TRAINING MANUAL INSTRUMENTATION

Unit No. UnitIntroduction 1 - No. 1 - Introduction

UNITS IN THIS COURSE

UNIT 1 UNIT 2 UNIT 3 UNIT 4 UNIT 5 UNIT 6 INTRODUCTION TO INSTRUMENTATION PRESSURE MEASUREMENT THE PRESSURE TRANSMITTER FLOW MEASUREMENT MEASUREMENT OF LEVEL PRACTICAL TASKS

TABLE OF CONTENTS
Para 1.0 1.1 1.2 1.3 1.4 COURSE OBJECTIVE INTRODUCTION INSTRUMENT WORK BASIC DEFINITIONS PROCESS CONTROL 1.4.1 1.4.2 1.5 Open Loop (Manual Control) Closed Loop (Automatic Control) Page 3 4 4 5 7 7 8 9

CONCLUSION

Module No. 1: Instrumentation 1 Module No. 1: Instrumentation 1

1.0

COURSE OBJECTIVE The student will be able to Explain in general terms the duties of an instrument technician. Define the following terms used in instrumentation. Instrument Instrumentation Process and process variable.

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Controller Correcting unit. Transmitter and transmission signal Process loop and plant Indicate and record.

Unit No. 1 - Introduction

Explain in general terms the purpose of instrumentation to obtain automatic control.

1.1

INTRODUCTION The aim of this unit is to introduce the subject of instrumentation, the duties of the instrument technician and what is meant by instrumentation and control.

1.2

INSTRUMENT WORK The duties of an instrument technician fall into five main areas. Repair and calibration of instruments which measure physical quantities, for example pressure, level, gas concentration, acidity, etc. Repair and calibration of instruments that indicate and record the value of a physical property. For example, temperature (thermometer), pressure (gauges), chart recorders, etc. Repair and calibration of the final control element, for example a control valve, electric heater, thermostat, etc. Repair and calibration of a complete control system, for example the control of a gas turbine, steam plant, etc. Carry out preventive maintenance programs.

The instruments in use are very varied, depending on how old the installation is. They may be air (pneumatic), liquid (hydraulic) or electric / electronic in operation. The way the information is shown or recorded may be simple, like a clock or thermometer. It may use the latest information technology to display information on a personal computer screen (video display unit).

Module No. 1: Instrumentation 1

The aim of this course is to introduce all the above topics. Real working instrument systems will have to be learnt in the plant after this course is over. 1.3 BASIC DEFINITIONS Instrumentation uses a lot of words which need to be explained. Before we can talk about instrumentation and process control you need to understand the following words.
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Instrument

Any

device

for

measuring,

indicating,

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controlling, recording and adjusting a physical or chemical property e.g. flow, pressure, acidity, weight, gas concentration, etc. Instrumentation A complete set of instruments used to control a process, e.g. refining, oil/gas production, LNG, LPG, etc. A device which shows a measured value to the operator. A device which continuously records measurements, either electronically or on an ink chart. It is used to show production figures, etc. A group of instruments used to control a single process variable e.g. pressure, flow, level, etc. The operator's word for a manufacturing unit e.g., refining, liquefying gas, etc. The value of the property being controlled by a single process loop e.g. pressure flow, or Process Variable level, etc. The value required by the operator. The difference between the measured variable and the set point should be zero for good control. A device, either pneumatic or electrical / electronic, which adjusts the error signal to zero. A device which works on the command of the controller. It is used to adjust the measured value to obtain a zero error signal, e.g. control valve, etc. A method of standardising signals sent from various parts of the plant. A device which takes a measurement and changes it into a standard signal. A device which changes one form of energy to another; particularly from electrical to pneumatic.

Indicator Recorder

Process Loop

Process Measured Variable or Process Variable (MV) Desired Value or Set Point (S P) Error Signal (ES) Controller

Unit No. 1 - Introduction

Correcting Unit (Final Control Element) Transmission Transmitter Transducer

oduction

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1.4

PROCESS CONTROL

1.4.1 Open Loop (Manual Control)

Unit No. 1 - Introduction

Figure 1-1 The Open Loop Figure 1-1 shows what is called OPEN LOOP or MANUAL control. The process is temperature control. The indicator is a thermometer. The correcting unit is the gas control valve. The controller is the operator who uses his own judgement to keep the water temperature constant. Manual control has its uses as it is cheap to install and maintain, and simple to operate. However, it is very seldom used in industry because: The operator must remain in position at all times. It cannot be used if the operator is placed in a dangerous area. The process changes faster than the operator can react. A mistake by the operator can have dangerous results.

These problems are avoided by using automatic control (closed loop). The job of the instrument technician is to make sure that this type of control operates correctly. Modern household appliances now use automatic control to make work easier. For example:

Module No. 1: Instrumentation 1

Refrigerators and water heaters use automatic temperature control. Washing machines use automatic heating and water control.

1.4.2 Closed Loop (Automatic Control)

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Unit No. 1 - Introduction

Figure 1-2 Simple Automatic Control. Figure 1-2 shows a simple automatic controller. The boiler now has the loop closed and no operator is required. The following items are added. The temperature transmitter (T.T) which measures (senses) the temperature of the hot water and changes it to a standard signal. A signal line from the transmitter to the controller, the signal may be either pneumatic or electrical. A controller which keeps the temperature of the hot water at a position set by the operator (set point) The controller adjusts the correcting unit (automatic control valve) using an output signal line similar to the input line from the transmitter. The controller may provide alarm signals to alert the operator if the system fails. It may also shut off the gas if the water starts to boil.

1.5

CONCLUSION This unit has introduced instrumentation and control. The following units will explain in detail how control loops are made and operated. We will start with the measurement (sensing) and transmitting unit.

Module No. 1: Instrumentation 1

There are many process variables in the petroleum industry but most of these variables fall into four main groups: pressure, flow, level, and temperature. We will look at these groups. Most of the other process variables (e.g., density, gas concentration, acidity, etc.) will be explained when needed during a specialist analyser course.

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