Process and Instrumentation and Control

ELEC5506 2020
Week 1

Unit coordinator: Professor Brett Nener

March 8, 2020
ii
Contents

1 Introduction 1
1.1 Chemical Engineers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Relay Logic 5
2.1 Relay logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Relay logic design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 A design problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3 PLC 15
3.1 PLCs and Ladder logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Examples of ladder programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3 Counter intuitive function of a ladder program . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.4 Tank filling Ladder program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5 Timers and counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.5.1 Wave forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.6 Conveyor belt program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.7 The parking problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.7.1 Conversion to binary coded decimal TOD . . . . . . . . . . . . . . . . . . . . . . . 45
3.8 The traffic light problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.9 PLC laboratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.9.1 Allen-Bradley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
iv CONTENTS
Chapter 1

Introduction

The following animation gives an overview of the operation of a distributed processing system.1 We
recognize the need for the input of measurements, decisions to be made based on this information and
outputs to actuate pumps, valves etc. Further we note that the flow of this information is distributed over
the whole network of the process.
Most importantly, process control must be safe and economical. The system must operate under
external influences and be able to adapt in the right amount of time to changes in demand. Systems need
to be go through a Start-up or a Shut-down process and this must be done in a safe and economical way.
Good control systems ensure that critical values are not exceeded, that alarms are installed to alert the
appropriate response and that interlocks are in place so that unacceptable control requests are not applied
Control theory was developed by engineers. However, much of this knowledge is now incorporated
in off-the-shelf systems. It is no longer necessary for electrical engineers or chemical engineers to design
the required hardware to control a system. However, it is still necessary for both chemical and electrical
engineers to understand the processes to be able to apply the hardware.
How well a system is controlled often translates to money. While on average the system is meeting the
required value, if the range of variations around the average is high this can lead to system damage and
low quality of service to the customer.
Communication is an important part of this business of control. This need arises in a number of ways.
When describing the system and the desired outcomes we need to be able to talk the same language.
Often this language is through the use of symbols in drawings. However, unless there is an agreement
on the meaning of symbols we will have very different outcomes depending on the interpretation and this
can lead to dangerous situations. To avoid this, international standards are established to ensure that the
same language is used across borders.
Standards are a very important part of engineering and ensure that things are done in a safe manner, to
appropriate standards and that there is no ambiguity in the descriptions in contracts between customers
and providers.
Modern industrial processes are controlled by Programable Logic Controllers (PLCs).These are spe-
cialised computers that are programmed with a special language called Ladder Programming. This lan-
guage processes the input signals and produces output signals in a sequence.

1.1 Chemical Engineers

The following are extracts from IChemE-Australia’s document “Accreditation of engineering programmes
A guide for higher education providers and assessors”:
Learning outcomes
A2.5 Systems – Level B
Students graduating from an accredited programme will:

• Understand the principles of batch and continuous operation and criteria for process selection.
1
(http://electrical-engineering-portal.com/an-introduction-to-scada-for-electrical-engineers-beginners)
2 CHAPTER 1. INTRODUCTION

• Understand the inter-dependence of elements of a complex system and be able to synthesise such sys-
tems by integrating process steps into a sequence and applying analysis techniques such as balances
(mass, energy) and pinch.

• Understand system dynamics, be able to predict the response to changes in a dynamic system, and
be able to design and determine the characteristics and performance of measurement and control
functions.

A3.2 Learning Outcomes – Level B

Students graduating from an accredited programme will:

• Have a knowledge and understanding of laboratory practice, and able to operate bench- (or larger)
scale chemical engineering equipment.

• Be able to undertake well-planned experimental work and to interpret, analyse and report on exper-
imental data.

• Be able to find and apply, with judgement, information from technical literature and other sources.

• Be aware of the importance of codes of practice and industry standards and have some experience
in applying them.

• Be aware of quality assurance issues and their application to continuous improvement.

• Be aware of the range of applications of chemical engineering and the roles of chemical engineers.

• Be aware of the concept and implications of ‘professional’ (chartered) engineers and the role of
Professional Engineering Institutions.

B2.6 Process Safety – Level D

Students graduating from an accredited programme will:

• Be familiar with the inherent nature of safety and loss prevention, and the principal hazard sources in
chemical and related processes – including flammability, explosivity and toxicity (including biological
hazards).

• Be familiar with the principles of risk assessment and of safety management, and be able to apply
techniques for the assessment and abatement of process and product hazards.

• Be aware of the methods of identifying process hazards (e.g. HAZOP), and of assessing environmental
impact.

• Be aware of specialist aspects of safety and environmental issues, such as noise, hazardous area
classification, relief and blowdown, fault tree analysis,

• Have broad knowledge of the local legislative framework and how it is applied to the management of
safety, health and environment in practice and in the workplace, from the perspectives of all involved,
including operators, designers, contractors, researchers, visitors and the public.

A4.3 Learning Outcomes at Level F

Students graduating from an accredited programme will:

• Have a comprehensive understanding of design processes and methodologies and an ability to apply
and adapt them in unfamiliar situations.
1.1. CHEMICAL ENGINEERS 3

• Be able to work with information that may be incomplete or uncertain, quantify the effect of this
on the design and, where appropriate, use theory or experimental research to mitigate deficiencies.

• Have the ability to generate an innovative design for processes, systems and products to fulfil new
needs.

• Have achieved, within the design project(s) some of the ‘Depth’ and ‘Breadth’ Outcomes of Advanced
Chemical Engineering at Masters Level described in Section A6. For example:

– Detailed design of control systems based on process dynamics;

– Design and operation aspects of start-up and shut-down;
– Design of a process for a novel product for which data are unreliable or limited;
– Environmental impact and Life Cycle Analysis;
– Evaluation of financial and other risks.
4 CHAPTER 1. INTRODUCTION