INSTRUMENTATION AND

PROCESS CONTROL
INSTRUMENTATION AND PROCESS CONTROL

COURSE OVER VIEW

1. INTRODUCTION
2. P & ID
3. PRESSURE MEASUREMENT
4. TEMPERATURE MEASUREMENT
5. FLOW MEASUREMENT
6. LEVEL MEASUREMENT
7. FINAL CONTROL ELEMENTS (Control Valves)
8. SYSTEMS
9. PROCESS CONTROLS

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1: INTRODUCTION:

INSTRUMENTATION AND
PROCESS CONTROL
INSTRUMENTATION AND PROCESS CONTROL

INTRODUCTION (INSTRUMENTATION)

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1. What is Instrumentation?

In Process industry, Art of using Instruments for;

1. Sensing the Process

2. Measuring the Process
3. Controlling the Process

Means: Making Automation or Control

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INTRODUCTION (INSTRUMENTATION)

Signals

Signals

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INTRODUCTION (INSTRUMENTATION)

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INTRODUCTION (INSTRUMENTATION)
PLANT
CONTROL ROOM

RACK ROOM
SYSTEM 1

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INTRODUCTION (INSTRUMENTATION)

Signals

RACK / CONTROL ROOM

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2. P & ID:

PIPING AND
INSTRUMENTATITION
DIAGRAMES
INSTRUMENTATION AND PROCESS CONTROL

PFD / P & ID

Every technical discipline has standardized way(s) of making descriptive diagrams.

In industry, Plant “Layout & its Process Flow” can be shown by:

• Process Flow Diagrams (PFDs)

• Process / Piping and Instrument diagrams (P & IDs)

A PFD provides the information of process flow & process parameters i.e. Pressure,
Temperature, Flow etc.

A P&ID shows the layout of all relevant process vessels, pipes, and machinery, but with
instruments superimposed on the diagram. It also provides the piping information.

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Process Flow Diagrams

PFD
Click Here

Process Flow Diagrams provides the information of Process flow & Process parameters
i.e. Pressure, Temperature, Flow etc.

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P & ID (Piping & Instrumentation Diagram)

P & ID
Click Here

A P&ID shows the layout of all relevant process vessels, pipes, and machinery, but with
instruments superimposed on the diagram. It also provides the piping information.
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INSTRUMENT SYMBOLS

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P & ID

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3. PRESSURE MEASUREMENT
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PRESSURE MEASUREMENT

PRESSURE.

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PRESSURE MEASUREMENT

PRESSURE.

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PRESSURE MEASUREMENT
PRESSURE.

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PRESSURE MEASUREMENT

PRESSURE.
Pressure depends on depth, not volume

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PRESSURE MEASUREMENT
PRESSURE MEASURING INSTRUMENTS

1. MANOMETERS
2. MECHANICAL PRESSURE ELEMENTS
3. ELECTRICAL PRESSURE SENSITIVE ELEMENTS
4. DIFFERENTIAL CAPACITANCE SENSORS

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PRESSURE MEASUREMENT

Manometers.

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PRESSURE MEASUREMENT

MECHANICAL PRESSURE ELEMENTS

Mechanical pressure-sensing elements include the bellows, the diaphragm, and the bourdon
tube. Each of these devices converts a fluid pressure into a force. If unrestrained, the natural
elastic properties of the element will produce a motion proportional to the applied pressure.

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PRESSURE MEASUREMENT

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PRESSURE MEASUREMENT

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PRESSURE MEASUREMENT

ELECTRICAL PRESSURE SENSITIVE ELEMENTS

Piezoresistive (strain gauge) sensors

Piezo resistive means “pressure-sensitive

resistance,” or a resistance that changes
value with applied
pressure. The strain gauge is a classic
example of a piezo resistive element, a
typical strain gauge element

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PRESSURE MEASUREMENT
ELECTRICAL PRESSURE SENSITIVE ELEMENTS
The most modern piezo resistive-based pressure instruments use silicon strain gauge
elements to sense deformation of a diaphragm due to applied fluid pressure. A simplified
illustration of a diaphragm / strain gauge pressure sensor is shown here:

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PRESSURE MEASUREMENT

DIFFERENTIAL CAPACITANCE SENSORS

An example of a Pressure instrument utilizing a silicon strain

gauge element in Differential Pressure transmitter

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4. TEMPERATURE
MEASUREMENT
INSTRUMENTATION AND PROCESS CONTROL

TEMPERATURE MEASUREMENT.

What is Temperature?

➢ Degree of Hotness or Coldness of a Body.

➢ Measure of average Molecular Kinetic energy within a substance.

What is Heat?

➢ Type of Energy Like other types Mechanical, Chemical, Bio etc.

Note: Heat flows from Higher Temperature to Lower one.

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TEMPERATURE MEASUREMENT.

Temperature Versus Heat

• When heat, i. e. energy goes into a substance one of two things can happen:

1- The substance can experience a raise in temperature. That is, the heat can be used to
speed up the molecules of the substance.

2. The substance can change state.

- Ice: Solid Liquid Vapor

- Dry Ice: Solid Vapor

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TEMPERATURE MEASUREMENT.

Heat Transfer : Three ways of Heat Transfer

1. Convection 2. Conduction 3. Radiation

Convection: Transfer of heat energy by actual Movement of the

warmed Matter or Molecules (Water in Boiler tubes)

Conduction: Transfer of heat energy by Vibration of Molecules

(Spoon end in cup of Tea)

Radiation: Transfer of heat energy by Rays

(Sun shine, High Flaring)

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TEMPERATURE MEASUREMENT.

Temperature is measured by:

1. Liquid / Gas bulb Thermometers

2. Bimetal indicators
3. Resistance Temperature Detectors (RTD)
4. Thermocouples
5. Thermistors
6. Non Contact Type (Infrared thermometers)

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TEMPERATURE MEASUREMENT.

Effective ranges of eight temperature-measuring instruments

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TEMPERATURE MEASUREMENT.

How To Measure Temperature?

Liquid Bulb Thermometers

A thermometer is a device used to measure

temperature.

1592 - Galileo Galilei builds a thermometer

using the contraction of air to draw water up
a tube

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TEMPERATURE MEASUREMENT.

Gas Bulb Thermometers

DIRECT MOUNTING TYPE

• Gas bulb thermometers measures temperature

by the variation in volume or pressure of a gas.

One common apparatus is a constant volume

thermometer. It consists of a bulb connected by a
capillary tube to a manometer.
REMOTE MOUNTING TYPE

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TEMPERATURE MEASUREMENT.

Bi-metal temperature principle

• Solids tend to expand when heated

• But Rate of Expansion is different for different material

• This bending motion is significant enough to drive a pointer mechanism

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TEMPERATURE MEASUREMENT.

• Bi-metal temperature sensors

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TEMPERATURE MEASUREMENT.

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TEMPERATURE MEASUREMENT.

Resistance Temperature Detector (RTD)

1. Heat Sensitive element

2. Material of Construction: Platinum, Nickel, Iron, Salver
o - RTDs Type: Pt100
o - Platinum resistance= 100 ohm at 0 degree C
o As temperature rises, resistance increases

Red
Red

White

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TEMPERATURE MEASUREMENT.

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TEMPERATURE MEASUREMENT.

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TEMPERATURE MEASUREMENT.
Thermocouples

Two dissimilar metal wires joined together at one end Hot Junction
Other end Cold Junction Provides EMF
EMF Proportional to Temp. difference between Hot Junction & Cold Junction

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TEMPERATURE MEASUREMENT.
Temp. Measurement by Digital multi-meter

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TEMPERATURE MEASUREMENT.
Thermocouple Hookup with Transmitter

Imbeded T/C on
Thrust bearing pad

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TEMPERATURE MEASUREMENT.

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TEMPERATURE MEASUREMENT.
Thermocouples by Tip Styles

Exposed Tip style provide maximum sensitivity and fastest

response. This design, however, makes the thermocouple more fragile

Sheathed tip (Un Grounded) are typical for industrial applications,

available in either grounded or ungrounded forms.

Sheathed tip (Grounded) thermocouples exhibit faster response

times and greater sensitivity than ungrounded-tip thermocouples, but
they are vulnerable to ground loops.

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TEMPERATURE MEASUREMENT.
Thermocouple Types & Range

Type Positive Wire Negative Wire Temperature Range

T Copper Constantan -250 to 400°C (600°C)
J Iron Constantan -200 to 700°C (900°C)
E Chromel Constantan -200 to 700°C(1000°C)
K Chromel Alumel -200 to 1000°C(1300°C)
N Nicrosil Nisil -200 to 1000°C(1300°C)
S Pt10%-Rh Platinum 0 to 1300°C(1600°C)
R Pt13%-Rh Platinum 0 to 1300°C(1600°C)
B Pt30% - Rh. Pt 6%Rh 0 to 1600°C(1800°C)

T/C Codes
Click Here

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TEMPERATURE MEASUREMENT. T/C Extension Cables Color Codes

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TEMPERATURE MEASUREMENT.
Thermistor

Small, Solid State (semiconductor of various Metal Oxides) and Temperature sensitive
device
Resistance decreases with an increase in temperature

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TEMPERATURE MEASUREMENT.

IC SENSORS

➢ The newest type of temperature sensor

➢ have a limited temperature range (-45° ~ 150° C)
➢ Mostly used on Temp. Sensitive Electronic Boards

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TEMPERATURE MEASUREMENT.

Non Contact Infrared Thermometer

➢ Used to measure furnaces tube temperature (Olefins-III)

➢ Temperature range: 500 to 3200°C

Cyclops 153 dust proof portable infrared thermometers

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5. FLOW MEASUREMENT
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FLOW MEASUREMENT

What is Flow

➢ Passing of Things, Fluids (Liquids or Gases) etc. from one place

➢ Usually not measured directly
➢ Affected by fluid properties (Viscosity, Density etc.), Physical installations

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FLOW MEASUREMENT

Types
of
Flows

Turbulant Flow Laminar Flow

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FLOW MEASUREMENT
TYPES OF FLOW MEASUREMENT
1. Direct measurement method
2. Indirect measurement method

1. Direct measurement method

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FLOW MEASUREMENT

1. Direct measurement method

Variable Area Flowmeters

➢ Conical Tube
➢ Marked Scale (Linear) on it with Flow Units
➢ Always installed Vertically
➢ Having Float inside which moves upward/Downward
according to Flow Rate

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FLOW MEASUREMENT

1. Direct measurement method

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FLOW MEASUREMENT

2. INDIRECT RATE MEASUREMENT

Pressure-based Fow Measurement

P TYPE FLOW ELEMENTS

1. Orifice plate
2. Flow nozzle
3. Venturi tube
4. Annubar
5. Pitot tube
6. Segmental wedge
7. Target
8. V-cone

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FLOW MEASUREMENT
Orifice Plate Types

1. Concentric Orifice Plate

2. Eccentric orifice plate
3. Segmental orifice plate ORIFICEPLATE
4. Quadrant Edge plate
5. Conditioning Orifice Plate

Conditioning Orifice Plate Concentric Eccentric Segmental Quadrant

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FLOW MEASUREMENT

D/P INSTRUMENT WITH & WITHOUT CHARACTERIZATION

D/P Flow
Click Here

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FLOW MEASUREMENT

EK-0201 Discharge Flow

V-cone cut view

BH-01001 Feed Flow

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FLOW MEASUREMENT

Seawater Flow Meters /

Annubar Air Flow Meters

Annubar Segment cut view. Annubar

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FLOW MEASUREMENT

Segmental Wedge
Target

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FLOW MEASUREMENT

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FLOW MEASUREMENT
FLOW METER TYPES
Magnetic Flow Meter 03-26-FT-6101 MEG. Flow
Click Here
SLURRY TO STRIPPING COLUMN
➢ Used for conductive fluid VC-2601A
➢ Proportional to the fluid Velocity

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FLOW MEASUREMENT 14-FE-8789

HP STEAM TO BLOCK "R"

Vortex Shedding Flow Meters

Flow hits the shedder bar, separates and

due to the shape of the bar, forms
vortices. The vortices create an
alternating pressure differential across
the bar. The bar is physically stressed
toward the low pressure side of the bar.

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FLOW MEASUREMENT

Vortex Shedding Flow Meters

A piezoelectric crystal converts a mechanical stress into an electrical pulse. The crystals
are hermetically sealed and not in contact with the process.
Vortex Flow
Click Here

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FLOW MEASUREMENT

POSITIVE Displacement Flowmeter

Positive displacement flowmeter is the only flow measurement technology that directly
measures the volume of the fluid passing through the flowmeter. Positive

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FLOW MEASUREMENT

Turbine Flowmeters
98-FT-4692 C3 FEED FROM ARAMCO

Turbine flowmeters use the mechanical energy of the

fluid to rotate a “pinwheel” (rotor) in the flow stream.

Rotor Speed is Directly proportional to the Fluid Flow

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FLOW MEASUREMENT

Turbine Flowmeters

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FLOW MEASUREMENT

Coriolis Mass Flow Meter

14- FI-4073A ETHYLENE VAPOR PRODUCT FROM EE-0420

In a Coriolis mass flowmeter, the “swinging” is generated

by vibrating the tube(s) in which the fluid flows. The
amount of twist is proportional to the mass flow rate of fluid
passing through the tube(s).

Coriolis Flow
Click Here

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FLOW MEASUREMENT
Coriolis Mass Flow Meter

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FLOW MEASUREMENT

ULTRASONIC Flowmeter

Ultrasonic flowmeters use sound waves to determine the velocity of a fluid flowing in a pipe.
At no flow conditions, the frequencies of an ultrasonic wave transmitted into a pipe and its
reflections from the fluid are the same. Under flowing conditions, the frequency of the
reflected wave is different due to the Doppler effect.

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6. LEVEL MEASUREMENT
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Level Measurement

In a Vessel, Tank, Storage drum etc. :

Position of Upper surface of Solid/Fluid with respect to the

Reference position

Level is another common Process Variable in industries. The method

used will vary widely depending on the nature of the industry, the
process, and the application.

➢ Inventory Constant supply or storage of material

➢ Control continuous, batch, blending, and mixing control

➢ Alarming hi/lo limits, safety shut down

➢ Data Logging material quantities for inventory and billing purposes

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Level Measurement

The measured medium can be Solids, Liquid or Gas (N2 Breather Tank Level), stored in
Vessels, Tanks (open/closed), Silos, Bins and Hoppers etc.

Units of Level can be expressed in:

➢ Feet, Meters, % etc.
In case of Inventory:
➢ Gallons, Liters, Tones etc.
➢ Cubic Foot, Cubic Mete etc.

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Level Measurement

Methods – Direct or Indirect

Hydrostatic Head
Float
Load Cells
Magnetic Level Gauge
Capacitance
Transmitters
Magnetostrictive
Ultrasonic
Microwave
Laser
Radar
Guided Wave Radar
Dip Stick
Vibration

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Level Measurement

DIRECT METHODS

Direct methods sense the surface or interface of the liquid and is not affected by
changes in material density (Specific Gravity)

Examples:
• Dip Stick
• Sight Glass
• Floats
• Ultrasonic

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Level Measurement

INDIRECT METHODS (INFERENTIAL)

Indirect methods “infer” liquid level by measuring some other physical parameter
such as pressure, weight, or temperature.
Changing materials means a corrective factor must be used or recalibrating the
instrument.

Examples:
• Hydrostatic head methods
• Load Cells
• Capacitance

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Level Measurement

Dip Stick

• Simple and cheap

• Can be used with any wet material and not affected by
density.
• Can not be used with pressurized tanks
• Visual indication only (electronic versions are available)

Rod Gauge - similar to a dipstick found in a car, it

has weighted line markings to indicate depth or
volume

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Level Measurement

Sight Glass

INSTALLED IN ALL
PLANT

Another simple direct method of measuring liquids.

Can be used in pressurized tanks (as long as the glass or plastic tube can handle
the pressure)

Good for applications where non-contact measurement is needed (like beverages)

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Level Measurement

Magnetic Level Sensors

03-39-LI-9115
Ammonia-Separator
VV-3902

Used where the sight glass level gauge can not be.
Magneto-resistive types can provide an electrical output.

Liquid/liquid interface (such as water and oil) can be measured by changing the buoyancy
of the magnetic float

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Level Measurement

FLOATS
03-39-LT-9115 Ammonia-separator VV-3902

Float rides the surface level to provide the measurement. Different styles are available.

Liquid density does not affect measurement

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Level Measurement

ENRAF GAUGES (48-LI-0576 RTK-4801 LEVEL)

Principle is based on Buoyancy of a displacer.

Level variation of product, in which the displacer is partially immersed, causes a change in
buoyancy and detected by transducer. Loss of Weight will cause variation in the position
of stepper motor.

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Level Measurement

Hydrostatic Head Level Sensors

➢ Indirect method of Level measurement Hydrostatic head converted to liquid Level
➢ Pressure measured at bottom of the tank is converted to Liquid Level.
➢ Different liquid densities or closed tank applications must be accounted for.

Liquid
Pressure exerted by the Height of the liquid is: Density (D)
Height
P = H x Density* (H)

If the Density of the liquid is known then

Pressur
H = Pressure ÷ Density* e PSI

*Note: For liquids other than water, use the density of water 0.0361 lb/in3 as a reference
and multiply by the SG of the liquid.

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Level Measurement

74-LT-6002/60023 74-LT-6002 FIRE WATER TANK CTK-7401A

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Level Measurement

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Level Measurement
Instrument input does
not matter
P

Bubblers Regulated purge system

(air/N2)

Bubblers allow the indicator to be

located anywhere.
The air pressure in the tube varies
with the head pressure of the
height of the liquid.

Bottom of tube
determines reference
point

Can’t be used in closed tanks or where purging a liquid is not allowed (soap). Very popular
in the paper industry because the air purge keeps the tube from plugging.

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Level Measurement

14- LT-8078 ESU-8401 SANITARY LIFT STATION NO. 1 LEVEL TRANSMITTER.

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Level Measurement

Capacitance Level Detection (RF Level Probes)

RF Capacitance level sensors are used when non-conductive liquids are measured.

14-LT-9012
PYROTOL FEED
SURGE DRUM
EV-0902 BOOT

The only variable is the dielectric of the tank material that varies in proportion to the level.
Conductive liquids like mineral water will short out the probe to the tank wall.
Good for solids

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Level Measurement

Ultra Sonic Level Measurement

• Non-Contact direct level sensor

• Level is a function of the time it takes an
ultrasonic pulse to hit the surface and return

Ultrasonic Level
Click Here

Limitations include:
➢ Surface foam absorbs signal, agitation create reflections
➢ High Pressure & High Temperatures affect the signal speed
➢ Vapour and condensate create false echo’s

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Level Measurement

Radar Level Sensors (Microwave)

30- LT-3337 SLOPS TANK NV-3018 LEVEL (Mineral Oil/ Solvents)
Similar to ultrasonic but at a much higher frequency (6.3 GHz)
Various designs
– Frequency Modulated Continuous Wave
– Pulsed Wave
– Guided Wave

Radar Level
Click Here

These sensors have better performance in applications where vapour, dust or uneven
surfaces exist.

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Level Measurement

Guided wave Radar Sensor A generated pulse of electromagnetic energy

travels down the probe. Upon reaching the
liquid surface the pulse is reflected.

03-127-LT-7170
VV-12704A SILO LEVEL

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Level Measurement

LOAD CELLS
80-WE/WT-8345 NHS-8011 PELLET BLENDER LEVEL
Tank level is determined by the weight of the quantity of material
Load Cells (strain gauge transducers) placed at the bottom of the tank measure the weight
and then convert it to an electrical signal.

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7. FINAL CONTROL ELEMENT

(CONTROL VALVES)
INSTRUMENTATION AND PROCESS CONTROL

CONTROL VALVES
INSTRUMENTATION AND PROCESS CONTROL

Control Valves

Mechanical devices which Regulates the Process Variable within a system or process.
Different types of valves are available: Gate, Globe, Plug, Ball, Butterfly, Check,
Diaphragm, Pinch, Pressure relief etc.

1. Valve operated with Hand wheel Manual Valve

2. Valve operated by its own mechanism Self Operated (PCV)
3. Valve operated with Automatic Actuator Control Valve 3

1 2

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Control Valves

Based on the valve construction, valves are classified in different names. Valves are
classified in to two general types based on valve Movement i.e. Linear or Rotary.

TYPE OF CONTROL VALVES CONTROL VALVE OPERATION:-

1.Air to Open
• Globe 2.Air to Close
• Gate 3.Air fail to Lock in the same position
• Butterfly
• Ball
• Angle
• Diaphragm
• Diverter valves

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Control Valves

VALVES SYMBOLS

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Control Valves

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Control Valves

ANTISURGE CONTROL
VALVE

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Control Valves

BUTTERFLY VALVE 3-Way Control Valve VARIPACK VALVE

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Control Valves

3-Way Control Valve

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Control Valves

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Control Valves

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Control Valves

De-Super-Heater Control valves

TV-1354A (Fur.# 1 VHP

TV-8178 (BFW TO EDS-0821) Steam De-Superheater)

EDS-0821
MP STEAM

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Control Valves

SLIDE VALVES XV-4860 , PPB ROTARY FEEDER NRF-4031 INLET

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Control Valves

SLIDE VALVES

XV-4860, PPB ROTARY FEEDER NRF-4031 INLET

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Control Valves

ROTARY VALVES AND GLOBE VALVES

Rotary valves (eccentric plug or segmented ball) or globe valves (linear motion) shall be
used for all services except where the allowable pressure drop is so low that a globe valve
would not function.
Cage-guided globe valves and balanced type valves, with the exception of double seated
control valves, shall not be used in services where coke may form. Cage-guided globe
valves shall not be used for fluids that contain solid particles.

ROTARY GLOBE VALVE

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Control Valves

ANGLE VALVE

Angle valves should be considered for:

- Hydrocarbon services where coke may form;
- Erosive services, e.g. Slurries;
- Applications where solid contaminants might settle in the body of a globe valve.
A special type of angle valve, the choke valve (6.4), is used for wellhead services

ANGLE VALVE

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Control Valves

BUTTERFLY VALVES
Butterfly valves shall comply with the piping class and shall be considered for the following
circumstances:
➢ If the required size (usually due to a high flow rate with a low pressure drop) would make
it economically attractive.
➢ If it is impossible to use eccentric plug / segmented ball or globe valves.
➢ For corrosive services, where body lining of globe valves becomes economically
unattractive, special butterfly valves (known as "high performance butterfly valves“) are
now proven. These butterfly valves can handle high temperatures and high differential
pressures, and can have a Class V or Class VI shut-off performance.

BUTTERFLY VALVE

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Control Valves

BALL VALVES
Ball valves shall be considered for on-off service. Ball valves shall comply with the piping
class. The type of actuator shall be as specified by the Principal. Ball valves for use in
erosive (e.g. slurry) service etc. and should be equipped with a scraper type of seat
construction.
Ball valves shall not be selected for throttling service without the approval of the Principal.
Unless equipped with a special trim, i.e. anti-cavitation or low-noise design, care should
be taken with the selection of ball valves for high differential pressures.

BALL VALVE

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Control Valves

CONTROL VALVE CHRACTERISTICS

Control valve flow characteristic are determined principally designs of the Trim. The three
inherent characteristics available are: Quick opening, Linear and Equal percentage.

VALVE FLOW
CHRACTERISTICS

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Control Valves

VALVE PLUGS ACCORDING TO FLOW CHRACTERISTICS

When valves are installed with pumps, piping, fittings, and other process equipment,
the pressure drop across the valve will vary as the plug moves through its travel.
When the actual flow in a system is plotted against valve opening, the curve is called
the Installed Flow Characteristic.

For blow down and For feed streams For Compressor surge
Vent services Services Controls

No. 114
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Control Valves

VALVE CAGES ACCORDING TO FLOW CHRACTERISTICS

No. 115
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Control Valves

CONTROL VALVE

Control valve consist of two major

subassemblies:
Valve body: The portion that
actually contains the process fluid. It
consist of a Body, internal Trim and
Bonnet.
Actuator: This assembly moves the
control valve in response to an
actuating signal from an automatic
or manual device.

No. 116
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Control Valves
Valve Actuator
Actuator is used to Operate the Valve i.e. Opening or Closing. There are many different
types of actuators Like;

1. Electric Motor Actuators

2. Pneumatic Actuators
3. Hydraulic Actuators
4. Solenoid Actuators

M. O. V Pneumatic actuator S. O. V
E/H Actuator

No. 117
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Control Valves

VALVE AND ACTUATOR TYPES.

1. Air to Open (Inst. Air Failure, Valve Closed)

Examples: Fuel gas valves on Boilers /
Furnaces, Reactor feed valves etc.
2. Air to Close (Inst. Air Failure, Valve Opened)
Examples: Vent valves, cooling water
supply valves, Anti-Surge valves etc.
3. Air fail to Lock in the same position.
Examples: BFW to boilers, Dilution
Steam to furnace tubes, F.D. Fan
Dampers, etc.

No. 118
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Control Valves

ACTUATOR BENCH SET

It is the amount of air required to start to move an uncoupled actuator to full stroke.
Example, if the bench set on a valve actuator is 3 to 15 PSI, it should take 3 PSI of
pressure to overcome the spring and start moving and at full stroke, it should take 15 PSI.

No. 119
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Control Valves

VALVE BODY BONNETS

The Bonnet of the control valve is that part of the Body assembly through which valve Plug
stem or Rotary shaft moves.

No. 120
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Control Valves

CONTROL VALVE STEM PACKING:

For a reliable seal between the Stem and the Bonnet, a gasket is needed. This is called a
Packing, and it is fitted with the following components.
1. Gland follower: Sleeve which compresses the packing gland into the Stuffing box.
2. Gland: Kind of bushing, which compressed the packing into the Stuffing box.
3. Stuffing box: Chamber in which the packing is compressed.
4. Packing: Available in several materials, like Teflon, Elastomeric, Fibrous material etc.
5. Backseat: Seating arrangement inside the bonnet. It provides a seal between the Stem
and Bonnet. It prevents system pressure from building against the valve packing, when
the valve is fully open. Back seats are often applied in gate and globe valves.

No. 121
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Control Valves

PACKING ASSEMBLY

No. 122
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Control Valves

Control Valve Accessories

1. I/P Transducer
2. Volume Booster
3. Limit Switch
4. Positioner
5. Quick Exhaust
6. Lockup Relay
7. Solenoid

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Control Valves

Control Valve Accessories

I/P TRANSDUCER

Current to Pressure converter (I/P) converts an Analog signal (4 to 20 mA) to a

proportional linear pneumatic output (3 to 15 psig). Its purpose is to translate the analog
output from a control system into a precise, repeatable pressure value to control
pneumatic actuators/operators, pneumatic valves, dampers, vanes, etc.

No. 124
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Control Valves

Control Valve Accessories

Positioner
Positioner is like a Proportional Controller. Set point is the control signal
from Primary Controller and the Controlled variable is the Valve Position.
The uses of Positioner are:
1. Exact Positioning.
2. When Signal pressure is not enough to operate the control valve.
3. To make Split range between the valves.
4. Used to reverse the Actuator action i.e. AO AC and vice versa.
5. To minimize the Hysteresis effect.
6. To minimize the Response time for the valve.

No. 125
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Control Valves

Control Valve Accessories

Valtek Beta Positioner

No. 126
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Control Valves

Control Valve Accessories

FORCE - BALANCE PNEUMATIC POSITIONERS

No. 127
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Control Valves
Control Valve Accessories
Different types of Positioners
Masoneilan 7400 Flowserve Logix 3000 Masoneilan SVI II AP

DVC6000 Masoneilan SVI I Valtek Beta I/P

No. 128
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Control Valves

Control Valve Accessories

Volume Booster:
Volume Boosters are used on throttling control valves to provide fast stroking action with
large input signal changes. At the same time, the flow boosters allow normal Positioner air
flow (and normal actuation) with small changes in the Positioner input signal.

No. 129
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Control Valves

Control Valve Accessories

Pneumatic Pressure Regulators

Pressure regulators, commonly called pressure-reducing valves, maintain constant output
pressure in air systems regardless of variations in input pressure or output flow.

No. 130
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Control Valves

Control Valve Accessories

LIMIT SWITCH

A switch preventing the travel of an object in a mechanism past some predetermined point,
mechanically operated by the motion of the object itself.

No. 131
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Control Valves

Control Valve Accessories

QUICK EXHAUST
Quick Exhaust Valve is a 3/2 valve with an extra large exhaust orifice designed to fit directly
onto the cylinder port connection. The purpose of a Quick Exhaust Valve is to evacuate
cylinder air directly to atmosphere and provide very Fast response. Usually used on Vent,
shutdown and anti-surge valves.

No. 132
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Control Valves

Control Valve Accessories

Trip / Lockup Relay:

Pneumatic lock up system are used with control valve to lock in existing actuator loading
pressure in the event of supply pressure failure. This devices can be used with volume tank
to move the valve to the fully open or fully closed position on loss of pneumatic air supply.

No. 133
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Control Valves

Control Valve Accessories

Solenoid Valve
A solenoid valve is an electromechanically operated valve. The valve is controlled by an
electric current through a solenoid: in the case of a two-port valve the flow is switched on or
off; in the case of a three-port valve, the outflow is switched between the two outlet ports.

No. 134
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Control Valves

14-FV-6126 C3 KICKBACK VALVE SERVICING

14-FV-6126 CAGE

14-FV-6126 CAGE
14-FV-6126 DISMENTLING
CAGE
PLUG/STEM

No. 135
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Control Valves

Overhauling

No. 136
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Control Valves

14-FV-6126 Transportation After Overhauling

No. 137
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8. SYSTEMS
INSTRUMENTATION AND PROCESS CONTROL

Systems

1. HONEYWELL DCS (TPS)

2. YOKOGAWA DCS (C3000)
3. ESD SYSTEM (TRICONEX TS1131 TMR)
4. BURNER MANAGEMENT SYSTEM (HONEYWELL FSC)
5. VIBRATION MONITORING SYSTEM (SYSTEM 1)

No. 139
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HONEYWELL DCS (TPS)

INSTRUMENTATION AND PROCESS CONTROL

Honeywell DCS (TPS)

❑ Collection of hardware and instrumentation

necessary for implementing control systems

❑ Provide the infrastructure (platform) for

implementing advanced control algorithms

No. 141
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The TPS (DCS) Architecture

No. 142
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The TPS (DCS) Architecture

No. 143
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OLEFINS-II OLD DCS

Critical Alarm
Annunciator

OLEFINS-II NEW DCS

No. 144
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YOKOGAWA DCS (C3000)

INSTRUMENTATION AND PROCESS CONTROL

Yokogawa CS3000 System

CENTUM CS 3000 is an integrated production control system used to manage and
control the operation of plants in a wide variety of industries like petroleum refineries,
petrochemical, chemical, pharmaceutical.

No. 146
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CS3000 System Architecture

No. 147
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ESD SYSTEM
(TRICONEX TMR)
INSTRUMENTATION AND PROCESS CONTROL

What is Triconex TMR?

Three identical system channels independently executes the control program, and
specialized hardware/software mechanisms vote all inputs and outputs.
The Triconex controller provides fault tolerance through Triple Modular Redundant (TMR)
architecture.
The controller consists of three identical system channels, except for the Power Modules
which are dual-redundant. Each channel independently executes the control program
(also referred to as the TriStation application) in parallel with the other two channels.
Hardware voting mechanisms qualify and verify all digital inputs and outputs from the
field; analogue inputs are subject to a mid-value selection process.

No. 149
INSTRUMENTATION AND PROCESS CONTROL
Triconex Controller Features / Fault Tolerance

FEATURES
▪ Triple redundancy (no single point of failure)
▪ Isolated architecture
▪ Diagnostics (transparent to the user)
▪ On line repair and replacement
▪ Control application program emulation
▪ Direct communication to Distributed Control Systems (DCS)
▪ Open communication with external Human Machine Interfaces (HMI)

Fault Tolerance
▪ The ability to detect transient and steady-state error conditions and to take the
appropriate corrective action on-line.
▪ Fault tolerance provides an increase in safety and an increase in the availability of the
controller and the process being controlled.
▪ No single point of failure in any one channel can pass to another channel.
▪ Removing and replacing (if and when necessary) a failed module in the faulty channel
whilst the Tricon is on-line.

No. 159
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Triconex Architecture

No. 151
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Triconex Architecture

No. 152
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BURNER MANAGEMENT
SYSTEM (HONEYWELL FSC)
INSTRUMENTATION AND PROCESS CONTROL

FAIL SAFE CONTROLLER (FSC)

What Is FSC?
Fail Safe Controller is a Safety Integrity Level (SIL) certified integrated safety
platform. Based on Quadruple Modular Redundant (QMR®) technology, FSC
supports a wide range of high integrity process control and safety functions
including Burner/boiler management systems

FLAME DETECTOR 95DS

A device which detects the
presence or absence of a flame in
order to prevent combinations of
fuel, heat, and oxygen at
inappropriate times.

No. 154
BMS PLC ARCHITECTURE
BMS (Burner Management System) PLC Architecture

No. 155
INSTRUMENTATION AND PROCESS CONTROL

A single input for a BMS!

Fail Safe Controller

No. 156
INSTRUMENTATION AND PROCESS CONTROL

OLE-III, VHP Boiler # 2 Burners Schematic

No. 157
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VIBRATION MONITORING
INSTRUMENTATION AND PROCESS CONTROL

Vibration Monitoring

WHAT IS VIBRATION?

A body is said to vibrate when it describes

an oscillating motion about a reference
position.

The number of times a complete motion

cycle takes place during the period of one
second is called the Frequency and is
measured in hertz (Hz).

Vibration
Click Here

No. 159
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Vibration Monitoring Architecture

PROXIMITTORS
COMPRESSOR / EQUIPMENTS

SYSTEM 1
CONTROL ROOM

VIB. RACK

No. 169
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Vibration Monitoring
Basic Vibration Sensors

No. 161
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Vibration Monitoring

No. 162
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Shaft Relative Motion

DEFINITION:
Shaft vibration measured relative to a chosen reference

Orbit Key Phasor

Click Here Click Here

X-Y Phase
Click Here

No. 163
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Casing Absolute Motion

DEFINITION:
Vibration of the casing relative to an inertial (fixed) reference frame. (An inertial reference
frame is also referred to as free space.)

Balancing
Click Here

No. 164
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Rotor Position

DEFINITION:
The average position or change in position of a rotor in the axial direction
with respect to some fixed reference point local to the thrust assembly.

*The thrust/rotor position probe measures the

average gap between the shaft and the probe.

No. 165
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Rotor Position Vs Thrust Position

No. 166
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Rotor Position Vs Thrust Position

No. 167
C3 COMPRESSOR TURBINE (OLEFINS-III)

No. 168
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Vibration Switch

Vibration Switches are installed on Fin fans and Reciprocating Compressor casing to
initiate trip signal on high casing vibration. Application: Fin Fans, Compressor Casing etc.

No. 169
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9. PROCESS CONTROL
INSTRUMENTATION AND PROCESS CONTROL

Process Control

1. What is Instrumentation?
2. What is Process?
3. What is Control?

No. 171
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Process Control

1. What is Instrumentation?

In Process industry, Art of using Instruments for;

1. Sensing the Process

2. Measuring the Process
3. Controlling the Process

Means: Making Automation or Control

No. 172
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Process Control

2. What is Process?

Oil TT Oil Temperature

Furnace
Fuel flow

No. 173
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Process Control

3. What is Control?

Things should Happen as per Desire

Things Equipment usually Plant

Happen Operate

Simply & Usually;

Plant / Equipment Operate Automatically & it is done through Instrumentation

No. 174
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Process Control

What is Process Control?

Block Diagram

(Black Box approach)

Input, Output,
Correcting PROCESS Controlled
Condition Condition

The Process is the part of a control loop

in which a
physical or chemical change and/or a conversion of energy occurs

No. 175
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Process Control

Control Objectives

The objective of a control is to operate the process

o Within the operating zone *depends on loop design objectives

o In safe manner
o In stable manner
o Minimum human interaction
o To achieve the process operational design objectives
o Optimum economics

No. 176
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Process Control

Control objectives can be achieved through

1. Sensing the status of Process

2. Measuring the status of Process
3. Comparing & Computing the Process Controlling
4. Finally taking action for Correction on the Process

oOnce above 4 Sections joined (Communicate) together with each other, they form Control
Loop
oEach Section is called as: Type of Control Element
oProcess is always Changing & called as: Process Variable (PV)
oPV are of 4 Categories: Level, Pressure, Flow & Temperature
oPV can be divided in 2 types: Controlled Variable & Manipulated Variable

No. 177
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Process Control

Control loop

Outlet Temperature
Fuel Flow
TT

TIC

Set Point

Combination of Instruments to keep PV at Set Value or within range of Values

No. 178
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Process Control

Control loop

TDC

SP + Bar Flow Temp

PID Valve PROCESS
- controller

PV
Feedback Path
Transmitter

Combination of Instruments to keep PV at Set Value or within range of Values

No. 179
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Process Control

Control Loop Types

1. Close Loop Feedback System

2. Open Loop Feedforward
3. Open Loop No Feedback

No. 180
INSTRUMENTATION AND PROCESS CONTROL

Process Control
Close Loop

Closed Loop

e.g. Furnace, TC in Auto

Control action is dependent of Process Output.
i.e. feedback from the process

Auto Mode

TIC Set Point

Process

No. 181
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Process Control

Close Loop

No. 182
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Process Control

Open Loop

Open Loop

e.g. Furnace, TC in Manual

Control action is independent of Process Value & No Feedback

Manual M ode

TIC Set Point

Process

No. 183
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Process Control

Process Control could be

▪ Regulatory Control DCS; Honeywell, Yokogawa etc.

▪ Batch Control PLC; Siemens, Modicon etc.
▪ Emergency Shut Down Safety System; Triconex
▪ Turbomachinery Control CCC, TriSen etc.
▪ etc. etc.

No. 184
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COMPLEX CONTROL SCHEM. CASCAD LOOP

No. 185
INSTRUMENTATION AND PROCESS CONTROL

INST. LOOP DIAGRAM (CONTROL LOOP)

No. 186
INSTRUMENTATION AND PROCESS CONTROL

INST. LOOP DIAGRAM DCS & TMR.

No. 187
INSTRUMENTATION AND PROCESS CONTROL

INST. LOOP DIAGRAM (TMR SYSTEM)

No. 188
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Process Control

Control Actions

o ON-OFF
o Differential Gap
o Proportional
o Proportional + Reset
o Proportional + Reset + Integral
o etc. etc.

No. 189
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Process Control

Controller Modes

o Manual
o Auto
o Cascade
o Program
o etc.

No. 190
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Process Control

Simple vs. Complex Control Loop

Simple loops:
– Basic Single feedback control loop
– Basic cascade loop
Complex loops:
– Any thing other than that:
• Ratio control
• Split range
• Feed forward

No. 191
INSTRUMENTATION AND PROCESS CONTROL

Process Control
Simple Control Scheme

C-1
Fin
C-1
LC

C-2
SV
FC P2
P1 PV F

No. 192
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Process Control

PID Control Loop

SP

OP FIC PV
PID
AO AI

Flow Feed Water

Level

No. 193
INSTRUMENTATION AND PROCESS CONTROL

Process Control

Complex Control Scheme

High
pressure
column
LC

LSS

ARW ARW
PC
Low pressure
Plant

No. 194
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Process Control
Cascade Control
Cascade Control uses the output of the primary controller to manipulate the set point of
the secondary controller

Reasons for cascade control:

o Allow faster secondary controller to handle disturbances in the secondary loop

o Allow secondary controller to handle non-linear valve and other final control element
problems
o Allow operator to directly control secondary loop during certain modes of operation
(such as start-up)

Requirements for cascade control:

o Secondary loop process dynamics must be at least four times as fast as primary loop
process dynamics
o Secondary loop must have influence over the primary loop
o Secondary loop must be measured and controllable.

No. 195
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Process Control

Cascade Control

No. 196
INSTRUMENTATION AND PROCESS CONTROL

Process Control

Cascade Control

OP LIC SP
PID
SP PV
FIC
OP PID PV
AO AI AI

Flow Feed Water

Level

No. 197
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Process Control

Ratio Control

FT RFIC Ratio SP
AI
PVI CALC

SP
Fluid - A

FIC
OP PID PV
AO AI

Fluid - B

Mixer
Fluid – A+B

No. 198
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Process Control

Ratio Control

No. 199
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Process Control

Ratio Control

Ratio control is used to ensure that two or more flows are kept at the same ratio even if
the flows are changing.

Applications of ratio control:

o Blending two or more flows to produce a mixture with specified composition

o Blending two or more flows to produce a mixture with specified physical properties
o Maintaining correct air and fuel mixture to combustion

No. 200
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Process Control

Split Range Control

0 -100%

50 -100%
PIC
3218
Liquid + Gas
0 - 50%

V-2131

LIC
3218

No. 201
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Process Control
Override Control

o Override control is used to take control of an output from one loop to allow a more
important loop to manipulate the output
o The output from two or more controllers are combined in a high or low selector
o The output from the selector is the highest or lowest individual controller output
o The selector is shown in the diagram by the < or > symbol

No. 202
INSTRUMENTATION AND PROCESS CONTROL
Process Control

Feed Forward Control

• Feed forward control is a strategy used to compensate for disturbances in a system before
they affect the controlled variable .

• A feed forward control system measures a disturbance variable, predicts its effect on the
process, and applies corrective action.

No. 203
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Process Control
3 – Element Control Feed Forward Control

FT FWD OP
AI
PVI CALC
Main Steam Flow

LIC SP
SP PID

FIC PV
OP PID PV
AO AI AI

Flow Feed Water

Level

No. 204
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References.

1. Lessons In Industrial Instrumentation

2. Emerson (animations)
3. E & H (animations)

No. 205
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No. 206