ICE 515

PRELIMS: INSTRUMENTATION AND CONTROL

FUNDAMENTALS.

MIDTERM: PROCESS VARIABLES FUNDAMENTALS

SEMI FINALS: PRESSURE AND TEMPERATURE

MEASURING INSTRUMENTS

FINALS: LEVEL AND FLOW MEASURING INSTRUMENTS.

Basic Instrumentation
Fundamentals
 The Manufacturing Plants

How do these
huge plants
work and being
controlled?

INSTRUMENTATION
Instrumentation and
Instrument
 Starry
night..
What is Instrumentation?

Sometimes it refers to
research instruments..
Denotes musical instruments..
General Definition of Instrumentation:

Instrumentation can be defined as the art and

science of measurement and/or control.

Instrumentation is achieved by utilizing an

“Instrument”.
Definition of Instrumentation based on the
Concept of Industrial Application :

“It is the application of instrument for the purposes of

measuring, observing, transmitting, indicating, recording,
monitoring and controlling of any industrial process
variable.” (Such as: Pressure, Temperature, Level, Flow, Product
Quality and etc.)

Instrumentation exist in the following examples:

1. Use of thermometer to determine fluid temperature.
2. Use of fuel and temperature gauge in a car.
What is an Instrument?

An “Instrument” is any device used directly or

indirectly in order to accomplish an objective or task.

In instrumentation, an instrument is any sensing,

measuring, transmitting, indicating, or controlling device
associated with a process or system.

Example: Measuring body temperature using a thermometer.

Thermometer is what is called the instrument.
 Deep Well Water Supply Instrumentation System

PRV
Instruments
70 psi

Vapor Space PG

Vp
Manual Switch

MCC pH
AI
Cut-in = 20 psi
Cut-out = 60 psi Pressurized
Tank Water to
consumer

PS = Pressure Switch
Pump MCC= Motor Control Circuit
PG = Pressure Gauge
RV = Relief Valve

Deep Well Drain AI = Analytical Indicator

Instrument Application
Categories & Instrumentation
Functional Divisions
 Instrument Application Categories:

This category includes instrument

directly used in automating factory
This category includes instrument
operational sequences. Mostly
directly used in safety instrumented
involves conveyor controls and Factory system. Ex: Plant abnormal
other switching processes.
Automation condition alarm & trip system
Instruments including fire & gas protection
Plant Safety or system.
Safeguarding
Instruments
Process Variable This category includes
Measurement and Product Quality instrument directly used in
Monitoring/Cont monitoring product quality
Control Instruments such as: color, density,
rol Instruments viscosity, pH and etc.

Environmental
This category includes instrument Condition
directly used in monitoring This category includes
Monitoring/Control
variables involve in converting raw instrument directly used in
material to a finished product both Instruments
monitoring environmental
in a chemical & physical processes conditions. Ex: SO2, CO, CO2,
Variable such as level, pressure, NOx and etc.
temperature and flow.
 Deep Well Water Supply Instrumentation System

PRV

Auto Run Command

70 psi

PS
Vapor Space PG

Vp
Manual/Auto
Switch
MCC pH
AI
Control Pressurized
Cut-in = 20 psi Parameters: Tank Water to
Cut-out = 60 psi consumer

PS = Pressure Switch
Pump MCC= Motor Control Circuit
PG = Pressure Gauge
RV = Relief Valve

Deep Well Drain AI = Analytical Indicator

Mechanized Factory Automation:

Filling Capping Sorting

Machine Machine Machine

Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30

Z-30

Z-30

Z-30 Z-30

Product Canning Process

Z-30 Z-30 Z-30 Z-30

How is Instrumentation Implemented?

1. Simple or stand alone system.

2. Complex system.
Simple or Stand Alone System:

Temperature
is 70 Deg.C

Fuel is
50%
Instrumentation System
and Automation
Instrumentation System:

Instrumentation system is an arrangement of two or

more instruments connected together to perform a
unified task.
Each instrument operates independently according to its
specific task. Failure of one member instrument, means
failure of the entire instrumentation system.
A simple example of an instrumentation system is a
Control Loop.
 Operator enter the
Ex: Complex System desired SP during
normal operation.

25
If TICA and FICA m3/hr
250ºC

Smoke Stack
O2 AI SP SP
control outlet 2%
FICA TICA

temperature and
flow respectively in 80ºC TI
Operator Operator

an AUTOMATIC
manner, THEN, F-01 FT TT
process is safe and
therefore plant is
I/P
safe.
Heated Crude to Distillation Column

Gas Fired
Crude Furnace
Oil FICV
Basic Process
Control System
I/P (BPCS) of a Crude
Comb. Air Oil Heating Process

Fuel TICV
Gas

Crude Oil Heating Process

Instrumentation System and Automation

Automation is a system concept that utilizes

instrumentation system to perform certain task or
sequences of operations in an automatic manner or
without human intervention.
Relationship between Instrument, Instrumentation
System and Automation:

Automation

Instrumentation
System

Instrument
Automated Process
Instrument, Instrumentation System & Automation:

Applying the concept of automatic

Automation control strategy.

Instrumentation 2 or more instruments connected

System together doing a unified task.

Device used to measure/control

Instrument
process variable.

Conversion of raw materials to finished

Process product.
What is an Automated Process?

Automated Process is a process or sequence of

production activities done in an automatic manner
or without human intervention.
Types of Automated Process:

• Highly Mechanized Process

• Chemical and Physical Process
Highly Mechanized Process (Car Assembly)
 Filling Capping Sorting
Machine Machine Machine

Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30 Z-30

Z-30

Z-30

Z-30 Z-30

Highly Mechanized Process

(Product Canning) Z-30 Z-30 Z-30 Z-30
Chemical & Physical Processes
(Petroleum Processing Plant)
Factors that could influence the effectiveness of
an automated process operation:

• Proper system design and equipment selection.

• Proper equipment installation and commissioning.
• Good maintenance.
• Properly trained operating and maintenance staff.
Overall Benefit in Implementing Plant
Automation (Business Point of View)

• Increases production efficiency.

• Increases product quality assurance.
• Increases plant safety.
• Lowers production cost.
• Increases profit & real wages of labor
Automation and the Society:

Plant Automation has made a major contribution

towards an increase in both free time and real wages
enjoyed by most workers in industrialized nations.
Automation has greatly increased production volume,
quality and lowered cost, thereby making products and
other goods available to more people. It has allowed
production and wages to increase, and at the same time
the work week has decreased from 60 to 40 hours.
Automation and the Individual:

The effect of plant automation on the individual has

been more drastic. The worker is either displaced or
unemployed. Workers who remain must operate or
maintain technologically advance machines, and they
may also be required to monitor more of the plant
operation and to make on-the-spot decisions. Thus, the
education and experience levels of these workers are
considerably above those of the workers who were
displaced.
Common Industrial
Applications
 Oil & Gas

Chemical & Petrochemical

Aeronautics & Aviation

 Marine Science & Navigation

Power Industry

Oil & Gas Overview Medical Sciences

Instrumentation
Symbols
Instrumentation Symbols:

SYMBOL is considered the language of instrumentation.

Understanding and interpreting these symbols are easier
when everybody speaks the same language.
Consequently, by putting symbols together in a drawing,
a process diagram can be achieved which provides an
overall view of the process and the different
instrumentation as well.
Types of Instrumentation Symbols:

• Instrument Symbols
• Line Symbols
• Valves & Actuators
Instrument Symbols:

Instrument symbols such as

circles, lines, letters, and
numbers are used to provide
information about the
process.
Symbols may represent
devices in the system or
indicate how devices are
connected to each other or to
the process and also
indicates its function. ( i.e.
measure, indicate, record or
control)
 General Symbol Notion (As to Function)

Discrete Indicates a stand-alone

Instruments instrument.

Shared Display, Indicates an instrument has

Shared Control shared display or control.

Computer Indicates a computer function.

Function

Programmable Indicates a programmable

Logic Control logic control.
 General Symbol Notion (As to Mounting)
Panel Field Auxiliary Behind
Mounted Mounted Room Panel

Discrete
Instruments

Shared Display,
Shared Control

Computer
Function

Programmable
Logic Control
Line Symbols:

Line symbols indicate

how instruments are
connected to each other
and to the process and
represents the types of
signals transmitted in the
process.
Line symbols could be
either a process line
symbol or a signal line
symbol.
Process Line Symbols:

Process line symbols used

to represent process lines and
instrument connections.
Process piping is generally
shown with thick solid lines.
Process line.
Thin solid lines indicate
instrument-to-process Instrument
connection line.

connections or instrument
tubing. In general, assume all
instrument line is fine in
relation to process piping line.
Types Connection:
Signal Line Symbols:

Signal lines represent

unique and critical
information on a P&ID. They
may be pneumatic, electric,
or optical.
In general, one signal is used
to indicate the connection
between two instruments
even though they may be
connected physically by more
than one line.
Common Signal Line Symbols
Valves and Actuators:

Valves and actuators that

position them are critical
parts of all process systems.
Just as it is essential to
know the meaning of the
symbols for instruments,
primary elements, lines, and
tag numbers, when
interpreting a process
diagram, it is also necessary
to recognize the symbols for
actuators to interpret how
these components function
within the process.
 Valve and Actuator General Symbols (ATO):

Actuator

Air

Valve Body

Spring-to-Close
or
Air-to-Open
Valve and Actuator General Symbols (ATC):

Air

Actuator

Valve Body

Spring-to-Open
or
Air-to-Close
Valve and Actuator General Symbols (Manual Valve):

Handle

Valve

Manual Valve
Symbols of Common Types of Process Valve
Body:
Common Types of Valve Actuator:
Control Valve Fail Mode
The Process “Fail Safe
Concept”
 What is the basis in determining the
right Control Valve action to be used?
(ATC or ATO)

“The Fail Safe Concept”

The action of the control valves are based on “Fail Safe Concept”
What is Fail Safe Concept?

Fail Safe Concept is an applied instrumentation concept

wherein during plant emergencies, the instrumentation
system will bring down the plant into safe condition.
Instrument Tag
Numbers
What is a Tag Number?

Instrument Identification Number or Tag Number is an

alphanumeric codes that provides specific information about an
instrument or its functions.

A typical Tag Number contains

two types of information:
• Functional Identification
• Loop Identification
 Functional Identifier/Identification:

A functional Identifier is a series of letters, or letter code, that

identifies the function of the instrument.

The first letter identifies the

measured or initiating
variable.
The succeeding letters
designate one or more
readout or passive functions
and/or output functions.
Typical Tag Number - Functional Identifiers

Functional
FICA identifiers
101

I/P
FI

101

FT-101
FICV-101 or
FCV-101

Process
Example 1: Functional Identifier – Typical Tag Number

FICA–101
What does FICA it mean?

F = Flow (Initiating Variable)

I = Indicating Function
C = Control Function
A = Alarm Function
Loop Identification:

Loop identification numbers

indicate the loop in which
an instrument belongs. The
loop identification number
is assigned to all of the
instruments included in the
loop regardless of their
function or location.
 Typical Tag Number - Loop Identifiers

FICA Loop identifiers

101

I/P
FI

101

FT-101
FICV-101 or
FCV-101

Process
 Expanded Tag Numbers

32-FICA-101

I/P
32-FI-101

32-FT-101

32-FCV-101

Process
Example 1: Expanded Tag Number

32-FICA–101
What does it mean? 32 = Optional Prefix
F = Flow
I = Indicating Function
C = Control Function
A = Alarm Output
101 = Loop Number
Example 2: Expanded Tag Number:

TDICA–101
PDIC –202
What does it mean?

TD = Stands for Temperature Differential

PD = Stands for Pressure Differential
Example 3 :
Expanded
Tag
Number:
Tag Prefix and Suffix:

A prefix may be added to the Tag No. to denote

area or plant location.
A suffix may be added to the loop number in
loops that contain more than one instrument with
the same functional identification.
32-FI-101

32 = Prefix
A = Suffix

32-FT-101A 32-FT-101B

Process
Loop Numbering:

Loop numbering may be parallel or serial.

With parallel numbering, a numerical sequence is
started for each new first letter.
Example : TIC-100, FRC-100, LIC-100

Serial numbering uses a single sequence of numbers

for a project or for large sections of project
regardless of the first letter of the loop
identification.
Example : TIC-100, FRC-101, LIC-102
Exercise: Identify the different instrumentation
symbols:

PI-1 6.

7. 5.

4.

3. PT-1

2.

1.