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Contents
Page
7.0
Instrumentation
7.1
7.2
Process Control
Objectives of Process
2
2
7.3
7.3.1
Control
The Control Loop
Tasks of Control Loop
3
3
7.4
7.5
Loop
Signals
References:
Fundamentals of Industrial Instrumentation
and Process Control By William C. Dunn
Chapter 7
Instrumentation
Instrumentation is the basis for process control in industry. However, it comes in
many forms from domestic water heaters and HVAC, where the variable temperature is
measured and used to control gas, oil, or electricity flow to the water heater, or heating
system, or electricity to the compressor for refrigeration, to complex industrial process
control applications such as used in the petroleum or chemical industry.
In industrial control a wide number of variables, from temperature, flow, and pressure
to time and distance, can be sensed simultaneously. All of these can be interdependent
variables in a single process requiring complex microprocessor systems for total control. Due
to the rapid advances in technology, instruments in use today may be obsolete tomorrow, as
new and more efficient measurement techniques are constantly being introduced. These
changes are being driven by the need for higher accuracy, quality, precision, and
performance.
2
7.1
Process Control
Process control is the automatic control of an output variable by sensing the
amplitude of the output parameter from the process and comparing it to the desired or set
level and feeding an error signal back to control an input variable
7.2
Manufacturers control the Production Process for the following three reasons:
1.Reduce Variability
7.2.1
2. Increase efficiency
3.Ensure safety
Reduce Variability
Process control can reduce variability in the end product, which ensures a consistently highquality product. Manufacturers can also save money by reducing variability.
Reducing variability can also save money by reducing the need for product padding to meet
required product specifications.
Padding refers to the process of making a product of higher-quality than it needs to be to
meet specifications
When there is variability in the end product (i.e., when process control is poor),
manufacturers are forced to pad the product to ensure that specifications are met, which adds
to the cost. With accurate, dependable process control, the set point (desired or optimal point)
can be moved closer to the actual product specification and thus save the manufacturer
money.
Figure 7.1 Variability Reduction
7.2.2
Increase Efficiency
7.2.3
Ensure Safety
manufacturers do not maintain precise control of all of the processing variables. The
consequences of a run-away process can be catastrophic.
Precise process control may also be required to ensure safety. For example, maintaining
proper boiler pressure by controlling the inflow of air used in combustion and the outflow of
exhaust gases is crucial in preventing boiler implosions that can clearly threaten the safety of
workers.
a predetermined value, in this case, the maximum tank level established by the plant operator,
and finds that the values are equal. The controller then sends a signal to the device that can
bring the tank level back to a lower levela valve at the bottom of the tank. The valve opens
to let some liquid out of the tank.
2.Flow
3.Level
7.Mass
4.Temperature
5.Density
8.Conductivity
It is the monitored output variable from a process. The value of the monitored output
parameter is normally held within tight given limits.
Figure 7.4 Process Variables
7.4.4 Instrument
It is the name of any of the various device types for indicating or measuring physical
7.4.5 Sensors
These are devices that can detect physical variables, such as temperature, light intensity, or
motion, and have the ability to give a measurable output that varies in relation to the
amplitude of the physical variable. The human body has sensors in the fingers that can detect
surface roughness, temperature, and force.
Because sensing devices are the first element in the control loop to measure the process
variable, they are also called Primary Elements. Examples of primary elements include:
1.Pressure sensing diaphragms
2.Capacitance cells
4.Thermocouples
5.Orifice plates
6.Pitot tubes
6
7.Venturi tubes
7.4.6 Transducers
These are devices that can change one form of energy to another, e.g., a resistance
thermometer converts temperature into electrical resistance, or a thermocouple converts
temperature into voltage. Both of these devices give an output that is proportional to the
temperature. Many transducers are grouped under the heading of sensors.
7.4.7 Converter
A converter is a device that converts one type of signal into another type of signal. For
example, a converter may convert current into voltage or an analog signal into a digital
signal. In process control, a converter used to convert a 420 mA current signal into a 315
psig pneumatic signal (commonly used by valve actuators) is called a current-to-pressure
converter.
7.4.8 Transmitters
These are devices used to amplify and format signals so that they are suitable for
transmission over long distances with zero or minimal loss of information.
The transmitted signal can be in one of the several formats, i.e., pneumatic, digital, analog
voltage or analog current signal. Digital transmission is preferred in newer systems because
the controller is a digital system, and as analog signals can be accurately digitized, digital
signals can be transmitted without loss of information.
7.5 Signals
There are three kinds of signals that exist for the process industry to transmit the process
variable measurement from the instrument to a centralized control system.
1. Pneumatic signal
2. Analog signal
3. Digital signal
running electrical signal wire through a plant as opposed to running pressurized air tubes has
made pneumatic signal technology less attractive.