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Instrumentation and Control

The document provides information about Armando R. Diaz and his qualifications and experience in mechanical, electrical, plumbing and fire protection systems. It then outlines a presentation in three parts: Part 1 defines instrumentation terms and compares instrumentation and control engineering; Part 2 discusses calibration of instruments; Part 3 covers instrument tune-up and adjustment. Key points covered include definitions of accuracy and precision in instrumentation, reasons for calibration, common instrumentation errors like deadband and hysteresis, and calibration setup diagrams.

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Mira Alvarez
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583 views126 pages

Instrumentation and Control

The document provides information about Armando R. Diaz and his qualifications and experience in mechanical, electrical, plumbing and fire protection systems. It then outlines a presentation in three parts: Part 1 defines instrumentation terms and compares instrumentation and control engineering; Part 2 discusses calibration of instruments; Part 3 covers instrument tune-up and adjustment. Key points covered include definitions of accuracy and precision in instrumentation, reasons for calibration, common instrumentation errors like deadband and hysteresis, and calibration setup diagrams.

Uploaded by

Mira Alvarez
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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MEPF ORGANIZATION. OF THE PHIL. INC.

NOBLE ADVANCEMENT OF MARVELOUS PEOPLE


OF THE PHIL. INC.
ABOUT THE PRESENTOR
ARMANDO R. DIAZ
Master of Science in Business Administration (MBA)
ASEAN CHARTER PROFESSIONAL ENGINEER
Professional Electrical Engineer ( PEE )
Registered Master Plumber
Certified Plant Mechanical( CPM )
Accredited Pollution Control Officer
Licensed Professional Engineer with more than 40 years experience in the field of
building and facility design, consultancy, construction, operations and maintenance
involving various mechanical electrical plumbing and fire protection system

2021 CHAIRMAN IIEE COFNAP


2020 TOCAE AWARDEE
2019 MEPF ORG. OF THE PHIL. INC. PRESIDENT
2018 PSUMP NATIONAL PRESIDENT
2011 IIEE NATIONAL PRESIDENT
2010 MITEEA MOST OUTSTANDING ALUMNI
1998 MOST OUTSTNDING PRACTIONER IN INDUSTRY
PART 1 :
- Definition of Terms
- Instrumentation vs Control Engineering
- Reading of Instrumentation
Design Drawing

PART 3:

- Instrument Tune-up and Adjustment


PART 1
- Definition of Terms

- Instrumentation vs Control Engineering

-Reading of Instrumentation
Design Drawing
INSTRUMENTATION
- defined as the art and science of
measurement and control of process
variables within a production or
manufacturing area.
A COLLECTION OF INSTRUMENTS OR THEIR
APPLICATION FOR THE PURPOSE OF
OBSERVATION , MEASUREMENT OR CONTROL

Ref. ISA Std. S51.1


ANSI Std. C85.1
Control Engineering or Control Systems Engineering
-is the engineering discipline that applies control theory to design systems with
desired behaviors.

Control engineers are responsible for the research, design, development and
control devices/systems, typically in manufacturing facilities and plants.

The practice uses sensors to measure the output performance of the device being
controlled and those measurements can be used to give feedback to the input
actuators that can make corrections toward desired performance.

When a device is designed to perform without the need of human inputs for
correction it is called automatic control (such as cruise control for regulating a
car's speed).

Multi-disciplinary in nature, control systems engineering activities focus on


implementation of control systems mainly derived by mathematical modeling of
systems of a diverse range.
Control Engineering or Control Systems
Engineering
(ICS) Industrial Control System (ICS) is a general term that
encompasses several types of control systems used in
industrial production,

(SCADA) Supervisory Control And Data Acquisition

(DCS) Distributed Control Systems

(PLC) smaller control system configurations such as


Programmable Logic Controllers (PLC) often found
in the industrial sectors and critical infrastructures.
Control Engineering or Control Systems
Engineering

(SCADA) Supervisory Control And Data Acquisition

- is a system for remote monitoring and control that


operates with coded signals over communication channels
(using typically one communication channel per remote
station).
System Platform Workstations
Expansion to the Next higher level connecting several SCADA systems of different manufacturers

Operator & Engineering Workstations (Desk-top PC or Tablet)


Initial minimum of 1 station, expandable to several as required. Local or Remote.

Data Highway Network


Ethernet-based communication backbone or individual
connections dedicated to proprietary systems

Controllers, PLCs, Recorders from different manufacturers


centralized or individually dedicated to different plant utilities
Input / Measurement devices:
Sensors, Transmitters, Transducers
Process Analyzers, Power analyzers, Output devices:
Process switches Control Valves, Dampers, VFDs,
Compressors, Chillers, Boilers, Waste Water
Solenoids, Pilot lights, audible devices
Wonderware SCADA System – Basic Concept Architecture
Control Engineering or Control Systems
Engineering

(DCS) Distributed Control SystemsDistributed Control

Systems (DCS) have been the primary solution for process


automation

(DCS) is a control system for a process or plant, wherein


control elements are distributed throughout the system.

This is in contrast to non-distributed systems, which use a


single controller at a central location.
Control Engineering or Control Systems
Engineering

(DCS) Distributed Control Systems


Control Engineering or Control Systems
Engineering

(DCS) Distributed Control Systems


Control Engineering or Control Systems
Engineering

The elements of a DCS may connect directly to


physical equipment such as switches, pumps
and valves and to Human Machine Interface
(HMI) via SCADA.

The differences between a DCS and SCADA is


often subtle, especially with advances in
technology allowing the functionality of each to
overlap
Control Engineering or Control Systems
Engineering
PART 2
WHAT IS CALIBRATION ?

It is a procedure that compares instrument


inputs
and outputs to known standards
CALIBRATION SET-UP DIAGRAM FOR
THE INSTRUMENTS THAT HAS INPUT OR
AN OUTPUT ONLY
INSTRUMENT INSTRUMENT
STANDARD UNDER TEST

COMPARATOR or
SIMULATOR
CALIBRATION SET-UP DIAGRAM FOR
THE INSTRUMENTS THAT HAS BOTH INPUT
OR AN OUTPUT
INPUT OUTPUT
STANDARD STANDARD

INSTRUMENT
UNDER TEST
WHAT IS THE IMPORTANCE
OF CALIBRATION ?
Since the instruments operate within
larger system in sequential loops,no
instrument within such a loop can perform
its assigned function in the process
unless it receives accurate information
from other instrument within the loop
WHAT IS THE IMPORTANCE
OF CALIBRATION ?
It is a quality assurance requirement

Ex. ISO 9000 Series

SAFETY
WHEN TO CALIBRATE ?

1.Upon Installation
2. After Repair
3.Rough Handling
4.Extended Shutdown
5. Environmental Change
6. Remounting Within a System
ACCURACY and PRECISION
ACCURACY is the measurement of how
closely inputs match outputs

PRECISION refers to the ability of the


instrument to repeat the same output or
measurement when given an identical input
a number of times
ACCURACY and PRECISION

SIMPLY

ACCURACY refers to us ; nearest to standard


value

PRECISION refers to us ; nearest to a certain


value
SPAN

-refers to the difference between


upper and lower limits

SPAN = UPPER RANGE minus


LOWER RANGE
EXAMPLE :
INSTRUMENT RANGE: 20deg.C to 210deg.C
Span= 210-20 = 190

INSTRUMENT RANGE: 0 to 300

Span = 300 – 0 = 300


DETERMINING the accuracy of gauges and
simple measuring devices

True Value - Measured Value


ACCURACY , % = --------------------------------- X 100
Span
Example :

Nameplate
Instrument Range : 30 – 330 deg C 1% Accuracy

Field Data
Measured Value or Instr. indication: 48 degC
True Value : 50 deg C

True Value - Measured Value


ACCURACY , % = --------------------------------- X 100
Span

Accuracy = 50-48/300 ( 100 )


= 0.67%
INSTRUMENT ERRORS
DEADBAND

It refers to situation that reveals a


delay between input change and signal
response.It is a condition that usually
results from mechanical problem.It is not
adjustable and may require repair of the
mechanical elements that causes it.
ZERO SHIFT
refers to an error in which an
instrument outputs signals that are
consistently higher or lower than the ideal
or expected signal based on the input
provided
100
90
80
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100

ZERO ERROR
SPAN ERROR
THE ORIGIN OF THE IDEAL AND
SIGNAL LINES ON THE OUTPUT GRAPH
ARE THE SAME BUT THE STRAIGHT
SIGNAL LINE REPRESENTS AN ANGLE
DIFFERENT FROM THE IDEAL . THIS
INDICATES THAT CORRESPOND WITH
THE SIGNAL SPAN .
100
90
80
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100

SPAN
HYSTERESIS

An instrument error that can be seen


by comparing an upscale series of test
points.It refers to a condition that
produces different signals from the same
input based on the order
(upward or downward) in which the inputs
are provided.
100
90
80
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100

HYSTERESIS
NONLINEARITY
An error that could indicate the need
for instrument repair.It is seen in an
input/output graph as a curved signal line
that corresponds with the ideal at its
origin and upper limit readings (and
sometimes at its 50% reading as well)
100
90
80
70
60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100

NON-LINEAR
COMMON METHOD OF
MEASURING
TEMPERATURE

THERMOCOUPLE OR T/C

RESISTANCE BULB OR RTD


CALIBRATION SET-UP
General Requirements

the instrument to be calibrated is set-up in


a situation that simulates its physical
position as well as its function within the
system
CALIBRATION SET-UP
General Requirements

Determine an appropriate input and output


standards that will allow testing of the
entire accurate range of the instrument
CALIBRATION SET-UP
General Requirements

always include the 50% test point to


detect
hysteresis
CALIBRATION SET-UP
General Requirements

appropriate and reliable power must be


provided for each element requiring power
CALIBRATION SET-UP
General Requirements

Check of current flow with tight electrical


connection that do not introduce
resistance and secure mechanical
connections
RECOMMENDED INSTRUMENT TO
BE CALIBRATED
•ALL PROCESS INSTRUMENTS RELATED
DIRECTLY TO
THE QUALITY OF THE PRODUCT
*ALL INSTRUMENTS HAVE AN IMPACT
ON THE SAFETY OF THE PERSONNEL
*ALL INSTRUMENTS NECESSITY FOR
PARTICULAR APPLICATIONS
*INSTRUMENT TRANDUCERS OR
SIGNAL CONVERTER
INSTRUMENT MAY NOT NEED TO

BE CALIBRATED
•SENSORS SUCH AS RTD AND
THERMOCOUPLE

*SECONDARY GAUGES SUCH AS PRESSURE AND


TEMPERATURE

*SELF- DIAGNOSTIC INSTRUMENTS


2010-ExperionMX-English.wmv
STEPS IN PREPARATION OF
CALIBRATION SYSTEM
PROCEDURE
1.Identify instruments to be calibrated
2.Prepare calibration procedure flow chart both
internal and external
3.Prepare calibration checklist
4.Prepare calibration schedule for one FY year
5.Determine target and objective
6.Provide instrument tag and label
7.Implement and monitor
8.Prepare calibration monitoring system
Part 3
INSTRUMENT TUNE - UP
AND ADJUSTMENT
PROCESS CONTROL

IS A TECHNIQUE OF BALANCING
SUPPLY AND DEMAND OVER A
PERIOD OF TIME

ITS OBJECTIVE IS TO MAKE


MEASURED VARIABLE EQUAL TO THE
SET POINT
TYPE OF CONTROLLERS

I. ON-OFF

II.PROPORTIONING
A.POSITION
B.TIME
INSTRUMENTS SIGNAL
Electric:
4-20 mA
1- 5 volts
Pneumatic:
3-15 psi
0.1 -1 bar
AUTOMATIC CONTROL
MODES
PROPOTIONAL VALVE OPENS IN
DIRECT PROPORTION TO ERROR

CORRECTION IS MADE ON THE SIZE OF


ERROR
E= M-R =DEVIATION
RANGE OF THE CONTROLLED VARIABLES REQUIRED
TO MOVE THE OUTPUT OF THE CONTROLLER FROM
ITS LOWEST TO HIGHEST VALUE
RANGE OF THE CONTROLLED VARIABLES REQUIRED
TO MOVE THE OUTPUT OF THE CONTROLLER FROM
ITS LOWEST TO HIGHEST VALUE
SETPOINT 25%
PB
20 mA 50%
PB
100% CONTROLLER OUTPUT
PB
4 mA 12 mA 20 mA

12 mA PB=100% 100 O C 200 O C 300 O C

PB= 50% 150 O C 200 O C 250 O C

PB = 25% 175 O C 200 O C 225 O C


4 mA
25% 50% 75 % 100%

% of Controlled Variable
SPAN= 200O C
100 O C 300 O C
AUTOMATIC CONTROL
MODES
RESET (INTEGRAL)
CONCERNED WITH DURATION
OF THE ERROR .

AVERAGE OF THE ERROR


OVER A PERIOD OF TIME

REPEATS/MIN
OR MIN/REPEATS
WHY OFFSET EXISTS IN

P CONTOLLER
WHY OFFSET EXISTS IN

P CONTOLLER
AUTOMATIC CONTROL
MODES
RATE (DERIVATIVES )
CAN REDUCE OVER PEAKING
BASED ON A RAPIDLY INCREASING
OR DECREASING ERROR SIGNAL.

CONCERNED WITH THE RAPID ERROR


CHANGE
Wintershall_Reference Video 2008.wmv
THANK YOU

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