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INTRODUCTION TO INDUSTRIAL
INSTRUMENTATION
1
CHAPTER HIGHLIGHTS
Instrumentation is the science of automated
measurement and control.
2
In Oil & Gas industry,
y, the first step,
p, naturally,
y, is
measuring the process variables such as; pressure,
fl
flow, level
l l , temperature, analytical,
l i l …etc.
Once the p
process variable measured,, transmit a
signal representing this quantity to an indicating or
computing device
d where
h either
h human
h or
automated action then takes place.
4
INSTRUMENTATION TERMS AND THEIR DEFINITIONS:
5
Primary Sensing Element (PSE): A device that
di
directly
l senses the
h process variable
i bl and
d translates
l that
h
sensed quantity into an analog representation (electrical
voltage, current, resistance; mechanical force, motion,
) Examples:
etc.). a p thermocouple,
o oup , RTD,, bourdon
bou do tube,
ub ,
potentiometer, electrochemical cell.
“Span”
Span the width of its range (URV − LRV).
10
EXAMPLE: WASTEWATER DISINFECTION
11
EXAMPLE: CHEMICAL REACTOR TEMPERATURE CONTROL
12
OTHER TYPES OF INSTRUMENTS
Indicators
I di t
Indicators give
i a convenient
i t way off seeing
i what
h t
the output of the transmitter is without having to
connect test equipment
13
14
NUMERICAL AND BARGRAPH PANEL-MOUNTED INDICATOR
15
LESS SOPHISTICATED STYLE OF PANEL-MOUNTED INDICATOR SHOWS
ONLY A NUMERIC DISPLAY
16
FIELD-MOUNTED INDICATORS
17
RECORDERS
18
CIRCULAR CHART RECORDER USES A ROUND SHEET OF PAPER
19
STRIP CHART RECORDER ON THE RIGHT AND A
PAPERLESS CHART RECORDER ON THE LEFT
20
EXAMPLE OF A TYPICAL “TREND” SHOWING THE RELATIONSHIP BETWEEN
PROCESS VARIABLE, SETPOINT, AND CONTROLLER OUTPUT IN AUTOMATIC MODE,
AS GRAPHED BY A RECORDER:
21
22
PROCESS SWITCHES AND ALARMS
Process switch is used to turn on and off with
varying process conditions.
conditions
23
THE FOLLOWING P&ID OF A COMPRESSED AIR CONTROL
SYSTEM SHOWS BOTH USES OF PROCESS SWITCHES:
24
ALARM MODULE
25
ANNUNCIATORS
Process alarm switches may be used to trigger a special type of
indicator device known as an annunciator.
The indicator light does not turn off until the actual alarm
condition (the process switch) has returned to its regular state.
26
AN ANNUNCIATOR LOCATED ON A CONTROL
PANEL FOR A LARGE ENGINE-DRIVEN PUMP
27
A SIMPLE LOGIC GATE CIRCUIT ILLUSTRATES THE ACKNOWLEDGMENT
LATCHING FEATURE (HERE IMPLEMENTED BY AN S-R
S R LATCH
CIRCUIT) COMMON TO ALL PROCESS ALARM ANNUNCIATORS:
28
INSTRUMENT CALIBRATION
M t iinstruments
Most t t contain
t i a facility
f ilit for
f making
ki t
two adjustments.
dj t t
These are
1. The RANGE adjustment.
2. The ZERO adjustment.
In order to calibrate the instrument an accurate gauge is
required This is likely to be a SECONDARY STANDARD.
required. STANDARD
Instruments calibrated as a secondary standard have
themselves been calibrated against a PRIMARY STANDARD.
PROCEDURE
An input representing the minimum gauge setting should be
applied. The output should be adjusted to be correct. Next
the maximum signal is applied. The range is then adjusted to
give the required output. This should be repeated until the
gauge is correct at the minimum and maximum values.
29
CALIBRATION ERRORS
RANGE AND ZERO ERRO
After obtaining correct zero and range for the instrument, a
calibration graph should be produced. This involves plotting the
indicated reading against the correct reading from the standard
gauge.
g g This should be done in about ten steps p with increasing g
signals and then with reducing signals. Several forms of error could
show up. If the zero or range is still incorrect the error will appear
as shown.
shown
30
HYSTERESIS and NON LINEAR ERRORS
Hysteresis is produced when the displayed values are too
small for increasing signals and too large for decreasing
signals This is commonly caused in mechanical instruments
signals.
by loose gears and linkages and friction. It occurs widely with
things involving magnetisation and demagnetisation.
The calibration
Th lib ti may be
b correctt att the
th maximum
i andd minimum
i i
values of the range but the graph joining them may not be a
straight line (when it ought to be). This is a non linear error.
The instrument
inst ment may
ma have
ha e some adjustments
adj stments for
fo this and it
may be possible to make it correct at mid range as shown.
31
TRANSMITTERS
A transmitter sends representative signal of the
value of measured variable from the sensor to the
indicator or controller. This has the advantage of
keeping hazardous process fluids outside the
control room and allows the use of a common
signal range. Transmitter picks up the
measurement provided by the sensor and converts
it to a standard signal range. Sensors and
transmitters are combined in to one device.
The two most common types of transmission used in
industry are.
1. Pneumatic, and
2. Electronic
32
Pneumatic System
Air systems operate in the range of 3 to 15 psi (0.2 to 1.0
Bar) and make use of small – bore piping to transmit the
signal around the plant.
The main advantages of this system are:
1. Freedom to a certain extent from the fear of electrical
power failures
2
2. Abilit
Ability to transmit
t a it and
a d send
e d signals
ig al th o gh
through
hazardous areas without the fear of explosion.
3. Noise immunity from external sources
33
Electronic
Electronic systems make use of cables to send
current signals in range of 4-20 mA around the use
off a li
live zero usedd in
i currentt ttransmission,
i i allows
ll
for an easy method to detect a loss of signal due to
cable
cab e da
damage.
age. Further
u t e tthe
e cu
current
e t iss tthee sa
samee at
all points the loop.
Electrical signals do not suffer from lag and signal
di
distortioni problems
bl when
h long
l transmission
i i
distances are encountered. Unfortunately they can
Suffer from noise problems and all signals are lost
when the power fails unless an Uninterruptible
power Supply (UPS) Is available. The main
problem
bl with
i h the
h electrical
l i l Signals
Si l is
i the h explosion
l i
risk in hazardous areas.
34
Digital
The traditional favorite means communicating a process
signal from the field to the control room is via the 4-20 mA
analogue current loop.
loop
This is a fast reliable industry standard but it leaves a lot
to be desired in terms of maintenance capabilities,
performance and diagnostics.
Analogue field instruments can be expensive to install and
maintain.
i t i
Smart field instruments may not only address this issues
but can provide further benefits the features of Smart
transmitters issues but can provide further benefits.
The features of Smart transmitters can provide substantial
benefits to users in terms of time and labor savings as well
as providing an increase in plant operating safety.
35
HIGHWAY ADDRESSABLE REMOTE TRANSDUCER (HART) PROTOCOL
HART field communications protocol is widely accepted in the
industry as the standard for digitally enhanced 4-20 mA
communication with smart field instruments. The HART protocol
was designed specifically for use with intelligent measurement
and control instruments that traditionally communicate using 4 4-
20 mA analogue signals HART preserves the 4-20 mA signal and
enables two–way digital communications to occur without
di t bi
disturbing th integrity
the i t it off the
th 4 -2020 mA A signal.
i l Unlike
U lik other
th
digital communication technologies the HART protocol maintains
compatibility with existing 4 -20 mA systems and in doing so
provides users with uniquely compatible solution the HART
protocol permits the process variable to be transmitted by the 4 -
20 mA analogue signal and additional information about other
variables parameters , device configuration , calibration and
device diagnostics to be transmitted digitally at the same time .
36
HART makes use the technic of frequency shift keying (FSK) standard to
superimpose digital communications at a low level on top of the 4 -20
20 mA
signal.
This enables two-way field communications to take place and makes it
possible for additional information beyond just the normal process variable to
be communicated to from a smart field instrument the HART protocol allows
a host application (master) to get two or more digital updates per second from
a field device which is not fast enough for most applications.
HART is a master slave protocol, that means the field (slave) device only
speaks when spoken to by master sends out command signal (C) and the slave
sends back a response (R).
37
As with most protocol-based systems the manufacturer tries to “tie-
you” into his equipment.
you equipment The therefore if you use a HART based
system you cannot attach Honeywell equipment and expect it to work.
Hopefully with the final introduction of the Field-bus foundation
protocol this will change
p g and a ggreater flexibility
y will emerge.
g
The HART protocol permits all digital communication with field
devices in installation saving are possible with the multi-drop
networking capabilities of HART.
38
SMART INSTRUMENTS
Intelligent (microprocessor based) measurement.
measurement
Digital data communication
Includes diagnostic information as well as Process
Popular in hybrid 4-20 mA mode.
39