsupervised access is allowed in any of the laboratories. Permission must be given before entering a laboratory. Students are required to bring their own tool kits including breadboards to their practical sessions.

6.

TEST DATES: Test 1 Test 2 Date: TBA Date: TBA Venue: TBA Venue: TBA Time: TBA Time: TBA

7.

BOOKS:

The prescribed book for this course is: van Vuuren, G, An Introduction to Process Instrumentation, 3rd Edition. Quad Technologies, Durban, 2002. Students should also make use of the extensive range of instrumentation books in the Campus library. Several reference books will be found to be most useful, especially: 1. 2. Liptak, B G, Instrument Engineers Handbook Considine, D M, Process Instruments and Controls Handbook

8.

DATA SHEET:

A data sheet is provided for use in all class tests and the main examination. This data sheet gives basic physical data as well as a list of the important equations that are used during the Process Instrumentation course. A copy of the data sheet can be found attached to this document.

9.

SUBJECT SYLLABUS:

9.1

Process Control Basics Introduction terms and definitions On / off control Continuous control PID Transmission Signals / Telemetry Introduction Analogue signals Pressure, voltage, current, frequency + standards Loop powered instruments Signal conversion + calcs Digital signals / networks RS232, RS485, TCP/IP HART protocol Flow Introduction Bernoullis derivation, correction coefficients, calcs DP flow measurement Venturi tube, Dall tube, orifice plate, target meter Open channel flowmeters weirs and flumes Variable area flowmeter Turbine flowmeter Ultrasonic flowmeters + calcs Electromagnetic + calcs Vortex shedding Mass flowmeters Thermal Coriolis Positive displacement flowmeters

9.2

9.3

9.4

Valves & Actuators Introduction Valve flow characteristics Valve types Cavitation Valve flow coefficient Actuators Positioners Pumps Introduction Types of pumps Control methods Using VSDs as means of controlling pump speed

9.5

10.

OUTCOMES:

At the end of this course the learner will know how to measure the following basic variables: force and mass, linear movement, volumetric flow and mass flow. The learner will also have a good knowledge of both on/off and basic PID control systems, the control of flow, pumps as well as both analogue and digital signal transmission. Basic electronic skills will be developed and demonstrated.
Outcomes The learner will know the difference between on/off control and continuous control, and will know what the function is of the proportional, integral and derivative stage of a controller in a feedback control system. The learner will know how to measure flow in both open channels and closed conduits. The measurement of volumetric flow and mass flow will be known. The learner will know how to control flow rate in a system, the various types of valves available and problems associated with incorrectly sized valves on a process. The learner will also know basic calculations based on valve flow coefficients. The learner will know the various types of pumps available as well as the methods of controlling these pumps. The learner will know the difference between analogue and digital signals and the standards available. The learner will also know methods of converting between the various types of analogue signals. Assessment Method The learner will be required to answer questions based on the operation of the various types of process control methods. Syllabus See section 9.1.

The learner will be required to answer See section 9.3. questions based on operation of various flow measurement devices and be able to perform calculations relating to flow measurement. The learner will be required to answer See section 9.4. questions relating to the control of flow as well as the problem of cavitation. The learner will also be required to perform calculations based on valve flow coefficients. The learner will be required to answer See section 9.5. questions based on pumps and the control of pumping rate and volume. The learner will be required to answer See section 9.2. questions based on analogue and digital signals and to perform various calculations based on these signals.

PROCESS INSTRUMENTATION DATA Conversion Table for Pressure Units

Unit bar kPa psi mmHg kg/cm atm torr
2

bar 1 0,01 0,06895 0,00133 0,98067 1,01325

kPa 100 1 6,89476 0,13332 98,0665 101,325 0,13333

psi 14,5038 0,14504 1 0,01934 14,2233 14,696 0,001934

mmHg 750,064 7,50064 51,7151 1 735,561 760 1

kg/cm2 1,01972 0,0102 0,07031 0,00136 1 1,03323 0,0013595

atm 0,98692 0,00987 0,06805 0,00132 0,96784 1 0,0001316

torr 0,00133 75,00188 517,0631 1 735,5592 7598,7842 1

Thermocouple Reference Table

C 0 100 200 Type J 300 400 500 600 700 800 C 0 100 200 300 Type K 400 500 600 700 800 900 1000 0 0,00 5,27 10,78 16,33 21,85 27,39 33,11 39,15 45,53 0 0,00 4,10 8,13 12,21 16,40 20,65 24,91 29,14 33,30 37,36 41,31 10 0,50 5,81 11,34 16,88 22,40 27,95 33,70 39,78 46,18 10 0,40 4,51 8,54 12,63 16,82 21,07 25,34 29,56 33,71 37,76 41,70 20 1,02 6,36 11,89 17,43 22,95 28,52 34,29 40,41 46,82 20 0,80 4,92 8,94 13,04 17,24 21,50 25,76 29,97 34,12 38,16 42,09 30 1,54 6,90 12,45 17,98 23,50 29,08 34,88 41,05 47,46 30 1,20 5,33 9,34 13,46 17,67 21,92 26,19 30,39 34,53 38,56 42,48 40 2,06 7,45 13,01 18,54 24,06 29,65 35,48 41,68 48,09 40 1,61 5,73 9,75 13,88 18,09 22,35 26,61 30,81 34,93 38,95 42,87 50 2,58 8,00 13,56 19,09 24,61 30,22 36,08 42,32 48,73 50 2,02 6,13 10,16 14,29 18,51 22,78 27,03 31,23 35,34 39,35 43,25 60 3,11 8,56 14,12 19,64 25,16 30,80 36,69 42,96 49,36 60 2,43 6,53 10,57 14,71 18,94 23,20 27,45 31,65 35,75 39,75 43,63 70 3,56 9,11 14,67 20,20 25,72 31,37 37,30 43,60 49,98 70 2,85 6,93 10,98 15,13 19,36 23,63 27,87 32,06 36,15 40,14 44,02 80 4,19 9,67 15,22 20,75 26,27 31,95 37,91 44,25 80 3,26 7,33 11,39 15,55 19,79 24,06 28,29 32,48 36,55 40,53 44,40 90 4,73 10,22 15,77 21,30 26,83 32,53 38,53 44,89 90 3,68 7,73 11,80 15,98 20,22 24,49 28,72 32,89 36,96 40,92 44,78

Constants

Temperature Conversions

Hg = 13600 kg / m 3
WATER = 1000 kg / m 3
g = 9 , 81m / s 2 speed of sound dry air = 344 m / s speed of sound water = 1461m / s

TKelvin = t Celsius + 273 ,15 5 t [C ] = (t [ F ] 32 ) 9

Formulae
N = N 0 e t ln 2 t1 =
2

E=

1 1 m2

Q = A2 2 g

PABS = PATM + PG
a PManometer = gl + sin A

Q RECT = 0.094(L 0.2 H )H 1.5

QTRAP = 0.095 LH 1.5

v P ( P e ) . Ae e

Hg 1 H = 2 h L Hg 1 H = 2 h H 1 L Hg Z = 1 h L
R=

QV = 0.07 tan H 2.5 2 Q FLUME = 4.43CBKH 1.5 Ae Q= BD AC FT FR Q= 2 cos FT

l
A VS eG 2(2 + x )

VOBridge =

AC 2 Q= 2 L cos Ad Q= F St H W = C P t
CV = Q

Rt = R0 (1 + t )

R R0 = 100 100.R0

N PVALVE
x xmax

R = Ae

B T

Q = Qmin R
h

Q = 0.003998CZEd 2

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