107 basic instrumentation
TRANSCRIPT
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Basic Instrumentation
By: Md.Saquib Ansar Malick
Arabian Petrochemical Company ( Petrokemya) SABIC
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Contents
Definition of instrumentation & Process ControlP&IDs & Instrument symbolsProcess Measurement
Transducer (Temperature-Pressure-Flow-Level)Transmitting and Switching Elements
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Definition of Instrumentation & Process Control System
Instrumentation: A collection of instruments for the purpose of observation, measurement, protection or control.
Process ControlRegulation or manipulation of variable influencing the process to achieve desire quantity/quality in an efficient manner
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Block Diagram of Process Control Loop
Measurement
Controller
Final Control Element
Process Set Point
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P&ID and Instrument Symbols
P&ID stands for Piping & Instrumentation Diagram
Definition:diagram where it will show the process piping and instrumentation connections with Process tanks and vessels, reactors, exchangers, …etc. in order to produce particular product or perform specific task.The P&IDs contains detail connections for the instrumentations where defined by graphical symbols and identification letters.
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Instrumentation Identification
Example of instrument IdentificationFIC4003 (Flow indication and Control)FI4002 (Flow Indication)FT4003 (Flow Transmitter)FV4003 (Flow Control Valve)PIC4002 (Pressure Indication and Control)PV4002 (Pressure Control Valve)PDSL1234 (Pressure Differential Switch Low)
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Control Loops
FT-1
FV-1
FIC1 SV
PV
MV
FE-1
FY1Vent
AFC
FSL1
IA
i
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Process Measurement
In this lecture we will cover the measurement instruments:
Temperature ElementsPressure ElementsFlow ElementsLevel Elements
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I. Temperature
Definition:It is the Degree of Coldness or hotness or in other word related to the kinetic energy of molecules.Temperature generated by heat energy.Heat energy has unit of BTU (Brithish Thermal Unit) or Calorie
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Temperature (Cont.)
Units:Fahrenheit (ºF), Centigrade (Celsius) ºC, Kelvin ºK, Ranklin ºRF= 5/9 x C + 32C= 9/5 (F-32)K= 273.15 + CR= 459.7 +F
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Temperature (Cont.)
ºF ºC ºK ºR-459.7
32
212
-273.15
0
100
0
273.15
373.15
0
459.7
671.7
Water Freezing
Water Boiling
Absolute zero
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Temperature (Measurement)
Thermocouple: Consists of two dissimilar metals joined at one end and other end connected to meter. When joined end (Hot junction) heated, voltage will be produced at the other end (Cold Junction).
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Temperature (Measurement)
T/C Type Chemical Composition
Range
J-Type Iron - constantan -196 to 760 deg C
K- Type Chromel – Alumel -190 to 1260 deg C
S- Type Platinum/Rhodium – platinum
-18 to 1760 deg C
T- Type Copper – Constantan -185 to 371 deg C
E- Type Chromel – Constantan -196 to 982 deg C
R- Type Pt87/Rh13 – Platinum -17.7 to 1704 deg C
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Temperature (Measurement)
Resistance Temperature Detector (RTD)Heat Sensitive element prepared with carefully made electric resistance.Used material: Platinum, Nickel, Iron, Salver
In our plant most of RTDs used are Pt100 platinum resistance= 100 ohm at 0 degree C
As temperature rises, resistance increases.
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Temperature (Measurement)
Thermostor:Very small Solid thermo-electric devise made of solid semiconductor of various metal oxides.The electric resistance of thermostor decrease with an increase in temperature.
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II. Pressure
Definition:Defined as the normal force per unit area acting on surface of an object.P=F/A
Units:Pa, psi, inches of mercury, inches of water, BAR, atm, Kg/cm2
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Pressure (Cont.)
Scale of measurement:Gauge Pressure ScaleAbsolute Pressure ScaleVacuum Pressure Scale
Pg= Pa - Atmospheric Pressure
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Pressure (Cont.)
vacuum
Gage pre.Range
Barometric Atm.Range
Zero gauge
Zero (Absolute)
Abs.Pressure
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Pressure (Measurement)
Manometers:Used for the direct measurement of pressure and vacuum.U-Tube Manometer
A glass of U- tube shape, partially filled with liquid.The zero is connected to the scale when both ends of the U-glass opened to atmosphere.
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P1 P2
h
U-Tube Manometer
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Pressure (Measurement)
U-Tube Manometer (Cont.)When applied pressure at one end of the tube, difference in level will occur:P2-P1=. h : Density (lb/in3) h : height (in)P2-P1: Pressure (psig)
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Pressure (Measurement)
Well Manometer (Single Leg):Used for low pressure application with higher accuracy from the U-Manometer.P2-P1= (1+A1/A2) h
P1
P2
h
zero line
A2
A1
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Pressure (Measurement)
Inclined-Tube ManometerUsed for extreme low pressure applicationP2-P1= (1+A1/A2) L. sin
P1
P2
zero line
A2A1
h L
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Pressure (Measurement)
Pressure ElementMechanical devices changed its shape when pressure is appliedThe pressure elements sometimes called elastic deformation pressure elementEach type has its range of operation pressure.
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Pressure (Measurement)
Pressure elements Minimum range Maximum rangei)Diaphragm 0”to 2” water column (WC) 0 to 400 psiii).Bellows 0”to 5” water column (WC) 0 to 800 psiiii)Capsule 0”to 1” water column (WC) 0 to 50psiiv)Bourdon tube 0 to 12 psi 0 to 100,000 psiv)Spiral 0 to 115 psi 0 to 4,000 psivi)Helix 0 to 50 psi 0 to 10,000psi
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Pressure (Measurement)
Pressure TransducersElastic deformation element joined to electrical device.Changes in resistance, inductance, or capacitance
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Pressure (Measurement)
Strain Gauge:Fine wire in form of grid.When the grid distorted, resistance of the wire will change according to:R=K. L/AK : Resistively of the metalL : Length of wireA : Cross sectional Area
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Pressure (Measurement)
Grid Wire
Ceramic or paper backing
Lead wires
Strain Gage
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Pressure (Measurement)
Strain Gage (Cont.)As Strain Gage is distorted by the elastic deformation length will increase and area will reduced.Resistance will increase accordingly.
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Pressure (Measurement)
Inductance TypeConsists of Coil, Movable Magnet core, and elastic deformation element.AC current pass through coil.As the pressure varies the elastic deformation, the magnet core will move through the coil.This will change the inductance.
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Pressure (Measurement)
Movable Iron Core
Coil Non Conductive Tube
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Capacitance TypeConsists of two conductive plates, dielectric, and diaphragm.As the pressure increases diaphragm will move the plate changing the capacitance.
Pressure (Measurement)
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Pressure (Measurement)
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Flow (Measurement)
Flow rate and flow quantity of materials is made primarily for determining the proportions of materials introduced to the process.Method of measurements:
Head ElementsArea ElementsQuantity Velocity Elements
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Flow (Measurement)
The following properties are important for the flow measurement:
Pressure: Force applied on AreaDensity : Weight divided by volumeViscosity : Resistance to flowVelocity : Speed of the fluid. It determine the behavior of the fluid.
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Flow (Measurement)
Flow Types:When the average velocity is slow, the flow is called laminar, i.e fastest layers at the center and the slowest at the edgesWhen the average velocity increases, the flow is called turbulent. The measurement of laminar, turbulent flow is as per Reynolds number
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Flow (Measurement)
Laminar Flow
Turbulent Flow
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Flow (Measurement)
Most Flow are design to work in turbulent flowUnits of Flow:
lb/Hr, Kg/Hr, T/Hr: mass flowcfm, M3/H, KNM3/Hr: Volumetric Flow
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Flow Measurement
Head Flow ElementsWhen the liquid flows through a restriction, the energy converted kinetic energy.The pressure will drop and velocity increases.
PCQ
C: constantP: Differential pressure across restriction
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Flow Measurement
Head Flow ElementsOrifice Plate: the loss in the pressure is more that other type of flow measurement.
The selection of orifice plate based on ratio of bore diameter to (d) to inside pipe diameter (D). = d/Dbest accuracy is when: 0.2 < < 0.6Taps used :
– Flange tap– Pipe taps– Vena Contracta tap
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Flow Measurement
Venturi tube: expensive and the most accurate type >0.75
Pressure recovery is excellent
Upstream Tap Downstream Tap
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Flow Measurement
Flow Nozzle: cheaper than venturi,accuracy less than venturi>0.75pressure recovery is not as good as venturi
Upstream Tap Downstream Tap
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Flow Measurement
Variable Area Flow MeterRotameter: consists of tapered, vertical glass consists of float.Flow will carry the float from bottom to top through variable area glass.
ghAQ 2
A: cross sectional area of the glassg: gravitational acceleration
constanth: the height of the float.
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Variable Area Flow Meter
In
Out
Float
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Flow Measurement
Quantity Flow MeasurementPositive displacement
Measure the total quantity of the flowseparate the liquid into discrete volumesTotal of these volumes in time period will give the total flow amount
Mass Flow meter:measurement of the weight per unit time.Continuous measurement of density
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Level
There is two ways of measuring levelDirect level measurement
by varying liquid will get the level
Indirect level measurementby using a variables which changes with the liquid level changes.
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Level Measurement
Floatspecial material designed to follow the level or the interface level of a tankThe specialty is the density of the float shall be always touching the desired measurement level.As the level increases/decreases, float will follow and causing a connecting tape to change its length.
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Level Measurement
DisplacerArchimede’s Principle: a body wholly or partially immersed in a fluid is buoyed up by a force equal to the weight of the fluid displaced.The level is measured by detecting the buoyancy force of an immersed displacerThe major difference between float and displacer is that displacer is partially or totally immersed, while float is always floating in the surface of the level.
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Displacer
Flexible Cable
Float
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Level Measurement
Differential pressureh = P/ (British unit) inchesh= P/(g.) (SI unit) metersas level changes differential pressure will change accordingly.
LT
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Instrument Signal Types
All measurement elements are sent to DCS/ESD/PLC Either for alarming, interlocking or controlling.Measurement Instrumentation consists of two parts
Measurement elements (Transducer)-Covered in the previous sectionsTransmitting elementsSwitching elements
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Instrument Signal Types
Transmitting ElementsTransmitting element will convert the Transducer signals into either electronic or pneumatic signalsTransmitting elements are commonly used for indication and control Electronic transmitter will send 4 ~ 20 mA
4mA : min. range20mA: max. range
Pneumatic transmitter will convert the transducer signal into 3~15 psi
3 psi = min. range 15 psi = max range
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Instrument Signal Types
Switching ElementsSwitching elements will convert the transducer signal into a switching contactThe contacts are used commonly in alarming and interlocking processes
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Conclusion
Definition of instrumentation & Process ControlP&IDs & Instrument symbolsProcess Measurement
Transducer (Temperature-Pressure-Flow-Level)Transmitting and Switching Elements
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??QUESTIONS??
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THANK YOU