HOW MUCH INSTRUMENTATION IS ENOUGH

Submitted to: Submitted by: Dr. Ing. Naveed Ramzan Syed Ali Sultan (08-Chem-50) Submission Date: 05-11-2011

ACKNOWLEDGEMENT

All the praise is for Allah, the most merciful and beneficent, who blessed me with the light of knowledge, gave me courage and allowed me to accomplish this task. I am especially indebted to all my teachers for instilling in me enough knowledge and to my parents who made me what I am today.

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ABSTRACT The use of newly developed instruments in industry is a common thing but it must be kept in mind that large amount of instrumentation on equipments in industry is not an appreciated thing. In fact, instrumentation must be done just according to the need because over need can cause problems for economical growth of the industry. Large amount of instrumentation is only a burden on the economy. They just do the same as moderate amount of instruments because many of the variables are inter-dependent and can be determined from each other. The report provides knowledge about instrumentation and the instruments whose installation on equipments cannot be denied. Then it carries on and gives information about how much instrumentation is quite enough for process in different equipments and a whole P.F.D by different case studies so that its readers can go to the depth of it. The report has been arranged so that a layman can read it and understand the basics of it. Each topic has been perfectly described keeping in mind about the readers. This report, by its nature, is a collection of knowledge of different books and articles. And I acknowledge all the resources and references I took to complete this report. It is hoped that this report will serve as a basic guidance step for the people who wants to do the research and advancement in it. SYED ALI SULTAN

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Table of Contents
ACKNOWLEDGEMENT...1 ABSTRACT..2 1. BACKGROUND.4 2. INTRODUCTION...4 2.1. 2.2. IMPORTANCE..5 ELEMENTS...6

3. MUST INSTRUMENTATION......................................................................................................9 3.1. TEMPERATURE MEASURING INSTRUMENTS......................................................9 3.1.1. 3.1.2. 3.2. Importance.......9 Types of Temperature Measurement Instrument..10

PRESSURE MEASURING INSTRUMENTS......11 3.2.1. 3.2.2. Importance.11 Types of Pressure Measuring Instruments.12

3.3.

FLOW MEASURING INSTRUMENTS...13 3.3.1. 3.3.2. Importance.13 Types of Flow Measuring Instruments13

3.4.

LEVEL MEASURING INSTRUMENTS..14 3.4.1. 3.4.2. Importance.14 Methods for Measurement...14

4. CASE STUDIES....15 4.1. 4.2. 4.3. 4.4. 4.5. EXOTHERMIC REACTION IN CSTR....15 STORAGE TANK...17 HEAT EXCHANGER.18 FLASH SEPARATOR20 INSTRUMENTATION ON PFD...21

REFERNCES.........................................................................................................................................22

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1. BACKGROUND Although the sensory organs of the human body can be extremely sensitive and responsive, but the parameters to be sensed in the industry are out of range of the human body so there was need of advancement in measuring techniques. The modern science used in industry heavily relies on the development of much more precise measuring and analytical tools for studying, monitoring, or controlling all kinds of phenomena. [9] 2. INTRODUCTION The progress of measurement is the progress of science. Likewise advancement of industrial progress must be preceded by advancement in the art and science of measurement, for the whole foundation of industrial processing and manufacturing lies in the measurement of materials entering into manufacture, measurement of product, and, not the least, measurement of cost. One important phase of measurement is the utility of measuring instruments designed for guiding the progress of various steps in manufacturing and processing. [2] Instrumentation deals with the measurement of desired variables and control of systems. It is carried out to obtain required information for completion of process. Instrumentation is a philosophy based on: [3] i. ii. iii. iv. The preposition that the condition of human society and of industrial processes and operations, i.e. the force of nature, should be controlled, The principle that, before a condition can be controlled, it must be measured, The dictum that, in order to measure a condition or property, it must be segregated, and The logic If you control it manually you should control it automatically.

Instrumentation involves both measurement and control functions so it refer to all those devices that are used in one way or another to measure or control the process parameters involved in the operations. If it relates with measurement then parameter sensing and measuring comes in to it but if control, then it deals with the automatic control of variable by sensing and then comparing it with set point of process. The devices are Instruments and variables to be measured are Temperature, Pressure, Flow, Level, pH, Density, Conductivity, and Viscosity and

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so on. There are many instruments used for a measuring a single parameter and one can choose one of them according to his conditions and economy. For example, to measure temperature simple mercury thermometer to complex RTDs are available but one can choose from them according to his need. Same is the case with pressure measurement and other measuring instruments. Many types of instruments are used in industries as like thermocouples, thermistors, pyrometers (temperature), elastic pressure transducers, piezoelectric transducers (for pressure measurement), analyzers, mass spectrometers (composition). Instruments are not related to the industry only, in fact they are equally important in the house work as well. The common example is of smoke detector or a fire alarm used in houses. From the day one, instrumentation is the field that requires constant attention and development because it is such field that whole of the industry depends upon it. Slight mismanagement can cause havoc and destruction in industry to an endless level. So R&D teams are employed to develop technologies in this field. 2.1. IMPORTANCE

In this, we are very much interested in the measurement and control of the physical parameters that are required for the production of products. Instruments are the eyes for a chemical engineer. Broadly speaking instruments are the eyes with which an engineer can see inside the process i.e. what is happening in the process equipment, what is going in and what is going out. How temperature is changing and with instruments can control the temperature. The quality of product depends on the instrumentation used in particular type of industry. The importance can also be explained by the following points that include: i. ii. iii. Moderate instrumentation helps to ensure safety and health standards in industry. It helps in assuring better quality of end product. Economical growth of the industry.

This is such a field that both minimum and maximum use of instrumentation can create problems for industrial growth. The less number of instrumentation can damage the quality of product or on larger scale can cause havoc and on the other hand, the use of maximum number of instrumentation can cause problems

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regarding economic growth of industry as we all know , the latest techniques instrumentation is much expensive so over numbering is also not desired. 2.2. ELEMENTS

Main elements of instruments are: [5] i. Primary sensing element

First receives energy from the measured medium and produces an output depending on the measured quantify. ii. Variable conversion element

Convert the output signal of the primary sensing element to some other more suitable Variable.
iii.

Variable manipulation element

Change in numerical value according to some definite rule but a preservation of the physical nature of the variable, e.g. an electronic amplifier. iv. Data transmission element

When the functional elements are separated, it becomes necessary to transmit the data from one to another. v. Data presentation element

Present the information about the measured quantity to display. vi. Data storage / playback element

Store the data in the form of recorder or memory.

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Measured Medium

Primary Sensing Element

Variable Conversion Element

Variable Manipulation Element

Data Transmission Element Data Storage/ Playback Element Data Presentation Element
OBSERVER

Figure 1

Elements of Measuring Instrument

Figure 1 shows how the basic elements of instruments are inter-connected. The sequence of elements is not necessarily the same in all instruments. Some instruments skip some and others can skip other depending upon design but the theme will be the same.

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Figure 2 SINGH)

Filled-system Thermometer (Figure 1.2, Industrial Instrumentation and control by S K

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3. MUST INSTRUMENTATION Instrumentation, whose importance cant be denied and are must for proper product formation, can be divided into major sub categories like: 1. 2. 3. 4. Temperature Measuring Instruments Pressure Measuring Instruments Flow Measuring Instruments Level Measuring Instruments

Other categories include instruments to measure pH, Conductivity but are not widely used as instruments mentioned above. They are limited to certain industries.

3.1.

Temperature Measuring Instruments

Progress in the field of science is constantly widening the operating temperature range of processes in industry.[6] Thus, to meet this day by day increment in the range, several physical principles are formed and modified to form a base for temperature measuring instruments. 3.1.1. Importance These Instruments hold a firm position in maintaining the quality and production rate of any industry. The main reason for having such a major importance is the parameter they measure and how much changes in that parameter can affect product. Yes, parameter is temperature and it can effect in following manner: i. ii. iii. Change in temperature will result in the change in other physical properties that depend on it like density, viscosity etc. Variation in temperature will shift the pressure and more importantly shift the Equilibrium in endothermic/exothermic reversible reaction. Temperature change can destroy large scale production

Hence, industries whether small or large majorly depends upon temperature and for this reason temperature measuring instruments have much importance because these are the one which control the temperature up to set limit and tell observer about the emergency situation in industry.

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3.1.2. Types of Temperature Measurement Instruments Major types are described below: i. Filled-Thermal Systems

They are also known by the name of Pressure Spring Thermometers. They are simple in construction and are the inexpensive way of measuring Temperature. Basic construction includes bulb filled with material, capillary tube and expansion element. These are further divided into material that is filled into bulb i.e. Liquid, Gas, Liquid Vapor or Mercury. ii. Bi-metallic Thermometers

This type is based on characteristics of solid to expand upon heating. Different materials expand differently according to their thermal expansion co-efficient. Basic construction is welding of two different metal wires. iii. Thermo-Electrical Instruments

These use electric charge as a basis to measure temperature. Some produce EMF when heated while others oppose the flow of current through them. The sub instruments are Thermocouples Thermistors Resistance Temperature Device (RTDs) iv. Pyrometers

These are the practical application of Stefan-Boltzmann Law of radiant energy emitted by the heated body. These are non-contact type of instruments are furher divided into sub types Brightness Pyrometers Ratio Pyrometers Automatic Pyrometers

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3.2.

Pressure Measuring Instruments

Pressure defined as a force per unit area, is one of the most important of the measured and controlled mechanical-service variables. An exceedingly wide range of pressure from high vacuum to 5000 psi or greater must be measured and controlled accurately and reliably. [6] And to meet this situation these instruments are made with total attention. 3.2.1. Importance Our industrial mechanical systems are operated through pressure e.g. huge hydraulic press in industries is used to press different items. Similarly, car lifters in motor workshop or motor service pumps are operated by pressure. These lifters can lift vehicles to a desirable height so one can do the repairing by going underneath. Also the use of Air pumps and compressors are made easier by pressure. All the above examples describe the importance of pressure measuring instruments. If there were no such instruments installed with the setup, you could not tell how much pressure is required to do the job thus leading to some unwanted incidence. A Pressure gauge is usually a small round shaped instrument which is equipped with a dial and one or two needles pointing to different levels mentioned on the dial. The pointing needles move with increasing pressure and thus you can judge the inner pressure. There are a number of pressure measuring instruments available in the market. You can select one according to requirement of your job. [8] Along with industry, Pressure measuring instruments are important part of our houses. The major example is Blood Pressure Measuring instrument which is becoming a must common thing in our homes. One way or the other, all are familiar with the blood pressure measuring devices and use is very much common on doctor clinics and patients rely on its results. And it proves itself as a life saving device in medical field.

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3.2.2. Types of Pressure Measuring Instruments Major types are explained briefly as below i. Elastic Element Pressure Gauges

Basic principle on which these are built is Elastic deformation i.e. when force is applied on material a temporary deformation from original form occurs provided force is in elastic limit of material. Sub division in this type is due to the use of the material that is subjected to force i.e. Bellow, Diaphragm, and Bourdon. ii. Electrical Pressure Transducers

These are devices that generally convert mechanical output of elastic element pressure gauges to the electrical signals. These are considered as modified of elastic type pressure gauges. They include primary and secondary conversion element that convert output to readable signals. Sub-types include iii. Strain Gauge Piezoelectric Transducer Capacitive Transducer Potentiometric Transducer Inductive / Reluctive Transducer Vacuum / Low Pressure Measuring Instruments

These are used to measure temperature below atmospheric or the vacuum with reference to some reference pressure. The sub types include Pirani Gauge Thermocouple Gauge Ionization Gauge McLeod Gauge

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3.3.

Flow Measuring Instruments

Peak operating efficiency of entire systems demands the maintenance of maximum operating economies. Such flows as steam, air, water, oil, and gas must therefore, are accurately metered from the standard of both total flow and final distribution. [6] The rapid popularity of continuous process rather than batch processes has result in an increase use of flow meters and thus forces technologists to work on and improve the techniques of flow measurement. 3.3.1. Importance Just as pressure and temperature, Flow is another important parameter that leads to better quality of product and safe operations in industry. The accurate measurement of gas and liquid flow is attained by these instruments. As we all know the flow is important for many reasons like i. ii. iii. For the accurate measurement to get perfect proportions of feed. Cost is dependent on flow measurement Efficiency and production of high quality yield

The faulty flow measurement does not only affect required production but also can result in loss in terms of profit and in some cases can be very dangerous and disastrous. [4] 3.3.2. Types of Flow Measuring Instruments Flow sensors and meters are divided into types on the basis of different working principles and methods to find out flow and are as follows: [4] i. ii. iii. iv. v. Differential Pressure Flow Meters Positive Displacement Flow Meters Open Channel Flow Meters Velocity Flow Meters Mass Flow Meters

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3.4.

Level Measuring Instruments

The level measurement is also of great importance in the field of engineering and industry. Whether, the process is continuous, batch, semi-continuous it is necessary to be known of level. Level is important factor to known in any equipment from boiler to distillation columns. [1] Even in home we come across in a situation where we need to measure the level in any utensil. Level is affected very much by the pressure and rate of flow in and out of container. 3.4.1. Methods For Measurement Level is measured by direct or inferred methods described as follows [6], [1] i. ii. Direct Methods Sight Glass Cable and Float Conductivity Heat Transfer Inferential Methods Hydrostatic Pressure Float and Hydraulic Pressure Pneumatic Pressure Diaphragm Box Purge Systems Differential-Pressure Converter Mercury Manometer Non-indicating Pressure Controller Displacement Transmitter Capacitance Gauge Radiation Absorption Gauge

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4. CASE STUDIES Following are the case studies for the explanation of the fact that maximum instrumentation does not mean its perfect, despite that only necessary instrumentation on equipments are well enough for economically well product.

4.1.

EXOTHERMIC REACTION IN CSTR

Assume from somewhere Reactants are added into a CSTR reactor in which exothermic reaction takes place. Product leaves reactor from other side and Reactor is cooled by a coolant stream. So what will be the enough instrumentation to get an economically good product? [10]

Figure 3(a)

Reaction taken place in CSTR

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SOLUTION Reactants enter a jacketed CSTR where a reaction takes place and the products exit. The reactor is cooled via a coolant water stream. The temperature inside the reactor vessel is monitored with a temperature controller (also contained in the controller is a sensor, indicator, and transmitter), which electrically controls a valve. The valve can alter the flow rate of the coolant water stream, thereby controlling the temperature inside the reactor. So flow control instrument is not necessary because it can be controlled by a temperature controller. Same is the case with the pressure controller which controls the pressure as well as amount of feed to be introduced in the CSTR. Therefore, we can deduce that this reaction is most likely gas phase and if the CSTR becomes too full (high pressure) the inlet valve will close.

Figure 3(b) Instrumentation on CSTR

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4.2.

STORAGE TANK

Condensed product from reactor is fed into a storage tank. When the storage tank became full then it can clog the reactants in reactor. What should be Enough Instrumentation on it? [10]

Figure 4

Storage Tank

SOLUTION It is decided that condensed product is allowed to fill the tank up to 90% of total volume to efficiently control the process. So that Ii level increases 90% alarming situation will occur. No other instrumentation is necessary.

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4.3.

HEAT EXCHANGER

Suppose there is a heat exchanger which exchanges the heat from steam to process fluid so that fluid must approach to some set limit value of temperature and can react in reactor afterwards. What would be the Enough Instrumentation on this equipment?

Figure 5(a)

Heat Exchanger

SOLUTION As figure 5(a) clearly describes that the heat is transferred from high pressure steam to the process fluid. The major instrumentations required are Temperature measuring instruments without any doubt because we can only know about the amount heat transferred by checking the temperature. As the steam is of high

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pressure so pressure measuring instrument cannot be skipped. Moreover flow measuring instruments to check the amount of steam and process fluid added to system. Temperature of outlet hot fluid must be linked with the flow of stem into the exchanger by a diaphragm valve.

Figure 5(b)

Instrumentation on Heat Exchanger [11]

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4.4.

FLASH SEPARATOR

Assume we have Flash Separator in which feed comes after passing through two heat exchangers. The main purpose of heat exchanger is to take the temperature of feed up to the set limit before entering into the Flash Drum. Describe about the instrumentation to be used in this case.

Figure 6

Instrumentation on Flash separator [12]

SOLUTION Temperature measuring instruments on all four sides of first heat exchanger and flow meters to account for steam input into the exchanger. The flow of steam is controlled by the temperature controller on top product (vapors) of flash separator. Moreover, the level indicator for the bottom product must be used so as to maintain an optimum level in separator and on this level, flow out of separator is maintained. Flow out of separator from must also be taken into account.

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4.5.

INSTRUMENTATION ON PFD

Figure 7 shows all the necessary equipments of plant i.e. Pumps, Heat Exchanger, CSTR, and Flash Separator. All interconnected to form a process flow diagram of a certain plant. Describe how much Instrumentation is enough for production of efficient product.

Figure 7

Instrumentation on Process flow diagram [13]

SOLUTION All the above mention knowledge about each equipment alone is now joined together to apply on this particular flow diagram. Flow measurement after each pump is necessary. Temperature measurement is also important as far as heat exchangers are concerned. Temperature is also important parameter in reactor to be measured. Thus, this is a perfect example of how much Instrumentation is to be applied on plant i.e. neither too much nor too less, just moderate.

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REFERNCES BOOKS: 1. Austin E. Fabriance, 1962, Industrial Instrumentation Fundamentals, McGraw-Hill, Page 404. 2. Donald P. Eckman, 1957, Industrial Instrumentation, John Wiley & Sons Inc, New York, Pages 1-12. 3. S.K. Singh, 2009, Industrial Instrumentation and Control, 3rd edition, Tata McGraw hill publishers, Page 1. 4. Dr. Shahid Naveed, Dr. Naveed Ramzan, Ms. Sana Yousaf, 2011, Industrial Instrumentation, 1st edition, Allied Book Company, pages 1543, 50-74, and 82-83. 5. Tattamangalam R. Padmanabhan, 2000, Industrial instrumentation: principles and design, Springer-Verlag London limited, Pages 9-18. 6. Howard P. Kallen, B.M.E., M.M.E., P.E., Editor, Handbook of Instrumentation and Controls, 1st edition, McGraw-Hill Book Company, Pages 3-1, 4-1, 5-1, 6-1. WEBSITES: 7. http://en.wikipedia.org/wiki/Instrumentation 8. http://EzineArticles.com/4744755 9. http://www.britannica.com/EBchecked/topic/289430/instrumentation 10.https://controls.engin.umich.edu/wiki/index.php/PIDStandardNotation 11.http://instrumenttoolbox.blogspot.com/2011/04/piping-and-instrumentationdiagrams.html 12.http://www.pc-education.mcmaster.ca/Instrumentation/go_inst.html 13.http://www.lle.rochester.edu/media/omega_facility//documents/P%26ID.pdf

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