Instrumentation working Industrial Automation

Instrumentation working Industrial AutomationInstrumentation working Industrial AutomationInstrumentation working Industrial AutomationInstrumentation working Industrial Automation

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INSTRUMENTATIONINSTRUMENTATION

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DEFINATIONDEFINATION
InstrumentationInstrumentation is a branch of science which
deals with measure and control of process
variables.
Measure ControlMeasure Control
Sensors On-off controller
Transducer PID controller
Temp controller

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SIGNALSSIGNALS
SIGNAL
ANALOG S/G
•Current(4-20)ma
•Voltage(0-10)v
DIGITAL S/G

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SENSORSSENSORS
SENSOR
ANALOG
Temp sensors
Level sensors
DIGITAL
Proximity sensors

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TEMPERATURE TEMPERATURE
MEASUREMENTMEASUREMENT
RTD
THERMOCOUPLE
THERMISTOR
 PYROMETER

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RTDRTD

RESISTENCE OF ANY METAL CHANGES
WITH ITS TEMPERATURE CHANGE.

RTDs are Positive Temperature Co-
efficient device i.e. Their effective
resistance increases with the increase in
temperature
RTDs are sensors used to measure
temperature by correlating the
resistance of the RTD element with
temperature

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2 Wire PT 100  provides one connection to
each end of the sensor. This construction is
suitable particularly where the changes in lead
resistance due to ambient temperature changes
can be ignored.

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3 Wire PT 100  provides one connection to
one end and two to the other end of the sensor.
Connected to an instrument designed to accept
three-wire input, compensation is achieved for
lead resistance and temperature change in lead
resistance. This is the most commonly used
configuration

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Platinum (most popular and accurate)
Nickel
Copper
Balco (rare)
Tungsten (rare )
CCOMMON RESISTANCE OMMON RESISTANCE
MATERIAL FOR RTDS MATERIAL FOR RTDS

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TYPICAL DESIGNTYPICAL DESIGN

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RTD ELEMENTRTD ELEMENT
The RTD element is the simplest form of RTD. It
consists of a piece of wire wrapped around a
ceramic or glass core. Because of their compact
size, RTD elements are commonly used when
space is very limited.

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The RTD probe is the most rugged form of RTD.
A probe consists of an RTD element mounted
inside a metal tube, also known as a sheath.
The sheath protects the element from the
environment.
RTD PROBES RTD PROBES

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RTD PROBES (Thermowell)RTD PROBES (Thermowell)

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MOUNTING OF RTD

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THERMOCOUPLE THERMOCOUPLE
Thermocouples are sensors for measuring
temperature.
They consists of two dissimilar metals wires,
joined together at one end.
When this junction of the two metals is heated
or cooled a voltage is produced that can be
correlated back to the temperature.

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They are POSITIVE TEMPERATURE CO-
EFFICIENT devices.
i.e. Their effective Resistance increases with
the increase in Temperature

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BEADED WIRE BEADED WIRE
THERMOCOUPLESTHERMOCOUPLES
 Beaded wire thermocouples are the simplest
form of thermocouples.

Consist of two pieces of thermocouple wire joined
together with a welded bead.

Beaded wire thermocouples are a good choice
for the measurement of gas and air temperature.

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TEMPERATURE RANGETEMPERATURE RANGE
-150 degree TO 1800 degree CELCIUS
TYPE J (Iron – Constantine) - up to 800
deg.C
TYPE K (Chrome – Alumeel ) - up to 1150
deg. C
TYPE S (Platinum – Platinum alloy) - up to
1800 deg. C

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THERMOCOUPLE PROBETHERMOCOUPLE PROBE
A thermocouple probe consists of thermocouple
wire housed inside a metallic tube.
The wall of the tube is referred to as the sheath
of the probe.
Common sheath materials include stainless steel
and Inconel.
Inconel supports higher temperature ranges
than stainless steel, however, stainless steel is
often preferred because of its broad chemical
compatibility.

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THERMOCOUPLE PROBETHERMOCOUPLE PROBE

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THERMOCOUPLETHERMOCOUPLE

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THERMISTORTHERMISTOR
Thermistor  It is a negative coefficient
device. It is made of semiconductor material.
It’s used for low temp measurement.
R (increase) T (Decrease)
R (Decrease) T (increase)

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Pressure Transducers - Converts pressure into an analog
electrical signal.
Different type of transducers is used for pressure
measurement like LVDT, Capacitor method and Wheat-
stone bridge.
PRESSURE PRESSURE
MEASUREMENTMEASUREMENT

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THE ELECTRICAL OUTPUT OF THE ELECTRICAL OUTPUT OF
PRESSURE TRANSDUCERSPRESSURE TRANSDUCERS
Pressure transducers are generally available
with three types of electrical output.
 Mill volt
 Volt and
 4-20mA

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STYLES OF PRESSURE STYLES OF PRESSURE
TRANSDUCERS TRANSDUCERS
PC Board Mountable Pressure Transducers
are generally compact economical pressure
transducers designed to mount on an
electrical PC board and be integrated into
other products

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GENERAL PURPOSE GENERAL PURPOSE
TRANSDUCERSTRANSDUCERS
General purpose pressure transducers are
the most common since they are designed to
fit the broadest set of applications

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HEAVY DUTY/INDUSTRIAL HEAVY DUTY/INDUSTRIAL
PRESSURE TRANSDUCERSPRESSURE TRANSDUCERS
Feature a much more rugged enclosure than
other transducers.
They are designed to accommodate heavy
industrial environments.
4-20mA output provides much greater immunity
to electrical noise in industrial environments.

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HIGH STABILITY/HIGH HIGH STABILITY/HIGH
ACCURACY PRESSURE ACCURACY PRESSURE
TRANSDUCERSTRANSDUCERS
An accuracy of 0.25% of full scale or higher.
Although more expensive than general
purpose transducers, they may be the only
option if high precision is required.

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FLUSH DIAPHRAGM FLUSH DIAPHRAGM
PRESSURE TRANSDUCERSPRESSURE TRANSDUCERS
With flush diaphragm pressure transducers, the
diaphragm is flush to the process. This eliminates a
cavity above the diaphragm that could collect fluid
matter from the process.
Those applications include monitoring the pressure
of foods or liquids that have very high viscosity

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SPECIAL PURPOSE SPECIAL PURPOSE
TRANSDUCERSTRANSDUCERS
These include pressure transducers specially designed
for pressure measurement in very high or low
temperatures.
submersible pressure transducers, barometric
pressure transducers and pressure transducers with
digital communications output or wireless outputs.

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FLOW MEASUREMENTFLOW MEASUREMENT
ORIFIC PLATE
NOZZLE
ROTAMETER
MAGNATIC FLOWMETER
ULTRASONIC FLOWMETER
TURBINE FLOWMETER

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DP FLOWMETERSDP FLOWMETERS

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MAGNETIC MAGNETIC
FLOWAMETERFLOWAMETER

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PROPELLER PROPELLER
FLOWMETERSFLOWMETERS
It has a blade which rotates as the flow passes.
These rotations are interpreted as flow by a
totalizer. Propeller meters do not require a power
source to operate.

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ROTAMETERROTAMETER
The Rotameter consists of a metal float and a
conical glass tube, constructed such that the
diameter increases with height.
When there is no fluid passing through the Rota
meter, the float rests at the bottom of the tube.
As fluid enters the tube, the higher density of the
float will cause the float to remain on the bottom.
As flow increases in the tube, the pressure drop
increases.
.

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When the pressure drop is sufficient, the float
will rise to indicate the amount of flow.
The higher the flow rate the greater the
pressure drop.

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ULTRASONIC ULTRASONIC
FLOWMETERSFLOWMETERS
Ultrasonic pulses are beamed from transducers
mounted on opposite sides of the pipe. These pulses
are fired alternately upstream and downstream.
Pulses fired downstream travel faster as they are
carried by the flow. Pulses fired upstream travel
slower as it fights the flow.

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AIR/WATER FLOW AIR/WATER FLOW
SENSORSSENSORS
It can measure very low flow rates from 20
ml/min to 5 liters/min.
It is suitable for industrial, commercial and
laboratory flow applications.
It operate on 12 Vdc power

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MINI-FLOW MINI-FLOW
SENSORS SENSORS
This sensor is ideal for precision low flow &
Accurate Flow Measurements up to 500 ml/min
Typical applications include critical flows in labs,
fluid dispensing, bottling lines, medical flow
applications, liquid ingredient additions, such as
food dyes in the food processing industry

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PLASTIC FLOW SENSORS PLASTIC FLOW SENSORS
FOR LOW/MEDIUM FOR LOW/MEDIUM
FLOWS FLOWS
It is an infrared, electro-optical transmitter and
receiver molded into the flowmeter’s body
Suitable for clear, transparent and translucent
fluids which must transmit infrared light.

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LOW FLOW TURBINE LOW FLOW TURBINE
METERS METERS
It utilizes a wheel-like rotor whose motion is
converted by a pickup coil into a frequency
output that is proportional to flow .
4-20 mA, 0-5 V, or amplified pulse outputs
Turbine meters are used for clean fluids only

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LEVEL MEASUREMENTLEVEL MEASUREMENT
CAPACITIVE LEVEL SENSORS
INDUCTIVE LEVEL SENSORS
ULTRASONIC LEVEL SENSORS
FLOAT TYPE LEVEL SENSORS
PHOTOELECTRIC LEVEL SENSORS

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CAPACITIVE LEVEL SENSORCAPACITIVE LEVEL SENSOR
L = level, Z = impedance, 1 = tank
2 = liquid, 3 and 4 = electrodes.

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FLOAT TYPE LEVEL SENSORFLOAT TYPE LEVEL SENSOR
L = level, 1 = tank, 2 = liquid, 3 = float, 4 = magnet
5 = magnetic armature, 6 = contacts, 7 = bellows, 8
= lever.

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INDUCTIVE LEVEL TRANSDUCER INDUCTIVE LEVEL TRANSDUCER
(a) Variable-inductance type (b) transformer-type level
transducer
L = level, Z = impedance, 1 = tank, 2 = liquid, 3 = coil, 4 =core

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PHOTOELECTRIC LEVEL SENSORPHOTOELECTRIC LEVEL SENSOR
(a) Transmittance-mode (b) reflectance-mode L =
level, 1 = tank, 2 = liquid, 3 = light source, 4 = photo
detector, 5 = prism

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PRESSURE TYPE LEVEL PRESSURE TYPE LEVEL
SENSORSENSOR
L = level, 1 = tank, 2 = liquid, 3 = pressure
transducer

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LOAD CELLLOAD CELL
A load cell is a transducer that converts a
load acting on it into an analog electrical
signal.
This conversion is achieved by the physical
deformation of strain gages which are
bonded into the load cell beam and wired
into a wheatstone bridge configuration.

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STRAIN-GAUGE LOAD STRAIN-GAUGE LOAD
CELLSCELLS

Strain-gage load cells convert the load acting on them into
electrical signals.

The gauges themselves are bonded onto a structural
member that deforms when weight is applied.

In most cases, four strain gages are used to obtain maximum
sensitivity and temperature compensation. Two of the
gauges are usually in tension, and two in compression, and
are wired with compensation adjustments as shown in
Figure.

When weight is applied, the strain changes the electrical
resistance of the gauges in proportion to the load.

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PLATFORM AND SINGLE POINT PLATFORM AND SINGLE POINT
LOAD LOAD
It used for commercial and industrial weighing
systems. They provide accurate readings regardless
of the position of the load on the platform

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CANISTER LOAD CELLSCANISTER LOAD CELLS
It used for single and multi-weighing applications.
Suitable for wet areas

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COMPRESSION LOAD COMPRESSION LOAD
CELLSCELLS
It is a compression load cells often have an integral
button design. They are ideal for mounting where space
is restricted. They offer excellent long term stability.

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WHEATSTONE BRIDGE WHEATSTONE BRIDGE
CIRCUIT FOR LOAD CELLCIRCUIT FOR LOAD CELL

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COMPRESSION/TENSION COMPRESSION/TENSION
LOAD CELLSLOAD CELLS
It can be used where the load may go from tension
to compression and vice versa

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BENDING BEAM LOAD CELLSBENDING BEAM LOAD CELLS
It used in multiple load cell applications, tank
weighing and industrial process control.

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SPEED TRANSDUCERSPEED TRANSDUCER

Speed transducers are widely used for
measuring the output speed of a rotating
object.

Optical Types

They use a light beam and a light sensitive
cell. The beam is either reflected or
interrupted so that pulses are produced for
each revolution. The pulses are then
counted over a fixed time and the speed
obtained.

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SPEED SPEED
TRANSDUCERTRANSDUCER

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ENCODERSENCODERS

An encoder is a sensing device that provides feedback from the
physical world it converts motion to an electrical signal which
can be read by some type of control device. Currently, the
most common technology employed by encoders is optical.

Encoders may produce either incremental or absolute signals.

Incremental signals provide a series of high and low waves
which indicate movement from one position to the next.

Diagram is the basic construction of an incremental encoder.

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A beam of light emitted from an LED passes
through a transparent disk patterned with
opaque lines.
The light beam is picked up by a photosensor.
The photosensor produces a sinusoidal wave
form, which is transformed into a square
wave or pulse train.
 This pulse signal is then sent to the counter
or controller which will then send the signal
to produce the desired function.

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TACHOMETERTACHOMETER
There are two types, A.C. and D.C. The A.C. type
generates a sinusoidal output. The frequency of the
voltage represents the speed of rotation. The frequency
must be counted and processed. The D.C. type generates
a voltage directly proportional to the speed. Both types
must be coupled to the rotating body. Very often the
tachometer is built into electric motors to measure their
speed.

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MAGNATIC PICK UPSMAGNATIC PICK UPS
These use an inductive coil placed near to the rotating body. A
small magnet on the body generates a pulse every time it passes
the coil. If the body is made of ferrous material, it will work without
a magnet. A discontinuity in the surface such as a notch will cause
a change in the magnetic field and generate a pulse. The pulses
must be processed to produce an analogue or digital output.

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PROXIMITY OR POSITION PROXIMITY OR POSITION
SENSORSSENSORS
INDUCTIVE TYPE
CAPSCIVIVE TYPE
ULTRASONIC
PHOTOELECTRIC TYPE

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DIFFERENT INDUCTIVE DIFFERENT INDUCTIVE
SENSORSSENSORS

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CAPACITIVE SENSORSCAPACITIVE SENSORS
They detect the change in capacitance
caused by the approach of an object. Their
advantage lies in the ability to detect
virtually any material, from metals to oils

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HOT-GLASS AUTOMATED HOT-GLASS AUTOMATED
PRODUCT DETECTIONPRODUCT DETECTION
A glass manufacturer needed a reliable
method of counting defect-free hot ashtrays,
candle holders, bookends and more upon
removal from a molding machine.
 Differing product sizes and shapes
eliminated the use of typical thru-beam and
diffuse sensors. Infrared sensors solved this
problem!

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HOT-GLASS AUTOMATED HOT-GLASS AUTOMATED
PRODUCT DETECTIONPRODUCT DETECTION

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PHOTOELECTRIC PHOTOELECTRIC
SENSORSSENSORS
Control cable
Receiver
Emitter
Sensitivity Selector

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VERIFICATION OF FILL LEVEL VERIFICATION OF FILL LEVEL
OF COFFEE IN CANS OF COFFEE IN CANS

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TRANSMITTER
2-Wire Transmitter It use for current
signal.
3-Wire Transmitter It use for current &
voltage signal.
4-Wire Transmitter It is also used for
current & voltage signal.

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PRESSURE TRANSMITTER

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P-H TRANSMITTER

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HART- TRANSMITTER

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HART- TRANSMITTER
It is a ABB 2600-T series pressure transmitter.
It used the HART field communication
protocol.
Output signal=4-20(mA) + HART(R)
The full form of HART is highway addressable
remote transducer.

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VALVEVALVE
ACC. TO MECHNICAL CONSTRUCTION
Gate valve
NRV (Non return valve)
Butterfly
ACC. TO SIGNAL
On-off valve
Control valve

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CATEGORY OF VALVESCATEGORY OF VALVES
ON - OFF SERVICES :- Gate, Ball, Diaphragm,
Plug, Butterfly valves.
THROTTLING SERVICES :- Globe, Butterfly,
Diaphragm, Pinch valves.
NON - REVERSE FLOW :- Check valves.

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CONTROL VALVE – THEORY CONTROL VALVE – THEORY
& SIZING& SIZING
The control valve, commonly named the final
control element of control contains a pneumatic
device that converts the control signal from the
controller in action, regulating the process fluid
flow.
Valves make up approximately 15% of the total
expenditure for the materials and equipments
for the refinery or chemical processing industry.
Valves are used to handle variety of liquids ,
gases , steam, air etc.

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CONTROL VALVE – CONTROL VALVE –
PRINCIPAL OF PRINCIPAL OF
OPERATION OPERATION
It is based upon balanced forces between
pneumatic force from the diaphragm
against a mechanical force produced by
the actuator spring.
The control valve works with a pneumatic
signal 3 to 15 psi. The motion starts at 3 psi
and ends at 15 psi.

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CONTROL VALVE CONTROL VALVE
OPERATIONAL FORMSOPERATIONAL FORMS

AIR TO CLOSE:- 3 PSI – FULL OPEN
15 PSI – FULL CLOSE
AIR TO OPEN :– 3 PSI – FULL CLOSE
15PSI – FULL OPEN
At pressure higher than3 psi applied on
diaphragm,it will start overcoming the spring force
and move diaphragm plate which in turn moves
stem connected and operates the plug.

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CONTROL VALVE- HART POSITIONER
ACTUATOR
VALVE BODY
VENT PORT
POSITIONER
YOKE

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MOTOR OPERATED
VALVE

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VALVE

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GUIDELINES FOR CONTROL GUIDELINES FOR CONTROL
VALVE SPECIFICATIONVALVE SPECIFICATION
Valve trim is of stainless steel
Harden SS or Satellite is used for
Pressure drop of 150 psi or more
Steam
Slurry fluids
More temp
Teflon packing for les than 200 deg. Temp
Asbestos used above 200 deg temp

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CONTROLLERCONTROLLER
Temp. controller
On-off controller
PID controller

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A temperature controller gets input from
temperature sensor such as a thermocouple
or RTD.
It compares the actual temperature to the
desired control temperature, or set point,
and provides an output in the form of
transistor output or relay
HOW DO TEMPERATURE HOW DO TEMPERATURE
CONTROLLERS WORK?CONTROLLERS WORK?

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TEMPERATURE CONTROLLER

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ON-OFF CONTROLLER
The output from it is either ON or OFF, with no middle
state.
It will switch the output only when the temperature
crosses the set point.
For heating control, the output is ON when the
temperature is below the set point, and OFF above set
point.
Since the temperature crosses the set point to change the
output state, the process temperature will be cycling
continually, going from below set point to above, and
back below.

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On-off control is usually used where a precise
control is not necessary, where the mass of
the system is so great that temperatures
change extremely slowly, or for a
temperature alarm.

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ON-OFF CONTROLLER

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ON-OFF CONTROLLER

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PID CONTROL

PID controller provides proportional action
with two additional adjustments, integral and
derivative, which helps the unit automatically
compensate for changes in the system.
Integral and derivative, are expressed in time-
based units; they are also referred as RESET
and RATE.

The proportional, integral and derivative terms
must be individually adjusted or “tuned” to a
particular system using trial and error.

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
It is recommended in systems where the load
changes often and the controller is expected
to compensate automatically the amount of
energy available, or the mass to be
controlled.
It provides the most accurate and stable
control of the three controller types, and is
best used in systems which have a relatively
small mass and those which react quickly to
changes in the energy added to the process.

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PID CONTROLLER
PID controllers are process controllers with the
following characteristics:

Continuous process control Analog input (also
known as "measurement" or "Process Variable" or
"PV")

Analog output (referred to simply as "output")

Set point (SP)

Proportional (P), Integral (I), and / or Derivative (D)
constants

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Proportional Band is referred to as Gain
Integral Band is referred to as Reset
Derivative Band is referred to as Rate

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PID CONTROLLER

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PID CONTROLLER

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PID CONTROLLER

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ANY QUESTION ??????ANY QUESTION ??????