AND PROCESS

CONTROL

RISHIKA B SHETTY (T-NO.

3241)
SACHIN T (T-NO.
3244)
CONTENTS
INTRODUCTION
What is Instrumentation and Process control?
 “Science of measurement and Control of
process variables”
 The process variables are Level, Pressure,
Temperature, Humidity, Flow, pH, Level, Speed
etc.
Why Instrumentation in Process Industry ?
 “Material and Energy” balance of matter
 The efficiency and economy of the process
 The product quantity and quality depend upon the
maintenance of optimum parameters for the process.
 The conventional chemical analytical techniques are
laborious and time consuming. Hence process control
is done through “Instrumental Methods” of
analysis.
CLASSIFICATION:
Instrumentation can be classified as,

Field Instrumentation System

configuration
Level Distributed Control System
(DCS)
Pressure Programmable
Logic Controller (PLC)
Temperature
Flow
Analyzers
Field Instrumentation
1. Pressure
 Pressure is the measurement of force acting on area of
surface. i.e., “Force per unit area”.
 Gauge Pressure, Absolute Pressure, Vacuum Pressure

Units of Pressure measurement:

 kg/cm2 -for medium & high ranges
 PSI (Pounds per square inch)
 Bar
 Atm, abs, vacuum
 mmHg (millimeter of mercury)
 mmH2O (millimeter of water) –for low ranges
Pressure measuring instruments:
 Pressure gauges, Manometers, Barometers are used.
Element Range
Bellows 500 mmWC to 2
kg/cm2g
C-Bourdon 0 to 1500 kg/cm2g
Spiral 0 to 15 kg/cm2g
Helical 0 to 5600
kg/cm2g
Diaphragms 25 mmWC to 15 kg/cm2g
Strain gauges Vacuum to 6000 kg/cm2g
2. Temperature-
 enter
 Thermometer, Temperature gauges, Thermocouple,
Resistance temperature Detectors (RTD), Pyrometers are
used.

Units of Temperature measurement:

 Centigrade, Fahrenheit and Kelvin

Temperature measuring instruments:

1) Thermocouple: they work on Seeback effect.
 T type : bimetallic Element used is Copper-Constantan
 K type : Bimetallic element used is Chromel-Alumel
2) Resistance Temperature Detectors (RTD): Pt100
The range varies from -200°C to 800°C
Thermowell: Thermocouples and RTD’s are installed in
a Thermowell
Uses:
 Protects temperature sensor installed in the process
line
 Helps in online removal of temperature sensor
without fluid being exposed to environment/person
3. Flow-
 Flow is generally measured inferentially by
measuring the velocity of the fluid through a known
area.
Qv = A * V
 Flow is directly proportional to the DP

Units of Flow measurement:

Nm3/hr , m3/hr, kg/hr, Tons/hr
Flow measuring instruments:
Rate flow meters and quantity flow meters. The
different types are,
1) Differential Pressure Type: change in cross sectional
area of fluid stream caused by a restriction device in
the path causes a pressure drop across this
obstruction device.
 Orifice Plate
 Venturi tubes
 Pitot tube and Annubar
2) Vortex flow meters
3) Electromagnetic flow meter
4) Turbine flow meter
5) Mass flow meter
6) Ultrasonic flow meter
7) Pitot tube
8) Annubar
9) Rota meter
4. Level-
 ENTER
 Liquid Level Gauges for Local Indication are used.
These are used for direct visual observation of liquid
levels in tanks, stills and other process vessels types.
Units of Level measurement:
 ENTER
Level measuring instruments:
1. Differential Pressure Level measurement
2. Bubble type
3. Displacer type level measurement
4. Nucleonic level gauge
5. Radar level gauge.
5. Analyzer-
 Instruments like Electrodes, online analyzers, Gas
monitoring detectors are used.
System configuration
1. Distributed Control System (DCS)-
 COMPONENTS OF DCS:

FCS
(FIELD
CONTRO OPS
COMMUNICATION
L (OPERATING
BUS
STATION STATION)
)

FCS- Used to control the process.

OPS- Used for the operation and monitoring of the process. Sends the set
points to FCS.
COMMUNICATION BUS- Used to communicate between FCS and OPS.
Advantages of Distributed Control System:

 Control function is distributed among multiple CPU’s.

Hence failure of one FCS does not affect the entire plant.

 Interlocks are created by software.

 Generation and modifications of the interlocks are very

flexible and simple.
 Information regarding the process is presented to the
user in various formats.

 Field wiring is considerably less.

 Maintenance and trouble shooting becomes very easy.

 Cost effective in the long run.

2. Programmable Logic Controller (PLC)-
Advantages of PLC :
 They are very fast (scan time in milli secs) and
designed for the rugged industrial
environment.
 Uninterruptible Power Supply (UPS)- Provides
continuous electric power to connected loads.

Why UPS ?
 Increased Power Quality
 Increased noise rejection
 Power Black-out protection
TYPES OF INSTRUMENT
SIGNALS
Analog
Signal
4 to 20mA or
1 to 5V

Digital Signal
0.2 to 1.0
kg/cm2g or 3.0
to 15 psig
PROCESS CONTROL
Process variables in Process control:
The 3 main classes of Process control variable are,

Process variable
• Maintained at a desired level or value.
• Example: Temperature in a chemical reactor

Set variable/Value
• ideal value at which operator wants to operate.
• Example: Inlet conc. & temp. of reactants in a chemical
reactor

Manipulated variable
• An offset error i.e. generated due to difference between
PV and SV, which makes PV operate near desired value.
• Example: cooling by changing cold water flow rate in a
chemical reactor
Components of a Control System: Is a primary sensing or detection
system, which responds to the
measurable quantity (process
Sensor / Transducer Parameter) in a specified
functional manner.

Accepts the signal from

Sensor/Transducer and converts
Signal Transmission the same in to a suitable format,
(Transmitter) which can be transmitted to a
remote location.

Is a comparator, compares the

Display and Comparison signal received from transmitter
(Controller) with “Set-point” (desired value of
the process) and generates
corrective signal.

Regulation (Final Accepts the corrective signal sent

control element): by the Controller and changes /
regulates the process to match
with the set-point .
TYPES OF CONTROL SYSTEM
 Open Loop Control
 Closed Loop Control
Open Loop Control:
where the process parameter being measured is not
compared with any reference/desired value intervention
for taking the corrective action.
Example:
1) Indicators
2) Hand Indicated Controllers
Closed Loop Control:
This is feedback system, where process parameter
being measured is compared with desired value and the
corrective action is taken depending on the deviation
between the two, automatically
Example:
Any controller has a feedback system.
At MCF the DCS, PLC
used are:
 Urea, Ammonia, DAP, SAP, IAT, WHRB (CPP)
use DCS by Yokogawa, Centum VP software.
 Centum Vp: Ammonia urea sap WHRB
 Centum 3000 :DAP
 Centum 1000:SAP
 SNF uses PLC by Honeywell.
 The DCS of Ammonia and Urea have Operator Human
Interface System (HIS). There is a master HIS called
Engineering station, HIS 0164 has Field Control station
(FCS) and Safety control station (SCS).
 FCS- 0102,0104,0107 for Ammonia
 FCS- 0101, 0103 for Urea
 SCS- 0105,0106 use PLC, Prosafe RS software
 STN124 (EXaOPC) is communication protocol,
(EXaQuantum) is where all data can be fetched.
THANKYOU