Course Outline

Instrumentation and Controls

CNTR 252
Credits: 1.5 Total Modules: 31 Prerequisite(s): None Corequisite(s): None Description:
An introduction to process measurement and control, explaining how instrumentation and processes interact. These processes could be in any area of study, such as the oil/gas sector, chemical manufacture, agriculture, and mining, building systems or utilities. Areas of study will include measurement and control of variables such as fluid flow, level and pressure. Specific applications to apply the knowledge to design, operate, troubleshoot measurement and control systems.

Effective: January 2008

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CNTR 252 Instrumentation and Control

Course Evaluation
Exams Weighting Theory Mid-Term Theory Final Laboratory Write-ups Total Time Required 30% 35% 35% To Complete 3 Hours 3 Hours 32 Hours (10 Hours on simulator) 38 Hours

All work submitted for evaluation is expected to be of "industry acceptable standard." All assignments and laboratory write-ups are expected to be word processed, and presented in a "Duotang" type cardstock folder. Deadline to have a mark credited will be seven days from the date set, or as directed by the instructor. A major part of the mark will be awarded for presentation, remainder based on data collected, observations and conclusions. Laboratory teams, and study groups are encouraged to work together, but independent reports and assignments are required. Plagiarism will be dealt with severely.
Percentage Grade 90-100 85-89 80-84 77-79 73-76 70-72 67-69 63-66 60-62 55-59 50-54 0-49 Letter Grade A+ A AB+ B BC+ C CD+ D F Grade Points 4.0 4.0 3.7 3.3 3.0 2.7 2.3 2.0 1.7 1.3 1.0 Minimal Pass 0.0

According to Policy AC.3.10, SAIT will normally return students work to the students. However, in certain courses, SAIT retains the right to keep physical possession of the students work. Your instructor will discuss this with you at the start of the course.

Course Attendance
Effort and involvement are as essential for learning as they are for success in your career. To help assure your success, participation in all activities of this course is expected. The academic department offering this course will identify any specific requirements applicable to this class and delivery method. Reference: Procedure AC.3.8.1 - Attendance Requirements (available on http://www.mysait.ca)

Time Guidelines
Subject to change the following section times are a suggested guide in order to meet learning goals Theory Instructional Time Laboratory Time Laboratory / Assigned Homework Time Assigned Total Time Expected supplemental study time Expected Total Student Commitment Time OUTLINE Theory and recommended student time per module: Module Title Instrumentation Drawing Symbols Introduction to Process Instrumentation The Feedback Control Loop The Feedback Control Loop and its Dynamics Pressure Measurement Standards Basic Instrument Calibration Pressure Measurement Protection of Gages Basic Transmitter Principles Level Measurement Level Measurement II Flow Measurement-Orifice Plates Flow Measurement-Orifice Plate Installation Flow Measurement-Orifice Transmitter Installation Differential Pressure Flowmeters Positive Displacement and Other Flowmeters Temperature Measurement Devices The Control Valve Final Control Element Actuators 2 48 Hours 16 Hours 38 Hours 102 Hours 54 Hours 156 Hours

Hours/Module

Control Valve Actuator Accessories Control Valve Sizing Pneumatic Controllers I On-Off Control Pneumatic Controllers II Proportional Control Automatic-Manual Transfer Stations Introduction to Process Control Strategies I Introduction to Process Control Strategies II Electronic & Pneumatic Control Systems Electronic Instruments Computers in Process Control I Computers in Process Control II

Course Text(s)
Instrumentation for Process Measurement and Control by N. Anderson (Chilton) Fisher Control Valve Handbook by: Fisher Valve Company. Supplimental Reference Text: Instrumentation Symbols and Identification, ANSI/ISA-S5.1 Process Instrumentation Terminology, ANSI/ISA-S51.1 Process/Industrial Instruments & Controls Handbook - Considine Instrument Engineers Handbook (Meas. & Cont.) - Liptak

Materials
CNTR 252 Module Package (see time guidelines for module listing)

Lab Exercises
1. Transmitter calibration - Foxboro 13a DP cell, correct use of a calibration sheet and graphing of results, illustrating gain, (Bias) zero and linearity. 2. M1 Bridge - Analyze Negative feedback / Gain / Bias / Direct and Reverse Acting. 3. M1 Bridge - Compare On-Off controller with laboratory number three. 4. M1 Bridge - Compare PI controller with laboratory number three(possibly demonstrate PID controller) 5. Valve positioner calibration and inspection (stroke, air to open / air to close, characterization, piston actuator) 6. IBM computer Boiler Sim (Analyze P, PI, PID Controllers & Practice Controller Tuning) (Flex Time) 7. IBM computer (introduction to DCS type control) Boiler Sim simulation. (Examine Lead/Lag, P & P+I) (Flex Time) 8. IBM computer Boiler Sim simulation (examine 1 & 3 Element Drum Level Control) (Flex Time)

Course Content
Below is presented a list of the learning modules used to achieve the learning outcome(s) for this course.

1.

Instrumentation Drawing Symbols

Learning Outcome: Know how a simple closed loop control system is arranged, identify its major components, and employ the correct ISA drawing symbols. Objectives: 1.1 List and describe the job of the following control system parts; controller, transmitter, final control element (FCE) and process. 1.2 Sketch how the components listed in 1.1 would be correctly arranged in a typical control system. ____________________________________________________________

2.

Introduction to Process Instrumentation

Learning Outcome: Describe the importance of automation in relation to industry. Objectives: List and describe how the primary areas of industry are impacted by automatic controls. (e.g.. safety, efficiency, manpower, demands, distance/time, hostile environments, accuracy.) 2.2 Explain the importance of accurate measurement of process variables such as; level, pressure, flow, temperature, density and composition 2.3 State and describe the five purposes of instrumentation in a process plant. (Measure, Control, Alarm, Record, Indicate) ____________________________________________________________

3.

The Feedback Control Loop

Learning Outcome: Describe the basic closed loop control system, and its four main parts. Objectives: 3.1 Sketch and label a simple closed loop control system, label and describe the controller, transmitter, final control element and process. 3.2 Compare the relationship between process capacity and the controller. ____________________________________________________________

4.

The Feedback Control Loop and its Dynamics

Learning Outcome: Explain, with sketches, the feedback control loop and its dynamics. Objectives: 4.1 Describe with the aid of sketches how increasing gain will lead t instability and decreased gain to over damped conditions. 4.2 Show how phase relationships can affect stability. 4.3 Explain the relevance of process capacity on the selection of controller gain. ____________________________________________________________

5.

Pressure Measurement Standards

Learning Outcome: Describe the principles of operation and the limitations of various pressure measurement standards. Objectives: 5.1 5.2 Define a pressure standard. Describe the principle of operation of manometers, mercury barometers, dead weight testers, and comparison gauge testers and perform relative calculations. 5.3 Describe desirable characteristics of manometer fluids and describe factors that may introduce errors into manometer readings. 5.4 Describe limitations of manometers. 5.5 Describe factors that may introduce errors into dead weight tester measurements and calibrations. ____________________________________________________________

6.

Basic Instrument Calibration

Learning Outcome: Explain the procedure for calibrating some basic instrumentation devices. Objectives: 6.1 Briefly define the following terms: span, range, linearity, hysteresis, and repeatability. 6.2 Perform calculations to convert ranges, spans, and standard signals into percentages and back again. 6.3 Briefly describe the method for the calibration of a pressure gage. 6.4 Briefly describe a method of calibrating a pneumatic transmitter. 6.5 Briefly describe a method of calibrating an electronic transmitter. 6.6 Sketch and describe the transmitter connections to open tanks, closed tanks, and tanks containing pressurized condensing vapours and liquids (wet and dry leg). ____________________________________________________________

7.

Pressure Measurement
Learning Outcome: Describe the operation and application of pressure gages. Objectives: 7.1 7.2 Define absolute, gage, vacuum, and atmospheric pressure. Describe the operation of a C-type, spiral, and helix Bourdon tube pressure gage. 7.3 Describe the application of bellows and diaphragms to pressure measurement. 7.4 Describe the operation of an absolute pressure gage including an Aneroid barometer. ____________________________________________________________

8.

Protection of Gages
Learning Outcome: Discuss the hazards that gages are exposed to in industry. Objectives: 8.1 8.2 Identify the hazards that gages are exposed to in industry. Briefly describe the following methods of gage protection: snubbers, location, oil filled, needle valves, seal pots, chemical seals, and purging. ____________________________________________________________

9.

Basic Transmitter Principles

Learning Outcome: Discuss the basic principles of pneumatic and electronic transmitter operation. Objectives: 9.1 9.2 Describe the operation of a pneumatic transmitter. Describe the basic principle of operation of an electronic transmitter. 9.3 State the purpose of a pneumatic relay. 9.4 Define negative feedback and proportional output with respect to pneumatic and electronic transmitters. 9.5 Compare the basic principle of operation of electronic transmitter sensors. 9.6 Calculate the input of a transmitter when given the output. 9.7 State the purpose of current to pneumatic (I to P) transducers. ____________________________________________________________

10.

Level Measurement
Learning Outcome: Discuss the application and installation of float operated bubbler systems, diaphragm boxes, and level switches related to level measurement and control. Objectives: Discuss the application of Archimedes principle to level measurement using floats. 10.2 Sketch and describe float and cable and float and tape level measurement devices. 10.3 Describe a control valve and linkage arrangement used with float systems. 10.4 Sketch and describe a bubble pipe system for open and closed tanks. 10.5 Describe the characteristics of a bubble pipe or purge system and its application. 10.6 Sketch and describe a diaphragm box type of level measuring system. ____________________________________________________________ 10.1

11.

Level Measurement II
Learning Outcome: Discuss the application of level measurement by electrical capacitance, conductance, mass, radiation, ultrasonic, and thermal methods. Objectives: 11.1 Briefly describe level measurement using the following methods: (a) electrical capacitance (b) conductance (c) mass (d) radiation (e) ultrasonic (f) thermal sources (g) rotating paddles (h) vibrating paddles (i) laser, microwave, and optical devices ____________________________________________________________

12.

Flow Measurement Orifice Plates

Learning Outcome: Discuss the purpose of orifice plates and describe the most commonly used types. Objectives: 12.1 State the theory involved in the use of differential pressure flow meters. 12.2 Describe the types of orifice plates and their applications. 12.3 Discuss the mechanical requirements that are followed to ensure accuracy when using orifice plates. 12.4 Calculate the permanent pressure loss caused in a pipe by the orifice plate. ____________________________________________________________

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13.

Flow Measurement Orifice Plate Installation

Learning Outcome: Describe orifice plate installations. Objectives: 13.1 13.2 13.3 Describe the reasons and requirements for straightening vanes. Describe the types and locations of pressure taps. Describe the procedure to change orifice plates under pressure using a slide valve plate changer. ____________________________________________________________

14.

Flow Measurement Orifice Transmitter Installation

Learning Outcome: Discuss the installation requirements of secondary elements to provide accurate and maintenance free operation. Objectives: 14.1 State the installation requirements of the transmitter for measuring flow of steam, liquids, and gases. 14.2 Describe the purpose of a sealing liquid. 14.3 State the function of condensing pots or reservoirs used in the measurement of steam flow. 14.4 Describe the operation of a manifold. 14.5 Discuss winterizing a transmitter and the connecting sensing lines. ____________________________________________________________

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15.

Differential Pressure Flowmeters

Learning Outcome: Discuss the basic operation of differential pressure meters other than orifice plate meters. Objectives: 15.1 Briefly describe the principle of operation of the following differential pressure flowmeters: venturi tube, flow nozzle, pitot tube, elbow tap, and target meter. 15.2 Briefly describe the operation of the weir and flume types of open channel flowmeters. 15.3 State the advantages and disadvantages of each of these devices. ____________________________________________________________

16.

Positive Displacement and Other Flowmeters

Learning Outcome: Briefly explain the operation of positive displacement type flowmeters and variable area meters. Objectives: 16.1 16.2 Explain the difference between metering pumps and meters. Sketch and describe the following types of positive displacement flowmeters: nutating disc, bellows, reciprocating piston, rotating piston, sliding vane, rotary lobe, rotary gear. 16.3 Sketch and describe the operation of a variable area meter. ____________________________________________________________

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17.

Flow Measurement Velocity Flowmeters

Learning Outcome: Discuss the basic principle of operation of various velocity type flowmeters and state suitable process applications. Objectives: 17.1 State the basic flow equation that relates velocity to area of the pipe. 17.2 Describe the basic principle of operation of the turbine, vortex shedding, magnetic, ultrasonic, and mass flowmeters. 17.3 Define meter K-factor. 17.4 Describe a process application for each type of velocity flowmeter. ____________________________________________________________

18.

Temperature Measurement Devices

Learning Outcome: Discuss the basic principle of operation and the application of the various common temperature measuring devices. Objectives: 18.1 18.2 Describe the operation and application of bimetallic thermometers. Describe the operation, classes, and application of filled thermal element systems. 18.3 Describe the operation and application of thermocouples. 18.4 Describe the operation and application of resistance thermometers. 18.5 Describe the operation and application of radiation pyrometers. ____________________________________________________________

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19.

The Control Valve

Learning Outcome: Describe the various valve body types and determine which type of valve body is most practical for a particular application. Objectives: 19.1 19.2 19.3 Describe the various control valve bodies and seats. Describe the different types of control valve end connections. Indicate the type of control valve body which should be used for a given application, and explain the reasons for the choice. 19.4 State the different valve flow characteristics. ____________________________________________________________

20.

Final Control Element Actuators

Learning Outcome: Describe the components of a typical actuator, list the different types of actuators, and select the proper actuator for a specific application. Objectives: 20.1 Describe the operation of a typical actuator and list the major components. 20.2 Describe the different types of actuators and where they are used. 20.3 Explain how an actuator is sized, based on valve and process requirements. 20.4 Explain the criteria for selecting a safe fail position of an actuator. ____________________________________________________________

21.

Control Valve Actuator Accessories

Learning Outcome: List the accessories available for actuators, describe their function, and explain their operation. Objectives: 21.1 List the accessories available for valve actuators. 21.2 Explain the function and construction of each accessory. 21.3 Describe the operation of each general type of accessory. ____________________________________________________________

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22.

Control Valve Sizing

Learning Outcome: Describe why control valve sizing is important, and to determine the size of control valve required for particular flow rate applications. Objectives: 22.1 Define valve coefficient (Cv). 22.2 List the three basic formulas for Cv. 22.3 Perform basic calculations for sizing of control valves. 22.4 Explain the terms flashing and cavitation. ____________________________________________________________

23.

Pneumatic Controllers I On-Off Control

Learning Outcome: Discuss the principles and terms that apply to basic on-off control and explain the action of a pneumatic on-off controller. Objectives: 23.1 23.2 23.3 23.4 Describe the operation of on-off control. Differentiate between direct action and reverse action control. Describe the action of a flapper-nozzle relay. Sketch and describe the action of a flapper-nozzle based on-off pneumatic controller. ____________________________________________________________

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24.

Pneumatic Controllers II Proportional Control

Learning Outcome: Explain the principle of proportional control and the basic terms of the three-mode controller equation. Objectives: 24.1 State how an on-off controller is made into a proportional controller. 24.2 Define the term offset. 24.3 State the purpose of the integral mode in a controller. 24.4 State the purpose of the derivative mode in a controller. 24.5 Sketch and describe a three mode pneumatic controller. 24.6 Explain the terms for proportional, reset, and rate in the equation. 24.7 Describe the basic concept of the equation. ____________________________________________________________

25.

Automatic-Manual Transfer Stations

Learning Outcome: Discuss the principles, functions, and operation of automatic-manual transfer stations. Objectives: 25.1 25.2 25.3 Explain why processes are often run on manual control. Describe the operation of an automatic-manual transfer station. Sketch and describe the basic components of any automaticmanual transfer station in a process loop. 25.4 Describe the purpose of automatic-manual transfer stations. 25.5 Describe the term balanced transfer. ____________________________________________________________

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26.

Introduction to Process Control Strategies I

Learning Outcome: Discuss ratio, auto-select and split-range control theory, the interaction of each pertaining to a control loop and practical applications of each method. Objectives: 26.1 Describe the difference between a multiplier and divide function used in a ratio control loop. 26.2 Sketch a ratio control application. 26.3 Define an auto-select loop. 26.4 Describe typical auto-select loops. 26.5 Describe special applications of auto-select loops. 26.6 Employ a split-range control system to improve loop response of a controlled variable. ____________________________________________________________

27.

Introduction to Process Control Strategies II

Learning Outcome: Discuss cascade and feedforward control theory, the interaction of each within a control loop, and practical applications of each method. Objectives: 27.1 Describe the effective use of a cascade control on both supply and demand disturbances. 27.2 Give the general definition of feedforward control. 27.3 Sketch a typical cascade control loop. 27.4 Describe the general block diagram of a feedforward control system. 27.5 List four problems of feedback control. 27.6 Describe under what conditions cascade can improve loop performance. 27.7 Describe a general method of feedforward control design. 27.8 State the reasons for feedback trim on a feedforward system. 27.9 Discuss primary and secondary control loop tuning. ____________________________________________________________

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28.

Electronic & Pneumatic Control Systems

Learning Outcome: Compare electronic and pneumatic instrumentation as applied to typical industrial control systems. Objectives: 28.1 Describe the advantages and disadvantages of pneumatic vs. electronic instrumentation and control system. 28.2 Sketch and describe the equipment and components necessary to form a pneumatic control system. ____________________________________________________________

29.

Electronic Instruments
Learning Outcome: Discuss how electronics is applied to different measurement and control techniques. Objectives: 29.1 Explain the fundamental difference between analog and digital electronics. 29.2 Sketch and describe the fundamental components of a typical electronic control loop. 29.3 Describe the fundamentals of a smart transmitter, and explain its advantages and disadvantages as compared to conventional transmitters. 29.4 Sketch and describe the components of a typical electronic flow measurement/computing system. ____________________________________________________________

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30.

Computers in Process Control I

Learning Outcome: Explain the role computers play in the process control industry, describe the components and architecture of the computer, and use the language associated with computers. Objectives: 30.1 Describe the historical evolution of the computer and the criteria used to define a computer. 30.2 Define and describe the architecture and components that make up the computer. 30.3 Describe the use of software to accomplish tasks using the computer. 30.4 List the applications of the computer to the process control industry. ____________________________________________________________

31.

Computers in Process Control II

Learning Outcome: Describe the major components of process control computer systems (console) operations, and describe the hardware and software requirements for a typical computer control console. The student will also be able to describe a simple Supervisory Control and Data Acquisition (SCADA) system, major components of the system, and appropriate forms of communication between sites. Objectives: 31.1 Define the terms hardware and software, and state the difference between the two. 31.2 List the minimum hardware requirements for a process control computer system. 31.3 Define various input/output devices in a console, and describe the functions of these devices. 31.4 List various software functions found on a process control computer system. 31.5 Describe the functions of various software features found in control consoles. ____________________________________________________________

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SAIT Course Outline

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