4 - Process Control, Instrument & Safety Instrument - Zaini Edited

Training Basic Electrical, Process Control, Stationary &
Rotary Mechanical Equipment untuk HSE Marketing
Modul Process Control, Instrument & Safety Instrument
www.oilgascourse.com 1
Course Objective
1. Untuk mengetahui&memahami tentang Basic
Components pada Control System & Parameters
2. Untuk mengetahui&memahami tentang Pressure
Measurement,Temperature Measurement&Flow
Measurement
3. Untuk mengetahui&memahami tentang Control Valve
Classification
4. Untuk mengetahui&memahami tentang Flow
Characteristics&Leakage Classifications
5. Untuk mengetahui&memahami tentang Analytical
Measurement
6. Untuk mengetahui&memahami tentang Control Loop
Hardware
7. Untuk mengetahui&memahami tentang Process Safety
Control
Instrumentation and
control
Instrumentation and control system is designed
for minimum local manning and operator
attention.
The basic need of the instrumentation us for

safe operation and efficient functioning of the
plant.
This can be achieved by installing optimum

number measurement, indicating, transmitting
and controlling instruments for all required
parameters of the plants (e.g. pressure, level,
temperature, flow etc.)
BASIC COMPONENTS OF A
CONTROL SYSTEM
 Sensor
• Also often called as Primary Element.
• Acquires information about the status of the process
variables.
• Typical examples:
RTD/thermocouples (for temperature measurements),
Capacitance type cells (for liquid level /draft /pressure
measurements), etc.
 Controller
• The Brain or Heart Of the control system (the decision
maker).
• It is the hardware element with Built-in capacity for
performing the only task requiring some forms of
Intelligence.
Electronic controllers, digital computers used as controller.
CONTROL SYSTEM
 Transmitter
• Secondary Element.
• Responsible of passing the information acquired by
the sensor to controller and sending the controller
decision to the final control element.
• Measurement and control signals may be
transmitted or as electrical signals.
Electrical transmitters.
 Final control element

• Have the task of actually implementing the control
command issued by the controller on the process.
Control valve, variable speed motors, electric
motors etc.
CONTROL SYSTEM
• The importance of these components is that they
perform the three basic operations that must be
present in every control system:
1. Measurement:
Measuring the variable to be controlled is usually
done by the combination of sensor and transmitter.
2. Decision:
Based on the measurements and the set point, the
controller must then decide what to do to maintain
the variable at its desired value.
3. Action:
As the result of the controller's decision, the system
must then take an action. This is usually
accomplished by the final control element.
Basic Parameters
Measurement & Control of
following Parameters are
essential for Instrumentation :
• Pressure
• Temperature
• Flow
• Level
TAPPING POINTS
GASES
STEAM
GASES
LIQUIDS
Pressure
Pressure measurements are one of the
most common measurements required in
the boiler.
These range from very low -1500mmwc

Draft to very high steam pressure 150
kg/cm2 .That include different type of
media like steam ,water, fuel oil, air, gas
each with varying degree of accuracy and
reliability.
Pressure varies depending on altitude

above sea level, weather pressure fronts
and other conditions. The measure of
pressure is, therefore, relative and pressure
measurements are stated as either gauge
or absolute.
A gauge pressure device will indicate zero
pressure when bled down to atmospheric
Pressure
• Absolute pressure includes the effect of
atmospheric pressure with the gauge
pressure. It is denoted by an (a) at the end
of the pressure unit [e.g., kPa (a)].
• An absolute pressure indicator would

indicate atmospheric pressure when
completely vented down to atmosphere - it
would not indicate scale zero.
• Absolute Pressure = Gauge Pressure +

Atmospheric Pressure
• The majority of pressure measurements in

a plant are gauge.
Pressure
Temperature Measurement
Temperature is measured by following:
1. Temperature Gauge:
a. Mercury in Steel type
b. Bi-Metallic
c. Gas Filled
2. Temperature Sensors:
a. RTD
b. Thermocouple
Flow Measurement
The common flow measuring

devices used in boilers are :
• Head Meter :
• Orifice Plate
• Flow nozzle
• Rotameter ( variable Area Type)
• Positive Displacement meter
Flow Measurement
• Installation:
• Flow sensors are installed in line of the
fluid to create DP & hook-ed up with
transmitter for measuring Differential
Pressure, which corresponds to flow:
• Q = K1*  (P/T ) *  DP
Where,
DP= differential pressure across the flow
element
P = Main Steam Pressure
T = Main steam temperature
K1 = Constant
Q = Compensated flow
Drum Level
Drum Level Control Method

 Single Element
 Three Element
Shrink & Swell Effect

Shrink : When Steam Flow Decreases
Drum Level Decreases
Swell : When Steam Flow Increases
Drum Level Increases
Basic Elements
 Drum Level
 Steam Flow
 Feed Water Flow
Transmitter
• Typical Basic Operation of

Transmitter
SENSING
TRANSDUCER INDICATION
ELEMENT
Sensing Element + Transducer

= Transmitter unit
Transmitter
• Transmitters are generally use is of 2 wire

type. This is the most widely used method
for transmitter connections .There are
three basic elements in this loop, namely
Power Supply , transmitter and the
receiving instrument .They are connected
in series and the transmitter acts as a
current regulator in the series circuit . The
current in the series circuit changes with
respect to change in process parameter.
This simplifies cabling and reduces
erection and cable cost.
Transmitter
Normal Pressure Transmitter
Transmitter
Differential Pressure
Transmitter
Control Valve
Being the Final Control Element in a system is not

an easy job.
To start with, Control Valves are blamed for any

and all problems that crop up in the process.
Control Valve are subjected to corrosion, high

velocity, cavitations, flashing liquids, cryogenic
temperatures, abrasion, high temperatures and
thermal shock.
Control Valve are expected not only to throttle

along through all this, but most likely, you are
also being asked to act as a block valve and shut
off tight.
Control valve in action
(EMERSON,2017)
Sliding-Stem Control Valve
(EMERSON,2017) www.oilgascourse.com 22
Proses Variability
Process variability is a precise
measure of tightness of control
and is expressed as a
percentage of the set point.
(EMERSON,2017)
Important Design Aspect of Valve
Deadband
Actuator/positionerdesign
Valve response time
Valve type and characterization
Valve sizing
Deadband
The range through which an
input signal can be varied,
upon reversal of direction,
without initiating an observable
change in output signal.
(EMERSON,2017)
Actuator/positioner design
A positioner can be thought of as a high
proportional gain device.
Additional tuning parameters, such as
derivative gain, which largely exist to
remove undesirable characteristics and
further tune the assembly to the
desired performance.
Many positioners also include an
integral capability to remove any
offsets between valve set point and
position.
Valve response time
Valve response time is measured by a
parameter called T63.
T63 is the time measured from
initiation of the input signal change to
when the output reaches 63% of the
corresponding change.
It includes both the valve assembly
dead time, which is a static time, and
the dynamic time of the valve
assembly.
Valve type and characterization
The ratio of the incremental change in valve flow (output) to

the corresponding increment of valve travel (input) which
caused the flow change is defined as the valve gain.
Control Valve Flow
Characteristics
Performanc
e test
Performance test (2)
Itis critical to measure dynamic
performance of a valve under flowing
conditions so the change in process
variable can be compared to the change
in valve assembly input signal.
For Valve A, the process variable
responds well to input signals as low as
0.5.
Valve B requires input signal changes as
great as 5% before it begins responding
faithfully to each of the input signal
steps.
Valve C is considerably worse, requiring 31
www.oilgascourse.com
Valve sizing
Oversizing the valve hurts process
variability in two ways.
First, the oversized valve puts too much
gain in the valve, leaving less flexibility
in adjusting the controller.
The second way oversized valves hurt
process variability is that an oversized
valve is likely to operate more
frequently at lower valve openings
where seal friction can be greater.
Control Valve Standards
American Petroleum Institute (API)
American Society of Mechanical Engineers
(ASME)
European Committee for Standardization
(CEN)
Fluid Controls Institute (FCI)
Instrument Society of America (ISA)
International Electrotechnical Commission
(IEC)
Manufacturers Standardization Society (MSS)
NACE International
IEC Standard
 60534-1, Part 1: Control valve terminology
and general
 considerations
 60534-2-1, Part 2: Flow capacity - Section
One: Sizing equations for
 incompressible fluid flow under installed
conditions
 60534-2-3, Part 2-3: Flow capacity - Section
Three: Test procedures
 60534-2-4, Part 2-4: Flow capacity- Section
Four: Inherent flow characteristics and
rangeability
 60534-4, Part 4: Inspection and routine testing
 60534-5, Part 5: Marking
IEC Standard (2)
 60534-6-2, Part 6-2: Mounting details for
attachment of positioners to control valve
actuators - Section 2:Positioner mounting on
rotary actuators
 60534-7, Part 7: Control valve data sheet
 60534-8-1, Part 8-1: Noise considerations -
Section One: Laboratory measurement of noise
generated by aerodynamic flow through control
valves
Section Two: Laboratory measurement of noise
generated by hydrodynamic flow through control
valves
Section Three: Control valve www.oilgascourse.com
aerodynamic noise35
Control Valve Leakage Classifications
• Class I:
Identical to Class II, III, and IV in construction and design
intent, but no actual shop test is made.
• Class II:
Intended for double-port or balanced singe-port valves with a
metal piston ring seal and metal-to-metal seats. Air or water
at 45 to 60 psig is the test fluid. Allowable leakage is 0.5% of
the rated full open capacity.
• Class III:
Intended for the same types of valves as in Class II.
Allowable leakage is limited to 0.1% of rated valve capacity.
• Class IV:
Intended for single-port and balanced single-port valves with
extra-tight piston seals and metal-to-metal seats. Leakage
rate is limited to 0.01% of rated valve capacity.
Control Valve Leakage Classifications
• Class V:
Intended for the same types of valves as
Class IV.
The test fluid is water at 100 psig or
operating pressure. Leakage allowed is
limited to 5 X 10 ml per minute per inch of
orifice diameter per psi differential.
• Class VI:
Intended for resilient-seating valves.
The test fluid is air or nitrogen. Pressure is
the lesser of 50 psig or operating pressure.
The leakage limit depends on valve size and
ranges from 0.15 to 6.75 ml per minute for
valve sizes 1 through 8 inches.
Safety Instrumented
System
SIS is considered separate than the
basic process control system (BPCS) in
that the SIS is dedicated to taking the
process to a “safe state” should a
critical situation occur.
The SIS consists of several safety
instrumented functions (SIF), Each SIF
is a separate or interlinked loop
comprised of sensors, logic solver
(LS), and final control element (FE).
Safety Standards
IEC Standard 61508 (Functional Safety
of Electric, Electronic and
Programmable Electronic Systems) is
a general standard that covers
functional safety related to all kinds of
processing and manufacturing plans.
IEC Standard 61511 and ISA S84.01
(Replaced by ISA 84.00.01-2004) are
standards specific to the process
industries.
Components of a Safety
Instrumented System
Safety System Basics:
The Safety Instrumented System General abbreviation: SIS

AKA: Trip system, shutdown system, instrumented protection system
(IPS)
The SIS is an example of a Functional Safety System Meaning:

Safety depends on the correct functions being performed
Functional safety:
Part of the overall safety relating to the process and the BPCS which
depends on the correct functioning of the SIS and other protection layers.
(IEC 61511 clause: 3.2.25)
Process Control versus Safety Control
Separation of safety controls from process controls

DCS
Control
System
Operating
Equipment
Protection
System
SIS
What Is Hazard and What Is Risk?
Hazard
An inherent physical or chemical characteristic that has the potential for
causing harm to people, property, or the environment.
Risk
The combination of the severity and probability of an event.
Risk = frequency x consequence of hazard.
Simple Shutdown System: Example 1 Vapour Hazard
PSV
LC
1
I/P
Fluid
Feed
FC
LT
1
Basic tank level control with overflow hazard
Simple Shutdown System
HS LAHH
Reset 2 2 Tripped Alarm
Logic Solver
LI PSV
2
AS LC
1
I/P
Fluid
Feed
FC FC
LT LT
1 2
FC = fails closed on loss of air pressure
Typical multiple stage plant trip and ESD system
Stage 1 Plant Emergency Shutdown Command
high pressure
Stage 1
low level
Stage 3 tripped
Stage 1 Trip
Stage 2
high temperature
Stage 2
high level
Stage 3
high level
Stage 2 Trip
Time delay Stage 3 Trip
Measurement of Risk
Qualitative: High, Low, Moderate
An effective measure if we all have the same

understanding of the terms
Quantitative: 1 in 10 years x 5 people hurt
Effective if you can guess the numbers
Risk = Frequency of Event x Consequence
Fatal Serious Minor

injury injury
Risk
Consequences
Frequency
To Reduce Risk:
Reduce Frequency or Consequence or do both
Fatal Serious Minor

injury injury
Consequences
Risk
Frequency
Risk Reduction: Design Principles
Hazard Identified
Risk Tolerable Risk

Estimated/Calculated Established
Risk Reduction
Requirement
Safety Function Defined

SIL Target Defined
Safety Integrity Levels
SIL are quantifiable measurement of risk
used as a quantifiable way to establish
safety performance targets for SIS systems.
IEC standards specify four possible Safety
Integrity Levels (SIL 1, SIL 2, SIL 3, SIL 4);
however, ISA S84.01 only recognizes up to
SIL 3.
Hazards can be identified using a number
of different techniques; one common
technique is a HAZard and OPerability study
(HAZOP).
Safety Integrity Levels (2)
The HAZOP study is used to identify
the risk to personnel or the
environment and is carried out by a
multi-disciplinary team (HAZOP team).
Once the risk is identified, the
HAZOP/process hazard study (PHA)
will set the requirement for risk
reduction, thus define the required SIL
Level.
Safety Integrity Levels and
Associated PFDavg and RRF
Figures
SIS Failure
There are two basic ways for the SIS to
fail.
The first way is commonly called a
nuisance or spurious trip, which usually
results in an unplanned but relatively
safe process shutdown.
The second type, the failure remains
undetected, permitting continued
process operation in an unsafe and
dangerous manner.
These failures are known as hidden
failures and contribute to the probability54
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Intuitively what does SIL mean ?
Statistical representations of integrity of
SIS
For example: SIL 1….
◦ SIS with availability of 90% is acceptable
◦ High level trip in a liquid tank
◦ Availability of 90% (10% chance of failure)
◦ One out of every 10 times the high level was
reached, there would be a failure
◦ Subsequent overflow 1 out of every 10 times.
THANK YOU
Training Basic Electrical, Process Control, Stationary & Rotary
Mechanical Equipment untuk HSE Marketing
Modul Process Control, Instrument & Safety Instrument

4 - Process Control, Instrument & Safety Instrument - Zaini Edited

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Training Basic Electrical, Process Control, Stationary &

Rotary Mechanical Equipment untuk HSE Marketing

Modul Process Control, Instrument & Safety Instrument

The basic need of the instrumentation us for

This can be achieved by installing optimum

 Final control element

These range from very low -1500mmwc

Pressure varies depending on altitude

• An absolute pressure indicator would

• Absolute Pressure = Gauge Pressure +

• The majority of pressure measurements in

Temperature is measured by following:

The common flow measuring

Drum Level Control Method

Shrink & Swell Effect

• Typical Basic Operation of

Sensing Element + Transducer

• Transmitters are generally use is of 2 wire

Normal Pressure Transmitter

Being the Final Control Element in a system is not

To start with, Control Valves are blamed for any

Control Valve are subjected to corrosion, high

Control Valve are expected not only to throttle

The ratio of the incremental change in valve flow (output) to

The Safety Instrumented System General abbreviation: SIS

The SIS is an example of a Functional Safety System Meaning:

Separation of safety controls from process controls

Risk = frequency x consequence of hazard.

Basic tank level control with overflow hazard

Time delay Stage 3 Trip

Qualitative: High, Low, Moderate

An effective measure if we all have the same

Quantitative: 1 in 10 years x 5 people hurt

Effective if you can guess the numbers

Fatal Serious Minor

Fatal Serious Minor

Risk Tolerable Risk

Safety Function Defined

Modul Process Control, Instrument & Safety Instrument

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