Process Instrumentation

Introduction
– Process Instrumentation encompasses
techniques, systems, & devices required to
measure variables, physical & chemical
quantities encountered in processing work
& those means whereby automatic control
of these variables / quantities can be
accomplished.
 Why “Instrumentation” ?
 Ease of Operation
 Product Quality
 Direct Material Saving
 Cost Accounting
 Plant Safety
 Pilot Plants
 Co-ordination
 Process Simulators
 SCOPE
 Field Instrumentation related to
Pressure, Flow, Temp. , Level
Instrumentation and Final Control
Elements
 Control Room Instrumentation : Typical
Control Loop and Control Systems
 Pressure Measurement - 1
 Primary Elements
– Diaphragm Type
 Minimum 0 to 5 mmH2O / Vacuum

 Maximum 0 to 25 Kg/cm2g

 Maximum 0 to 750 Hg Vacuum

 Material of Construction : Beryllium

Copper, SS, Titanium, Monel.
 Application: Low Pressure
Measurement.
 Pressure Measurement - 2
 Primary Elements (Contd.)
–Bellow Type
 Minimum 0 to 125 mmH2O / Vacuum

 Maximum 0 to 55 Kg/cm2g

 Maximum 0 to 750 Hg Vacuum

 Material of Construction : Brass, Phosphor

Bronze, Monel, Beryllium Copper.
 Pressure Measurement - 3
 Primary Elements (Contd.)
–Bourdon Type
 Minimum 0 to 1 Kg/cm2g

 Minimum 0 to 750 mmHg Vacuum

 Maximum 0 to 7000 Kg/cm2g

 Material of Construction : Stainless Steel ,

Phosphor Bronze
 Different shapes viz... C, Helical & Spiral
 Pressure Measurement - 4

 Seals
–Used for Corrosive/Viscous Fluid Services
–Sealing Pot
–Fuel Oil / Steam etc........
–Chemical Seal Diaphragm
–Hf Acid, HBR Acid etc........
 4.1 Flow Measurement

 Head Flow
 Variable Area Flowmeters
 Positive Displacement Meters
 Magnetic Flowmeters
 Vortex Flowmeters
 4.2 Head Flow Measurement
 Principle : Conversion of energy from
one form to another.
 Orifice meters / Venturi meters where
Static Pressure is converted to kinetic
energy.
 Pitot Tube : Kinetic energy to static
pressure.
 Orifice is cheapest and most common.
 4.3 Variable Area Flowmeters
 Principle : Same as of Head Flow
meters.
 Orifice meters gives variable diff.
Pressure for fixed aperture, while in
Area flowmetres for almost constant
diff. pressure. variable area Pressure
is converted to kinetic energy.
 Pitot Tube : Kinetic energy to static
pressure.
 Orifice is cheapest and most common.
4.4 Positive Displacement
Flow Meters

 Highly Accurate for Volumetric Flow

Measurement.
 Useful for Custody Transfer.
 Tankfarms / Billing purposes.
 4.5 Magnetic Flow Meters
 Useful for Services which are
extremely difficult to handle. (e.g...
corrosive acids, sewage, slurries
etc.......)
 Highly sensitive with sustained
accuracy.
 Bi-Directional with Linear Output.
4.6 Micromotion Flow Meters
 Useful for accurate mass flow
measurement.
 Uses Coriolis Principle.
 Also useful for Density
Measurement.
 Useful for Clean as well as dirty
fluilds, Corrosive / abrasive liquids /
slurries.
 Also useful for Cryogenic services.
 5.0 Temperature
Measurement

 Thermocouples.
 Resistance Temperature Detector.
 Filled System.
 Bimetallic Type.
 Radiation Detection Type
 5.1 Thermocouples
 Most Common Method.
 Principle: An elect. current flows in
continuous ckt. of two metals if two junctions
are at different temp.
 “E” Chromel-Constantan -200 to 850 Deg. C
 “K” Chromel-Alumel -200 to 1110 Deg. C
 “J” Iron-Constantan -100 to 750 Deg. C
 “T” Copper Constantan -200 to 350 Deg. C
 “R” & “S” Platinum-Pt.Rhodium 0 to 1450
Deg. C
 5.2 RTD (Resistance Type)
 All pure metals increase in elect.
resistance with rise in temperature.
 Platinum -258 to 1000 Deg. C
 Nickel -150 to 300 Deg. C
 Copper -200 to 120 Deg. C
 5.3 Filled System
 Uses expandable liquids, vapors, or
gases in completely sealed systems.
 Volumetric Pressure - Mercury Vapor or
Liquid for range -240 to 535 Deg.

5.4 Bi-metallic Thermometers

 Uses composite metal strips.
 Used in most of the Temp. gauges /
Overload/overcurrent relays / Temp.
Switches.
 5.5 Radiation Type

 Total Radiation. ( IR Detectors)

 Optical Detection.
 Mainly used in Temp. Survey meter /
portable type.
 Useful for Flame Temperature
Detection.
 6.0 Level Measurement

Level measurement is divided

into two main sections:
- Liquid Level Measurement
- Solids Level Measurement
 6.1 Liquid Level Measurement
 Direct Measurement
– Float and Tape
– Bobs Tape
– Dip Stick
– Gauge Glass
 Tubular
 Reflex
 Transparent
 In-direct Measurement ( Liquid Level)
– Nucleonic.
– Buoyancy - Torque Tube.
– Pressure / Diff. Pressure.
– Bubbler.
– Ultrasonic.
– Conductivity.
– Capacitance.
– Radar.
– Magneto-strictive.
– Tuning Fork / paddle wheel for Level
Switches
 6.2 Solids Level Measurement
 Direct Measurement
– Bob and Tape.
 In-direct Measurement
– Nucleonic
– Ultrasonic.
– Capacitance.
– Radar.
– Tuning Fork / paddle wheel for Level
Switches.
 7.0 Final control Elements
 Control Valves
 Motor Operated Valves
 Rotary Equipments
 7.1 Control Valves
 Types of Valve Body
– Globe Type.
– Butterfly Type.
– Ball Type.
– Needle Valves.
– Angle Valves.
 Types of Valve Actuators
– Air Operated.
– Elect. Operated.
– Hydraulic Operated.
 7.2 Motor Operated Valves
 Used for Bigger Line sizes / large
pressure drops / where air or hydraulic
actuators are not capable.

7.3 Rotary Equipment

 Variable Speed Devices
– Rotary valves,
– Screw pumps,
 8.0 Typical Control Loop

Transmitter

I/P

Final Control Controller

Element

CONTROL
FIELD ROOM
 9.0 CONTROL ROOM
INSTRUMENTATION
 DCS
 SCADA
 ESD
 ANNUNCIATION SYSTEM
 PA SYSTEM
 9.1 DCS
 APPLICATIONS
– DATA MONITORING
– PROCESS CONTROL
– HISTORY
– ALARM / EVENT LOGGING
– REPORT BUILDING
– LOGICAL / SEQUENTIAL OPERATION
– STATISTICAL PROCESS CONTROL
– ADVANCED PROCESS CONTROL
– OPERATOR INTERFACE
 9.1 DCS (contd.)
 MANUFACTURES / MODEL
– ABB ( MOD300 ADVANT)
– FOXBORO (IA SERIES)
– YOKOGAWA (Centum)
– TATA Honeywell ( TDC 3000 )
– ROSEMOUNT (Provox & Delta V)
 9.2 SCADA
 APPLICATIONS
– DATA MONITORING
– HISTORY
– ALARM / EVENT LOGGING
– REPORT BUILDING
– OPERATOR INTERFACE
 9.3 ESD
 Application
– Safety Interlock.
– Operational Interlock

 Systems
– Relay Based.
– PLC Based.
– DCS / TCL Based.
 9.4 ANNUNCIATION

 Microprocessor Based.
 DCS Based.
 Event logging.
 9.5 PA SYSYTEM

 EPABX by TATA Telecom

 ITT Terryphone
 COEX PA System
10.0 Instrument Maintenence

 Predictive Maintenence
 Preventive Maintenence
 Breakdown Maintenence
 10.1 Preventive and
Predective Maintenence
 Predefined status monitoring /
maintenence schedules are prepared by
CES in co-ordination with the plant.
 The relevant maintenence reports are
generated and studied using VAX
system. History is also maintained.
 Preventive Maintenence is taken up in
co-ordination with Mech. / Elect. where
ever interface exist.
10.2 Breakdown Maintenence

 Normally being attended by Plant.

 CES Instruments provide services like
repairs, Control valve maintenence,
calibration of all types of Instruments,
Testing.
 Interface with Process / Mechanical /
Electrical Dept. during Breakdown
maintenence.
11.0 Instrument Documents
 PFD and P & I Drawings.
 Instrument Index.
 Instrument Loop Drawings.
 Instrument Interlock Drawings.
 Instrument Hookup Drawings.
 Trip and Alarm Schedule.
 Instrument Specifications.
 Instrument Instruction Manuals.
 Project Data Manual.
 DMR / Cal. & Test Reports
12.0 CES Instrumentation
 Maintenence Services:
– Repairs / Testing / Calibration of
Instruments.
– Servicing & Overhauling of Control Valves.
– Calibration of TCI / CSI.
– Calibration of Safety Instruments.
– PA System.
– FA System.
– ISO Procedures.
– Common Spares for DCS / PG / TG /
Transmitters.
 12.1 CES Instrumentation
 Engineering Services:
– Liasion with Weight & Measures Dept. for
verification and stamping of weigh-scales /
weigh-bridges and weights.
– Liasion with BARC for Radioactive
Instruments.
– Design / Sizing for Orifice, Control valves,
Safety Valves.
– Review of Plant Modification Proposals.
– Training on Various Instrumentation
systems.
– Failure Analysis / Recommendations.