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Automation Industrielle
Industrielle Automation
courtesy ABB
2.1.1 Market
2.1 Instrumentation
2.1.1
Market
2.1.2
Binary instruments
2.1.3
Analog Instruments
2.1.4
Actors
2.1.5
Transducers
2.1.6
Instrumentation diagrams
2.1.7
Protection classes
2.2 Control
2.3 Programmable Logic Controllers
Industrial Automation
Instrumentation 2.1 - 2
Emerson (Fisher-Rosemount): 27 %
Invensys: 4-5%
ABB: 4-5%
Honeywell: 3-4%
one dominant player a lot of small players
Industrial Automation
Instrumentation 2.1 - 3
Tranches
900MW
Tranches
1300MW
Tranches
1450MW
Capteurstoutourien
(binarysensors)|(Initiatoren)
1930
1560
1660
Finsdecoursedevannesmanuellesetderegistres
(positionsensorformanualvalvesanddampers
330
140
700
Capteursanalogiques(mesures)
(analogsensors)|(AnalogeMessgarte)
1360
2050
2280
Appareilsdecoupure6,6/7,2kV
(circuitbreakers)|(Leistungsschalter)
40
95
74
Contacteurs380V
(switches380V)|(Schalter)
340
600
540
Vannesmotorises
(motorvalves)|(Steuerschieber)
190
300
250
RobinetspneumatiquesTOR
(onoffpneumaticswitches)|(pneumatischeSchalter)
480
470
670
Vannesrglantes
(proportionalvalves)|(Regelschieber)
180
500
110
Industrial Automation
Instrumentation 2.1 - 4
Concepts
instruments = sensors (capteurs, Messgeber) and actors (actionneurs, Stellglieder)
binary (on/off) and analog (continuous) instruments are distinguished.
industrial conditions:
temperature range
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Instrumentation 2.1 - 5
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Instrumentation 2.1 - 6
+dust-insensitive, - magnetic
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Instrumentation 2.1 - 7
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Instrumentation 2.1 - 8
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Instrumentation 2.1 - 9
Not precise
Not accurate
Precise
Not accurate
Not precise
Accurate
Precise
Accurate
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Instrumentation 2.1 - 10
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Instrumentation 2.1 - 11
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Instrumentation 2.1 - 12
When the moving armature is centered between the two series-opposed secondaries, equal magnetic
flux couples into both secondaries; the voltage induced in one half of the secondary winding is 180
degrees out-of-phase with the voltage induced in the other half of the secondary winding.
When the armature is moved out of that position, a voltage proportional to the displacement appears
source: www.sensorland.com
Industrial Automation
Instrumentation 2.1 - 13
C=
A
d
movable
capacitance is evaluated by
modifying the frequency of
an oscillator
fixed
Industrial Automation
Instrumentation 2.1 - 14
= resistivity
A
"
R1
R3
measure
Uo
R2
compensation
Industrial Automation
R4
temperature compensation
by dummy gauges
frequently used in buildings, bridges,
dams for detecting movements.
Instrumentation 2.1 - 15
Piezo-electrical effect
Piezoelectric materials (crystals) change form when an electrical field is applied to them.
Conversely, piezoelectric materials produce an electrical field when deformed.
Industrial Automation
source: Kistler
Instrumentation 2.1 - 16
Optical encoders operate by means of a grating that moves between a light source and a detector.
The detector registers when light passes through the transparent areas of the grating.
For increased resolution, the light source is collimated and a mask is placed between the grating
and the detector. The grating and the mask produce a shuttering effect, so that only when their
transparent sections are in alignment is light allowed to pass to the detector.
An incremental encoder generates a pulse for a given increment of shaft rotation (rotary encoder),
or a pulse for a given linear distance travelled (linear encoder). Total distance travelled or shaft
angular rotation is determined by counting the encoder output pulses.
An absolute encoder has a number of output channels, such that every shaft position may be
described by its own unique code. The higher the resolution the more output channels are
required.
courtesy Parker Motion & Control
Industrial Automation
Instrumentation 2.1 - 17
open mounted
Photo: Baumer
Industrial Automation
Instrumentation 2.1 - 18
10 11 12 13 14 15
10 11 12 13 14 15
LSB
MSB
LSB
courtesy Parker
Motion & Control
MSB
0000
0001
0010
0011
0100
0101
0110
0111
0000
0001
0011
0010
0110
0111
0101
0100
Instrumentation 2.1 - 19
Linear encoder
Also with magnetic instead of optical grating
Industrial Automation
Instrumentation 2.1 - 20
Force measurement
Industrial Automation
Instrumentation 2.1 - 21
N
S
Ui ~ d / dt,
f~
transducer
analog: 4..20 mA
digital: 010110110
a simple tachometer is a rotating permanent magnet that induces a voltage into a stator
winding.
this voltage is converted into an analog voltage or current, later converted to a digital
value,
alternatively, the frequency of the signal can be measured to yield directly a digital value
Industrial Automation
Instrumentation 2.1 - 22
principle
range
resolution
repeatability
linearity
reactivity
remark
inductive
0..10mm
0,1m
1m
0,4..5%
0,35ms
for electrically
conducting
materials, small
optical
15..1000 mm
2m
2m
0,06..1,2%
0,9ms
for small and
mobile parts
ultra-sound
20..2599mm
300m
500m
0,5%
30ms
highly linear
long range
dust resilient
cheap
CCD
Industrial Automation
Instrumentation 2.1 - 23
Extension Assemblies
Thermowell
www.omega.com
Industrial Automation
Instrumentation 2.1 - 24
Temperature measurement
Thermistance (RTD - resistance temperature detector):
metal whose resistance depends on temperature:
+ cheap, robust, high temperature range ( -180C ..600C),
- require current source, non-linear.
Thermistor (NTC - negative temperature coefficient):
semiconductor whose resistance depends on temperature:
+ very cheap, sensible,
- low temperature, imprecise, needs current source, strongly non-linear, fragile, self-heating
Thermo-element (Thermoelement, thermocouple):
pair of dissimilar metals that generate a voltage proportional to the
temperature difference between warm and cold junction (Seebeck effect)
+ high precision, high temperature, punctual measurement
- low voltage, requires cold junction compensation, high amplification, linearization
Spectrometer:
measures infrared radiation by photo-sensitive semiconductors
+ highest temperature, measures surfaces, no contact
- highest price
Bimetal (Bimetall, bilame):
mechanical (yes/no) temperature indicator using the difference in the dilatation
coefficients of two metals, very cheap, widely used (toasters...)
Industrial Automation
Instrumentation 2.1 - 25
two dissimilar
electrical
conductors
Fe-Const
also: Pt/Rh - Pt
Fe
measured temperature
(hot junction)
Cu
4..20 mA
U (2-1)
Constantan
extension
wire
Cu
reference temperature
(cold junction)
4..20 mA
i = constant
2,3- or 4-wire connection
Instrumentation 2.1 - 26
Industrial Automation
Instrumentation 2.1 - 27
special requirements: intrinsic safety = explosive environment, sea floor = high pressure
Industrial Automation
Instrumentation 2.1 - 28
Level measurement
pulsed laser
load cell
pulsed microwave
nuclear
ultrasonic (40-60 kHz)
low power ultrasonic
F = mg
detector
row
Instrumentation 2.1 - 29
Flow measurement
Distinguish:
volumetric flow ( m3/s)
mass flow: (kg / s)
identical when the density of the liquid is constant
main methods:
-floater
-turbine
-pressure difference
-vortex
-temperature gradient
-ultrasonic
-electrodynamics
Industrial Automation
Instrumentation 2.1 - 30
piezo-electric
sensor
membrane
fluid of
viscosity
p2
p1
v
occultation
occultation
(Blende)
(Verengung)
p2 - p 1 =
1
2
v2
(Bernoulli effect)
the flow velocity is proportional to the square root of the pressure difference
Industrial Automation
Instrumentation 2.1 - 31
Flow measurement
Other means:
Magnetic-dynamic
Coriolis
Ultra-sound
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Instrumentation 2.1 - 32
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Instrumentation 2.1 - 33
2.1.4 Actors
2.1 Instrumentation
2.1.1
Market
2.1.2
Binary instruments
2.1.3
Analog Instruments
2.1.4
Actors
2.1.5
Transducers
2.1.6
Instrumentation diagrams
2.1.7
Protection classes
2.2 Control
2.3 Programmable Logic Controllers
Industrial Automation
Instrumentation 2.1 - 34
Actors (Actuators)
Stellantriebe, Servomoteurs
About 10% of the field elements are actors (that influence the process).
Actors can be binary (on/off) or analog (e.g. variable speed drive)
The most common are:
- electric contactors (relays)
- heating elements
- pneumatic and hydraulic movers (valve, pump)
- electric motors (rotating and linear)
Actors are controlled by the same electrical signal levels as sensors use
(4..20mA, 0..10V, 0..24V, etc.) but at higher power levels, e.g. to directly move a contactor
(disjoncteur).
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Instrumentation 2.1 - 35
Electric Motors
Solenoids,
DC motor
Asynchronous Motors (Induction)
Synchronous motors
Step motors, reluctance motors
Industrial Automation
Instrumentation 2.1 - 36
Instrumentation 2.1 - 37
Linear Motors
Industrial Automation
Instrumentation 2.1 - 38
fluidic switches
source: www.bachofen.ch
Instrumentation 2.1 - 39
2.1.5 Transducers
2.1 Instrumentation
2.1.1
Market
2.1.2
Binary instruments
2.1.3
Analog Instruments
2.1.4
Actors
2.1.5
Transducers
2.1.6
Instrumentation diagrams
2.1.7
Protection classes
2.2 Control
2.3 Programmable Logic Controllers
Industrial Automation
Instrumentation 2.1 - 40
Transducer
A transducer converts the information supplied by a sensor (piezo, resistance,)
into a standardized signal which can be processed digitally.
Some transducers have directly a digital (field bus) output and are integrated
in the sensor.
Other are located at distances of several meters from the sensor.
Industrial Automation
Instrumentation 2.1 - 41
Field house
Transducer
Current
Transformer
Protection
0..1A rms
R = Load
PLC
Industrial Automation
Control Room
4..20 mA
Emergency panel
Instrumentation 2.1 - 42
Transducer
instrument
1
instrument
2
instrument
3
voltage
source
10..24V
R1
measurand
i = f(v)
R2
R3
0, 4..20 mA
The transducer acts as a current source which delivers a current between 4 and 20 mA,
proportional to the measurand (Messgrsse, valeur mesure).
Information is conveyed by a current, the voltage drop along the cable induces no error.
0 mA signals an error (wire disconnection)
The number of loads connected in series is limited by the operating voltage (10..24 V).
e.g. if (R1 + R2+ R3) = 1.5 ki = 24 / 1.5 = 16 mA, which is < 20 mA: NOT o.k.)
Simple devices are powered directly by the residual current (4mA) allowing to transmit
signal and power through a single pair of wires.
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Instrumentation 2.1 - 43
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Instrumentation 2.1 - 44
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Instrumentation 2.1 - 45
Instrumentation Diagrams
Similarly to electrical schemas, the control industry (especially the chemical and
process industry) describes its plants and their instrumentation by a
P&ID (pronounce P.N.I.D.) (Piping aNd Instrumentation Diagram),
sometimes called P&WD (Piping and wiring diagrams)
The P&ID shows the flows in a plant (in the chemical or process industry) and the
corresponding sensors or actors.
At the same time, the P&ID gives a name ("tag") to each sensor and actor, along with
additional parameters.
This tag identifies a "point" not only on the screens and controllers, but also on the
objects in the field.
Industrial Automation
Instrumentation 2.1 - 46
P&ID example
Piping and Instrumentation Diagram for MTG100FC Engine Tests
TI
TA22C
TE
TE
7, Heat
exchanger
IC
IGNITC1
TI
TA22A
TI
TA22B
TI
TC1M1 - M10
TE
Ingnitor
Box C1
BS
FLAMDETC1
PI
PT22
Chimney
TI
TA21A
TI
TA21B
10 x
TE
BE
PT
TI
TA21C
TE
TE
PI
PT21
TE
TI
TA62
TE
TE
TI
TW72
PT
6, Recuperator
2, Air Heater C1
IC
VMPWMC1
Atmosphere
IC
VPPWMC1
IC
SVGAS3
FO
S
IC
SVGAS1
IC
SVGAS2
Fuel flow C1
MFM
Emission
Analysis
Fuel Supply
Fuel flow C2
Regulator Valve
I
TY
IC
VPPWMC2
TY
E
EMIO2
AIT
E
EMINOX
AIT
E
EMICO
AIT
E
EMIUHC
AIT
IC
TBVDEP
IC
TBVCOOL
AIT
MFM
E
EMICO2
FO
TE
TI
TA32C
TE
TE
PI
PT32
BS
FLAMDETC2
PT
BE
3, SOFC Outlet
PT
TI
TA12
TE
PT
PI
PT52
TE
TI
TA52
SI
SPEED
PI
LOP
ST
PT
Latchable
Check Valve
IC
V12
AC Grid
1,
C
PCS
Ingnitor
Box
TI
TA32B
PI
PT12
5,
T
IC
IGNITC2
TI
TA32A
IC
V52
TI
TC2M1 - M10
10 x
TE
TI
TA51A
PI
PT51
PT
TI
TA51C
TI
TA51B
TE
TE
TE
PI
PT02
PT
TI
TA02
TE
Modulatable
Load
0, Air Inlet
3, SOFC Inlet
4, Combustor C2
Industrial Automation
Instrumentation 2.1 - 47
P&ID
The P&ID mixes pneumatic / hydraulic elements, electrical elements
and instruments on the same diagram
It uses a set of symbols defined in the ISA S5.1 standard.
Examples of pneumatic / hydraulic symbols:
pipe
valve
one-way valve (diode)
350 kW
heater
vessel / reactor
heat exchanger
pump, also
Industrial Automation
Instrumentation 2.1 - 48
Instrumentation identification
The first letter defines the measured or initiating variables such as Analysis (A), Flow (F),
Temperature (T), etc. with succeeding letters defining readout, passive, or output functions such
as Indicator (I), Record (R), Transmit (T), see next slides, here: flow indicator digital
FIC
V1528
tag name of the
corresponding
variable
here: V1528
mover
(here: solenoid)
S
function
(here: valve)
Industrial Automation
Instrumentation 2.1 - 49
Field mounted
Auxiliary location
accessible to
operator
Discrete
instruments
Shared
display, shared
control
Computer
function
Programmable
logic control
1. Symbol size may vary according to the user's needs and the type of document.
2. Abbreviations of the user's choice may be used when necessary to specify location.
3. Inaccessible (behind the panel) devices may be depicted using the same symbol but with a
dashed horizontal bar.
Source: Control Engineering with data from ISA S5.1 standard
Industrial Automation
Instrumentation 2.1 - 50
Example of P&ID
The output of FIC 101 is an electrical signal to TY 101
located in an inaccessible or behind-the-panel-board location.
Instrumentation 2.1 - 51
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z
Analysis
Burner, combustion
User's choice
User's choice
Voltage
Flow rate
User's choice
Hand
Current (electrical)
Power
Time, time schedule
Level
User's choice
User's choice
User's choice
Pressure, vacuum
Quantity
Radiation
Speed, frequency
Temperature
Multivariable
Vibration, mechanical analysis
Weight, force
Unclassified
Event, state, or presence
Position, dimension
Industrial Automation
Modifier
Differential
Ration (fraction)
Scan
Time rate of change
Momentary
Integrate, totalizer
Safety
X axis
Y axis
Z axis
Instrumentation 2.1 - 52
Connection to process, or
instrument supply
Pneumatic signal
Electric signal
Capillary tubing (filled system)
Hydraulic signal
Electromagnetic or sonic signal
(guided)
Internal system link
(software or data link)
Source: Control Engineering with data from ISA S5.1 standard
Industrial Automation
Instrumentation 2.1 - 53
CAEX component
library
role
location categories
2
auxiliary signals
connections between
objects
Industrial Automation
Instrumentation 2.1 - 54
Industrial Automation
Instrumentation 2.1 - 55
1st digit
touching
none
1
2
large body
surface
finger
objects
2nd digit
water
none
object > 50 mm
vertically falling
object >12.5 mm
tools, wires
covered
object >1 mm
dust
hermetical
for dust
e.g. IP 67 connector
Industrial Automation
Explosion protection
Instruments that operate in explosive environments
(e.g. petrochemical, pharmaceutical, coal mines,...) are subject to particular restrictions.
e.g.
They may not contain anything that can produce sparks or high heat,
such as electrolytic capacitors or batteries without current limitation.
Their design or programming may not be altered after their acceptance.
Their price is higher than that of standard devices because they have to undergo
strict testing (Typentest, type test) by a qualified authority (TV in Germany)
Such devices are called Eex - or "intrinsic safety devices" (Eigensichere Gerte, "Ex-Schutz",
protection anti-dflagrante, "Ex" ) and are identified by the following logo:
Industrial Automation
Instrumentation 2.1 - 57
Instrumentation 2.1 - 58
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Instrumentation 2.1 - 59
Assessment
Industrial Automation
Instrumentation 2.1 - 60