Instrumentation and Control Engineering

• The text provides information on instrumentation and control engineering.

Instrumentation

• Instrumentation involves designing, equipping, and using measuring instruments to determine real-world conditions in a plant's processes for observation, measurement, and control.
• Instrumentation technicians install, maintain, and calibrate devices used in industrial automation.
• Accurate instrument measurements are important for safety, product quality, and profitability.
• Industries that rely on instrumentation are petrochemical, power, water treatment, pulp and paper, and mining/steel manufacturing.
• Job titles include instrument, I&E, I&C, electrical, and electronics technician.

Industrial Automation

• Enhances operational efficiency, product quality, and workplace safety.
• Automates hazardous tasks and provides timely data for decision-making to maintain operational standards.
• Enables performance analysis and optimization, reducing maintenance costs and downtime, driving advancements in productivity and operational excellence.

Instrumentation and Control Engineering (ICE)

• It measures and controls process variables.
• It designs and implements associated systems.
• Process variables include pressure, temperature, humidity, flow, pH, force, and speed.
• Combines instrumentation and control engineering branches.

Instrumentation Engineering

• Focuses on designing, developing, and maintaining instruments/devices that measure, monitor, and control physical and environmental variables like pressure, temperature, flow, and level.
• Integrates principles from electronics, control systems, and process engineering to ensure precise, reliable operation of industrial processes.

Control Engineering (Control Systems Engineering)

• It applies control theory to design systems with desired behaviors.
• Typically used in manufacturing facilities and process plants.
• It employs sensors to measure device output and provide feedback to the controller for correction purposes.
• Automatic control manages a device without human input, like cruise control.
• Control systems engineering activities are multidisciplinary and focus on control system implementation often derived from mathematical modeling.
• Instrumentation and control are key for gathering data and changing system parameters.
• They have a significant role in control loops.

Distinct Aspects

• Instrumentation engineering emphasizes measurement and monitoring process variables.
• Uses sensors and transducers to ensure accurate data collection.
• Control engineering applies data within feedback systems to regulate and automate processes.
• Ensures desired performance occurs without human intervention.
• Instrumentation focuses on gathering information.
• Control engineering uses this information to design dynamically responsive systems.
• Integration of the two optimizes and automates processes in industries.
• Ensures safety, efficiency, and precision in modern tech systems.

Purpose of Instrumentation and Control

• It maintains consistent product standards by monitoring/regulating process variables (temperature, pressure, flow).
• Minimizes variations in production for high-quality outputs that meet predefined specifications.

Conservation of Energy and Raw Materials

• Optimizes resource utilization to reduce energy consumption and minimize raw material waste.
• By implementing efficient monitoring and control systems, industries can achieve sustainable production, lower costs and lessen environmental impact.

Safety

• Protects workers, equipment and the environment through precise instrumentation and automated controls.
• Detects and prevents hazardous conditions.
• Ensures timely responses to potential risks and minimizes accidents, and ensure regulatory compliance.

Savings in Installation

• Designs and implements efficient instrumentation and control systems that simplify setup processes.
• Reduces installation time, and minimizes costs.
• Provides better performance with fewer components and less complexity through advanced technologies.

Material Balance & Product Accounting

• Accurately tracks materials entering and leaving a system.
• Allows industries to maintain balance, avoid losses, and account for resources.
• Enhances transparency and efficiency in process management.

Coordination of Process Variables

• Synchronizes multiple process variables such as temperature, pressure, and flow.
• Ensures smooth operations and reduces fluctuations.
• Improves the overall efficiency of industrial processes.

Research & Development

• Plays a vital role in R&D by providing precise measurements and controls for experiments and innovation.
• Researchers can simulate, test, and refine processes, advancing technology and industry practices.

Enterprise Management

• Integrates instrumentation and control systems into broader organizational strategies.
• Enables real-time monitoring, data analysis, and decision-making.
• Supports better resource allocation, process optimization, and overall business efficiency.

Instruments

• Instruments are devices used for direct or indirect measurement, monitoring, and/or control of a variable.
• Includes indicators, controllers, annunciators, switches, and pushbuttons.
• Instruments measure or manipulate physical variables such as flow, temperature, level, or pressure.
• They can be simple (valves) or complex (analyzers).
• Instruments often comprise control systems of varied processes.

Classification of Instruments

• Critical- Non-conformance could compromise product or process quality (ex: pressure gauge).
• Non-critical- Function is more operationally significant, but doesn't affect product/process quality (ex: temperature indicator).
• Reference only- Function is not critical to product quality or equipment operation (ex: wall-mounted room thermometer).

Instrumentation Systems

• Provides information about the physical value of some variable being measured.
• Variables are called process variables indicating a condition of process liquid/gas.
• Variables can change the manufacturing process.
• Consists of a single unit that gives an output signal or reading according to the magnitude of the unknown applied variable.

Elements of Instrumentation Systems

• Sensor- The first element in a measuring system, in contact with the process. Gives an output depending on the value of the variable.
• Variable conversion elements- Needed when the output variable of primary transducer is in inconvenient form where it has to be converted.
• Signal processing elements- Exists to improve the output quality of a measurement system.
• Signal Transmission- Transmits the signal to a remote point and displays/records the signal.

Types of Control

• Manual- Human operators directly monitor and adjust process parameters via instruments for desired conditions.
• Automatic- Automatic control uses instruments (PLCs or DCS) to monitor variables and make adjustments automatically.

Advantages

• Manual: Flexible and allows human judgment for unexpected situations.
• Automatic: Precise, consistent, and faster response to changes.

Disadvantages

• Manual: Prone to errors, slow response, less precise adjustments.
• Automatic: Higher initial cost, requires maintenance, depends on instrumentation.

Process

• A series of methods/steps to transform raw materials into a final product.
• Can involve physical, chemical, mechanical, or biological operations.
• Varies across industries (petroleum refining, pharmaceuticals, food/beverage)
• Each process is designed for a specific output, focusing on efficiency, quality, and cost-effectiveness.

Process Control

• Regulating/manipulating key variables in a process (temperature, pressure, flow rate, level, chemical composition).
• Ensures smooth, efficient operations that meet quality/quantity specifications.
• Maintains variables within acceptable limits to prevent equipment damage, ensure safety, and produce a consistent product.

System

• A collection/arrangement of physical components working together to achieve a specific function/purpose.
• Components are interconnected, and operate as a unified whole.

Control System

• System designed to regulate or direct behavior of another system/itself to achieve desired outcomes.
• Components measure, monitor, and adjust variables to optimize system performance.

Types of Control Loop

• Open- Actions are based on predetermined schedules/inputs without considering real-time conditions.
• Closed- Uses feedback to maintain the process variable at the desired setpoint.

Advantages

• Open: Simple, inexpensive, easy to implement.
• Closed: Accurate, self-correcting, responsive to changes.

Disadvantages

• Open: Prone to inefficiencies and errors if conditions vary significantly.
• Closed: Requires complex components, slower response.

Instrumentation & Control Loop (Instrument Loop)

• System that combines instruments/control functions to manage and regulate a process variable.
• Interconnected/allows signals to pass, enabling monitoring, measurement, and control.
• Ensures process operates efficiently, safely, and within parameters by maintaining control over key variables.

Elements of Instrument Loop

• Process- When raw materials are transformed by controlling certain variables.
• Measuring Element- Senses/measures a process variable (e.g. temperature, pressure), converting it into a signal.
• Receiving Element- Interprets signals (e.g. controller, indicator) and determines the necessary action.
• Final Control Element- Directly manipulates the process (valve or motor) based on signals from the receiving element.

Foundational Concepts

• Process Variable- Measured and controlled property of a process (temperature, pressure, flow, level).
• Set Point (SP)- Target value/desired level for the process variable (defined by the operator/system).
• Controller Output- Signal sent by the controller to the final control element.
• Manipulated Variable- Process variable adjusted by the controller to bring the measured variable closer to the set point.

Process Technology

• Includes techniques, tools, equipment, methods used to transform raw materials into finished goods or desired outputs.
• Encompasses design, development, and operation in industries like manufacturing, oil & gas, pharmaceuticals, and food.

Process Diagrams

• Back flow diagrams are a simplified representation of a process.
• Shows main process units/blocks, their interconnections (straight lines).
• Provides a basic overview without detailed equipment/process information.

Descriptions

• Simple flow sheet.
• Process engineer begins process design (block diagram) where only the feed and product streams are identified.
• Input-output diagrams: not very detailed, useful in early development stages.

Process Flow Diagram

• BFD processes are then broken down into functional elements like reaction/separation sections.
• Identifies recycle streams, additional unit operations (achieve desired operating conditions).
• Provides more detailed representation (process) versus a BFD.
• Includes more equipment, process flowlines, operating conditions, and key process parameters.

Process Description

• Does note include piping or minor instruments.
• Flow rate, composition, operating conditions (of each stream) are all important
• How much heat is involved, as well as what type of stream they are

Piping and Instrumentation Diagram

• Overall design document for a process plant
• Highly detailed schematic - shows piping, equipment, valves, instrumentation in the process.
• Includes tag numbers, process control loops, and interconnections.
• Serves as blueprint for construction, operation, maintenance.
• Includes all the symbols that depict mechanical equipment, piping equipment, and instruments.

Instrumentation Symbols

• Includes the circles, lines and letters that convey information about the process
• There may even be notations on what device is in the system and how they are connected.

General Instrument or Function Locations

• Discrete/Shared Control are types of instument locations
• Display/Computer Function can determine the location of computer
• It could be located on the central panel, behind the panel, in the field, or on the Local Control Panel

Compressors

• Some types of compressors are: reciprocrating compressor, compressor with silencerss, rotary compressors and centrifugal types

Types of Line Symbols

• Process Line Symbols are visual representations utilized in diagrams like P&IDs and PFDs to illustrate how process materials (such as liquids, gases, or solids) flow through the system and how instruments connect to the process.
• Thick Solid Lines: Indicates the main process.
• Thin Solid Lines: Shows the instrument connections.

Signal Line Symbols

• Signal Line Symbols represent signal types connecting instruments, controllers, final control elements.
• Includes: Mechanical, electrical, pneumatic, and digital communication.

Valve and Actuator Symbols

• Valves may also be drawn as a "bow tie", with other varying types of valves.

Instrumentation Tagging System

• Tag numbering and Loop Identification within the system are all part of the system
• This specifies the type and function within the instrument.

Examples Process Diagrams

• (A) Block Flow Diagram.
• Production of Ethane comes from Etahnol
• Process Flow Diagram

Module 3 Notes

• Measurements determine the quantity of a specific parameter by comparing it to a standard, rather then if a variable is present or absent.
• Instruments here are thermometers, rather then signal outputs

Analog Measuring Devices

• Diagram represents the function of a system that is continous by nature

Characteristics of a Measuring Element

• Accuracy in the reading
• Proportional relationship with input/output
• External influences must be considered

Methods of Measurement

• Direct method or Indirect (inferential) Method can be used for measurements

Types of Measurements

• Single Point vs Continous measurements

Switch

• A process switch can be normally on or off

Types of Switches

• Hand/Limit, Proximity/Pressure, level/temperature

According signals

• Recording in Analog, digital, or Bar Graph

According technology

• It can be Pneumatic, Electric, Electronic, Digital and Processor based

Temperature

• 3-15 psi range, and usually the mA for current

Module 6: Pressure Reading

• P= f/A, where p is pressure, f is the force, and a is the area

1. Can be measure directly by: a probe, thermometer,

• There must also be considerations for Safety, cost savings, and inferences

1. Guage- Measured relative to ambient pressure
2. Differential- Measured when NOT at vacuum or atmosphere
3. Absolute- Measured at VACUUM

Module 4: Instrumentation Ap

• Automation instruments are essential
• Safeguard instruments are designed to protect.
• Essential instruments measure and regulate key parameters