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Fundamentals of !ndustrial
Control WEEK 5
-This week : Process Control Primer
-Terminology
-
How was it last Week?
-Recap of last Week:
-Remember the terms?
-Types of Temperature Sensors
-When and Where to Use What We Need to Use
-Homework Done?
-Did You Read Up?
Thermometers P96
- Liquid !n Glass Type: Prinicpally used for
Commercial Services
-Expansion of An Alcohol based susbstance
-to expand within a fixed volume area in a
direct correlation to a fixed mechanical scale
Alcohol Basics
Filled Systems
- Have higher volume of volatile liquid
- Changing volume compresses gas fliquid
to make a pressure exert on a Bourdon
tube,identical to a pressure gauge!
- Good accuracy at limited small ranges
- !naccurate at large ranges
Different Class 8 Grades
- All operate the same
- Class 2A,B,C,D different ranges and
voltile liquid fills are used.but in the end
- They all do the same function..expand
and generate pressure!
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Nechanical Gas Operated
Thermometer
2 1/2(63mm), 3 1/2(90mm), 4(100mm), 4 1/2(115mm), 6(150mm), 8(200mm) dials
1/2(12.7mm) x 6(150mm) bulb is standard
Double braided copper capillary or stainless steel capillary
Numerous options: armour, duct flanges, compensated capillary, longer bulbs etc.
Other dial sizes available
Other bulb sizes available
2 accuracy Vapour actuated
Pro f Cons List
- Pro: Provide reliable indication and can
be remote located away from process.
- Pro: No Power required to operate
process !.e. Temperature
SwitchfRecorderfController
- Con: Expensive to manufacture, no
longer mass produced
- Con: !mpractical if Gauge is located
below Bulb,Need to be recalibrated.
Bimetallic Thermometers
- Taken over vapour filled market
- Economical and Nass Produced
- vibration Sensitive
- Accuracy 1
Bi-Netallic Construction
to a spiralhelic pressure
gauge in its Construction
Thermocouples
- Basic Principle: Seebeck Effect
- 1821. when two dissimilar wires are
joined they generate a very small
currentfvoltage potential
Types Of Thermocuples
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Thermocouple Extension Wire
Thermocouple Nanagement
- All connectors must be of the same type
- All joints to be done with connectors that
are rated fro the thermocuple type or
else dissimilar metals will falsify the
reading
- Runs of less that 200 feet recommended
Types of thermocouple design
- Grounded type: Wires are welded to the
casing. High (fast) response time
but.susceptible to noise and eNF
countershock.
- Ungrounded type: Tip is electrically
isolated by thin insulation so as not react
electrically with any field power systems
- Pro: less prone to burning out equipment
- Con: slower reaction time( nominally)
!nternal Construction
- Tubular : typical 1f+" diam to 3f8"
- Nicro tube 1f16" tube grounded
- Standard is 1f+" with NgO filling inside
the tube to prevent breakage of wire
joint
- P109 p120
+
RTD's
- Typically design is ceramic rod with
platinum wire wound around it.
- Nominal resistance =100 ohms @0 Deg C.
- Nominal accuracy= .1 !!
- Does not require special extension wire"
- Overall much less installed cost.
- Travel long didtance with 3rd wire
- Self heating is minimal problem
-100 deg c.
-=185.51 ohms
-Standard D!N Curve
-Nost Common
Thermistors P127
- Same idea but a lot higher ressitance
range.
- Works inversely of RTD ..decreases
resistance as temp. increases
- not as linear as RTD
- Typical = 1000-10000 ohms
- inexpensive = mass
produced=everywhere in industry
- !.e. motor windings
!nfra-Red Sensors
- Based on the principle that all objects
radiate energy..
- !ntensity of radiation increases as
temeperature increases
- Emissivity is best with blackened surfaces
-Pro : NON contact
-Safety:no risk
-relavent accuracy
-inexpensive
-Con:
-innacuracy from
-surface finish
-1 at best!!
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Profile for process use
Connectors - Electrical connections can gradually loosen the connector, and generate heat as a
result oI repeated heating (expansion) and cooling (contraction), and/or dirt, carbon deposits,
and corrosion. A noncontact thermometer quickly determines temperature increases that indicate
serious problems.
Electric Motors - To maintain liIespan oI motors, inspect supply power connections and circuit
breakers (or Iuser) Ior equal temperatures.
Motor Bearings - Detect hot spots and schedule repairs or replacements beIore problems lead
to equipment Iailure.
Motor Winding Insulation - Prolong the liIe oI winding insulation by measuring its
temperature.
Phase-to-Phase Measurement - Check cables and connectors Ior equal phase-to-phase
temperatures Ior induction motors, large computers, and other equipment.
Transformers - Check the windings oI air-cooled units Ior hotspots that indicate winding Ilaws.
Non-contact IR thermometers are quickly becoming an integral part oI
HACCP routines. Many Iood service proIessionals are Iamiliar with the Iood
saIety procedure known as HACCP and which is now mandated Ior meat,
poultry, and seaIood production plants, as well as Iruit and egg process
plants. HACCP looks at the Ilow oI Iood as it travels in and out oI the
Temperature Danger Zone
Also Food and Drug Administration (FDA) suggests the use oI inIrared
thermometers in the 1999 Federal Food Code, Annex 4, Section 8. and
recognizes that quick scans oI the surIace temperature with an inIrared
thermometer Iacilitates general Iood saIety:
"The inIrared thermometer quickly registers surIace temperatures, which
Iacilitates general Iood saIety system surveillance by allowing the scanning
oI numerous Iood temperatures over a short period oI time."
MiniTempFS assures the greatest accuracy in the Iood critical zone called
Danger Zone where harmIul bacteria grow most rapidly. The term Danger
Zone describes temperatures above 40F (4.4C) and below 140F (60C.) II
potentially hazardous Ioods such as dairy products, shellIish, meats, etc.,
remain within this range Ior more than Iour hours, Ioodborne bacteria can
grow. While precautions are taken and enIorced by health and Iood saIety
inspections, the owners, operators, and service personnel bear every day
responsibility oI providing healthy quality Iood which means an awareness
and plan oI action to ensure Ioods are out oI the Danger Zone.
Infrared Noncontact Thermometers Are Effective Equipment
Performance Monitoring & Diagnostic Tools
Noncontact thermometers give you instant, accurate temperature
readings oI most key HVAC components. Diagnose duct leakage,
supply and return air temperatures, plumbing lies, and other heat-
related problems with inIrared thermometers.
Technicians quickly and eIIiciently gather temperature data Irom
these applications:
Room Balancing: scan walls Ior unbalanced temperatures
Duct Work: scan the surIace oI ductwork to reveal temperature
spikes and poor insulation
Steam Distribution Systems: diagnose blown or plugged steam traps
Irom a saIe distance
Furnace PerIormance: test Iurnace perIormance by checking the Ilue
temperature
Supply/Return Registers: evaluate temperature diIIerential between
supply/return registers
Other Applications:
Check Ior coil sweating oI condensate lines
Check emergency relieI value temperature
Scan wet wallboard Ior water leaks
Measure existing air Irom a coil and at a supply air grill
Process Control
- What is a process?
- A method or technology used to produce
a desired result.
- Chemical;heat;pressure;mechanical;elect
rical all interact to produce the desired
result.
Types of processes:
- Batch: accumualtion of several components to
achieve a fixed quantity
- i.e: wine;BEEER,whisky where maturing times
are required
- Expensive process where waste is expensive:
i.e:perfumes
- Table 3-1 p183
Continuous Process
- Same production day in and day out
where process is continuous and provides
a standardized product.
- i.e. steel plate production;milk
pasteurization;Kraft D!NNER!
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Semi-Continuous
- Where a combination of batches provides
Another production line with its raw material
i.e: Bleaching plant requires cooker blowdown to
supply its raw stock
Bleaching plant in turn provides batches of white
stock to paper machine to make paper
!s !t Break Time Yet ?
Process control is required
because of....
- Ninimalize energy required to produce the
product
- Reduce human errorrr
- Efficient use of workers and their safety
interests
- Emissions and pollution requirements
- Naintain product quality
Types of process response
- Zero order=0 dead time=transfer of process
flow instantaneously
- i.e: Pipeline
- Second order: some lag time yet transfer the
process efficiently
- And combinations of 2 or more will increase
process response time
p.i.d.
- Ziegler Nichols effect =reduce error to pv
and sp within + passe of zero error
- Gain=100fPB
- PB=100 relative to range of input of
instrument
p.i.d.
- !ntegral= anticipatory adjustement
before the process overshoots Sv
- Derivative: changes the output
exponentially to rate of change of
process error
- Let the games Begin!!
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That's it for Tonight!
Thank for participating in you education
-You know where you can find me
-Next week!!
Good luck- Bonne chance!!

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