INSTRUMENTATION AND PROCESS

CONTROL
ENGR. ANDY A. DE TORRES
REE MBA MPA MEPF

Bachelor of Science in Electrical Engineering

Pablo Borbon Memorial Institute of Technology

Master in Business Administration

Master in Public Administration
Golden Gate Colleges

Instructor
Golden Gate Colleges
Westmead International School
De La Salle University
Lyceum of Batangas
Filipino Academy of Scientific Trades
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Flour Daniel Pacific Incorporated

General Electrical Foreman

National Power Corporation

Operation Supervisor
Electrical Control Operator

DMCI Power Corporation

Training Supervisor
Operation Supervisor

IIEE Metro Central Chapter – Life Time Member

IIEE Western Batangas Chapter – VP Technical
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Subject: Instrumentation Process and Control

Units : 2 Lec/1 Lab
Reminder:
➢ Attendance
➢ 2 points deduction for every absent
➢ 1 point deduction for every late
➢ Assignment
➢ must be submitted on time thru e-mail
➢ Use long coupon bond
➢ No computerized assignment
➢ Examination
➢ No special exam
➢ Time limit is strictly implemented
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➢ Passing grade
➢ 60%
➢ Below 60% is subject to removal exam
➢ Caught cheating is automatically failed
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INSTRUMENTATION & PROCESS CONTROL

1. Introduction to Instrumentation Technology
1. Fundamental definitions
2. Organization
3. Purpose of Instrumentation
4. Technology Development
5. The Loop
2. Principles of Measuring Elements
1. Measurement
2. Signals
3. Range Calculations
4. Measuring Elements Types
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5. Transmitter & Transducer Comparison

6. Wiring the measurement circuit
7. Smart & conventional Transmitters
8. Selection criteria
3. Instrument Symbol & the P&ID
1. Instrument Synbols
2. The P&ID
4. Industrial Pressure Measurements
1. Types of Pressure Measurement Industry
2. ISA Classification for Pressure Measuring
Elements
3. Operating Principles of Pressure Measuring
Instruments
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4. Accessories for Pressure Measuring

Instruments
5. Pressure Switches
5. Industrial Level Measurements
1. Importance ofc Level Measurements in
Industry
2. ISA classification for Level Measuring
instruments
6. Industrial Flow measurement
1. Importance of flow Measrment in Industry
2. Types of flow Measurements in Industry
3. ISA classification for flow measuring
elements
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4. Principles of Operation of flow measuring

instruments
7. Industrial Temperature Measurements
1. Temperature-What causes it?
2. Temperature Scales- Metric & English
3. ISA classification for Temperature measuring
elements
4. Operating Principles of Temperature
measuring instruments
8. Principles of Receiving Elements
9. Principles of Final Control Elements
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9. Principles of Final Control Elements

1. Types of Final Control Elements
2. The control valve
3. Control valves bodies
4. Valve bonnets
5. Valve actuator
6. Valve accessories
7. Control valve installation
8. Variable speed drive
10. Basic Analytical Measurements
1. Liquid Analysis (pH)
2. Gas Analysis (O2)
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12. Principles of Automatic Control & Tuning

13. Basic Process Control Strategies
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DEFINITIONS
“INSTRUMENT”
Source: 1. Webster’s New World Dictionary of the American language
2. Webster’s School Dictionary
(Latin – Instrumentum = to construct, instruct, is done)
➢ Any mechanical device or contrivance
➢ A tool, implement or apparatus
➢ A device to produce music
➢ A format legal document (as a deed, bond, contract or
agreement)
➢ An agen, agency or means whereby something is done
➢ An apparatus for measuring distance
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DEFINITIONS
➢ An electrical or mechanical device used for navigating
an airplane
➢ A measuring device for determining the present value
or quantity under observation

“INSTRUMENTATION”
➢ A collection of instrument or their application for the
purpose of observation, measurement control or any
combination of these.
➢ (Source: ISA 51.1, SAMA PMC 20.1 ANSI C85.1)
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DEFINITIONS
“PROCESS CONTROL”
➢ The regulation or manipulation of variables influencing
the conduct of a process in such a way as to obtain a
product of desired quality and quantity in an efficient
manner

“AUTOMATIC PROCESS CONTROL”

➢ A technical of balancing supply & demand over a period
of time, by maintaining or regulating a variable at a
desired value.

➢ The operation of a process with minimum or no

human intervention.
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ORGANIZATION

Instrument Society of America

Instrument, System & Automation

Society

International Society for Automation

Philippine Instrumentation & Control

Society
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PURPOSE OF INSTRUMENTATION & CONTROL

1. Quality Control – to maintain the quality of products

2. Conservation of energy & raw materials
3. Safety – of peoples & equipment
4. Savings in installation
5. Materials balance & product accounting
6. Coordination of process & process variables
7. Research & development – pilot plants
8. Enterprise management
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I & C DIVISION (ISA)

According to Industries & Sciences
➢ Aeroscape
➢ Automation & Vehicles
➢ Chemical & Petrochemical
➢ Construction, Engineering & Design
➢ Food & Beverage
➢ Glass & Ceramics
➢ Marketing & Sales
➢ Mining & minerals
➢ Oil & Gas, Petroleum
➢ Pharmaceutical, Medical, Biological
➢ Power & Energy
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I & C DIVISION (ISA)

➢ Pulp & Paper

➢ Semiconductor & Electronics
➢ Textile
➢ Water & Wastewater
➢ many others

According to Automation & Technology

➢ Automatic control system
➢ Analysis
➢ Computers
➢ Electro-optics
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I & C DIVISION (ISA)

➢ Maintenance
➢ Open system interconnection
➢ Management
➢ Process Measurement & Control
➢ Robotics & expert system, mechatronics
➢ Test Measurement
➢ Telemetry & communications
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SCIENCE & TECHNOLOGY INTERACTION WITH

INSTRUMENTATION & CONTROL

PMathematics PElectronics
PPhysics

PChemistry PNucleonics
IIINSTRUMENTATION
PMechanical & PInformation
Engineering Technology
CONTROL

PElectrical & PComputer &

Pchemical & Software
Electronics Process Engineering
Engineering Engineering
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BLOCK DIAGRAM IF THE INSTRUMENT LOOP

DISTURBANCE

MV PV

SP

CO PV
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The ELEMENTS of the INSTRUMENT LOOP

Process
➢ A machine or equipment to perform or produce something
(Def: operation involving physical or chemical change of
matter, conversion of energy state composition, dimension
or other procedure. e.g. changer of pressure, temperature
etc.)
Measuring Element
➢ Sensors, transmitter, transducers
Receiving Element
➢ Indicators, recorders, controllers alarm units totalizers,
computer base instruments & system
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The ELEMENTS of the INSTRUMENT LOOP

Final Control Elements

➢ Control valve, damper, variable pitcxh blades,
motor drives, feeders, relay/contactor, thyristor

PROCESS ELEMENT
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The ELEMENTS of the INSTRUMENT LOOP

MESURING ELEMENT

TRANSMITTER

PRESSURE SENSORR

PRESSURE TRANSDJCER
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The ELEMENTS of the INSTRUMENT LOOP

RECEIVING ELEMENT

CONTROL ROOM
FAULT RECORDER
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The ELEMENTS of the INSTRUMENT LOOP

FINAL CONTROL ELEMENT

CONTROL VALCE
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DEFINITIONS

Process
➢ Any operation of sequernce of operations involving a
change of energy, state composition, dimensions or
other properties that maybe defined with respect to a
datum

Process Variable or PV
➢ Any variables property of a process

Set Point or SP
➢ An input variable that sets the desired value of the
measured variables.
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DEFINITIONS

Controller Output or CO
➢ Output signal generated in response to a change of a
process variable

Manipulated Variable or MV
➢ A process variable linked to the controller output that is
used to influence the measured variables.
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Major Process Variables

➢ Pressure
➢ Level
➢ Flow
➢ Temperature

Minor Process Variables

➢ Analysis – ph, conductivity , concentration etc.
➢ Position
➢ Speed
➢ Vibration etc.
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“INSTRUMENTATION & CONTROL LOOP or

INSTRUMENT LOOP

A combination of two or more instruments

or control functions
arranged so that signals pass
from one to another for the
purpose of measurement
And/or control of a process variable.
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Principles of Measuring Elements

Topics Covered:
1. Measurement
2. Signals
3. Range Calculations
4. Measuring Elements Types
5. Transmitter & Transducer
6. Wiring the measurement circuit
7. Smart & Conventional Transmitters
8. Selection Criteria
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BLOCK DIAGRAM IF THE INSTRUMENT LOOP

DISTURBANCE

MV PV

SP

CO PV
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MESUREMENT
➢ The determination of the existence or the magnitude of
a variables.

Basic Function of Analog Measuring Devices

PV
ProcessVariable
Process Variables

Measuring Analog Variables

Element

PV Analog Signals
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Basic Characteristics of A Measuring Element

1. Output represents the input faithfully
2. Linear input/output relationship
3. No effect of temperature & others

RANGE
➢ The limit or extent of variation
➢ The lower limit is called LRV
➢ The upper limit is called URV
SPAN (of a Range)
➢ The number of units between two limits,the LRV and
URV (Span = URV – LRV)
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Standard Instrumentation Signals

Electrical or Electronic Signals

➢ The value of voltage or current represents the value of
the measured variables

Pneumatic Signals
➢ The value of air or gas pressure represents the value of
the measured variables

Hydraulic Signal
➢ The value of the fluid pressure represents the value of
the measured variable
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Telemetered Signals
➢ The value of certain frequencies or amplitude of ratio
signals represent the value of measured variables.

Standard Instrumentation Signal Ranges

Current - 4 – 20 mA dc
Voltage - 1 – 5 V dc
Pneumatic - 3 – 15 psig ; 0.2 – 1.0 bars

NOTE: The lower value represents the zero percent

hundred percent (100%) of full scale (FS)
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Example Problem
If you have a temperature of 32 to 2440F and you measure
12.5 mA, What i temperature does it represent?

Solution:
20 – 4 = 16 mA span of transmitter
12.5 – 4 = 8.5 mA span of measurement
8.5/16 = 0.53 % of measurement
244 – 32 = 212 span of FS
212 (0.53) = 112.36 span of measurement
112.36 + 32 = 144.36 0F answer
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CONVERSION OF A PV to SIGNAL
Measuring Range = 0 to 8 Bars
PV
0 Bars 8 Bars

PV Signal
4 mA 20 mA
3 psig 15 psig Output Range

0.2 Bars 1.0 Bars

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NON-STANDARD SIGNAL

Mechanical:
• Movement, Expansion, Contraction
• Pressure = other than 3 to 15 psig & 0.2 to 1.0 bars or
kg/cm2

Electrical or Electronics
• Current = 0 to 20 mA, 10 to 50 mA, 0 to 1 mA
• Voltage = 0 to 5 V, 0 to 10 V, -10 to 10 V, 0 to 100 mV
• Resistance ● Frequency
• Capacitance ● Inductance
• Telemetry ● Fieldbus
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TYPES OF MEASURING ELEMENTS

A. SENSOR
That part of a loop or instrument that first senses the
value of a process variable, and that assumes a
corresponding, predetermined, and intelligible state or
output.

B. TRANSMITTER
A device that senses a process variable through the
medium of a sensor and has an output whose steady-state
value varies only as a predetermined function of the
process variable.
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C. TRANSDUCER
A general term for a device that receives information in
the form of one or more physical quantities, modifies the
information and/or its form, if required, and process a
resultant output signal.
The transducer can be a primary element, transmitter,
relay, converted or other device.
Because the term “transducer” is not specific, its use for
specific application is not recommended.
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BASIC COMPARISON

TRANSMITTER TRANSDUCER
1. Expensive 1. Low Cost Cheap
2. Very accurate 2. Not so accurate
3. Very rugged 3. Not rugged
4. Repairable 4. Not repairable
5. Adjustable range 5. Fixed range
6. Standard signal output 6. Different outputs
by the Manufacturer
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BASIC PARTS OF A TRANSMITTER or

TRANSDUCER

Process Primary
Variable Sensor

Variable Signal
Conversion Transmission

Signal Output
Processing Signal
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+ 4 to 20 mA signal output
2 - Wire -

+ 4 to 20 mA signal output
3 - Wire -
V
24 Vdc Supply

+ 4 to 20 mA signal output
-
4 - Wire H
L 12, 24 Vdc
24, 110,220 Vac
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ADDING INSTRUMENTS IN THE MEASURMENT LOOP

1. Two (2) receiving instruments connected to the

transmitter output
2. More than 2 receiving instruments connected
to the transmitter output
3. More than 1 transmitter connected to 1 or more
receiving instruments
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USE OF THE 250 OHM RESISTOR

Convert 4 to 20 mA into 1 to 5 Vdc at the input terminals

of a receiver

R V IV = I x R
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BASIC COMPARISON OF TRASNMITTER TYPES

CONVENTIONAL SMART
1. Less Expensive 1. Expensive
2. Accurate 2. Very accurate
3. Very Rugged 3. Very Rugged
4. Repairable 4. Repairable
5. Moderate Rangeability 5. Hu Rangeability
6. Standard Output 6. Standard Output
7. Local Re-Ranging 7. Local/Remote Re-Ranging
8. No Communication 8. With Communication
9. No Diagnostics 9. With Diagnostics
10. Not Identifiable 10. Identiable
from signal
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FACTORS TO CONSIDER IN SELECTING A TRANSMITTER

1. Measuring range
2. Output signal
3. Accuracy
4. Rangeability
5. “Wtted” materials
6. Process connection
7. Built-in indicator
8. Enclosure standard
9. Calibration adjustment
10. Special communications
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A transducer is a device that converts energy from one

form to another. Usually a transducer converts a signal in
one form of energy to a signal in another.

A pressure sensor is a device for pressure

measurement of gases or liquids. Pressure
is an expression of the force required to
stop a fluid from expanding, and is usually
stated in terms of force per unit area. A
pressure sensor usually acts as a
transducer; it generates a signal as a
function of the pressure
imposed. Wikipedia
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