Process Control & Instrumentation

MEROX Block
 Process Control Concepts
 Process Control is to maintain certain process
variables (PV) of a process at a desired level (Set
Values)
 Instruments are used to obtain information about
the process variables (PVs)
 Controller ( a software program resident in DCS)
calculates the difference between SV and PV and
accordingly sends a signal, called Manipulated
Value (MV) to final control elements (Valves,
Vanes etc.).
 DESIRED VALUE
OR
SET VALUE
PID
CONTROLLER
Manipulated variable

PROCESS VARIABLE(Pv)
OR
CONTROLLED VARIABLE(CV)
P/I Convreter OR
(MV)

MEASERD VARIABLE
I/P Convreter

SENSOR

Process
FINAL CONTROL ELEMENT

TYPICAL CONTROL LOOP

 Process Control Concepts
 Automatic Control: Process Variables are
controlled by DCS resident Controller with out the
intervention of an operator except setting of SV
 Controller modes include Auto Mode, Man Mode,
Cascade Mode & Computer Mode
 Types of Controllers include Feed Back and Feed
Forward
 Controller Tuning parameters include P
(Proportional), Integral (I) and D (Derivative) a
 Pressure Measurement
 Absolute Pressure: Measured over total
vacuum/zero absolute
 Atmospheric/Barometric Pressure: Pressure
exerted by Earth’s atmosphere
 Differential Pressure: Difference between two
pressures
 Gauge Pressure: Pressure over the atmospheric
Pressure
 Hydrostatic Pressure: Pressure exerted by a liquid
column
 Pressure Measurement
 Line Pressure/Working Pressure/Static Pressure:
Pressure exerted by a flowing fluid on the pipe
surfaces
 Dynamic Pressure: Pressure exerted by a flowing
fluid parallel to the flow direction
 Vacuum: Pressure below the atmospheric pressure
 Compound Pressure: Measured from a reference
which is neither atmospheric nor total vacuum
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 A clear statement of your company’s long-

term mission. Try to use words that will
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be as concise as possible.
 Pressure Measurement
Devices
 Pressure is a force applied/distributed over a
surface.
 Pressure measurement is used for pressure itself,
flow, level and even temperature
 All measurement systems consists of :
– Primary Element which indirectly/ indirectly in contact
with fluid and interacts with pressure changes
– Secondary Element which translates this interaction
into values for use in indication, recording and control
 Pressure Measurement Devices –
Secondary Elements
 Mechanical Transducers
– Bellows
– Bourdon Tubes
– Diaphrams
– Force Balanc
 Pressure Measurement Devices –
Secondary Elements
 Electronic Transducers
– Variable Capacitance
– Variable Reluctance
– Vibrating Wire
– Variable Resistance
Mechanical Transducers
 Level Measurement
 Level measurement is divided into two groups:
Direct Level and Pressure-operated
 Direct Level Measurement:
– Hook type
– Sight Glass
– Float Gauging
 Pressure-Operated Measurement: Use is made of
the fact that pressure does not depend on the
cross-sectional area of a vessel, in stead it depends
on liquid height and density
Direct Level - Level Gauges
 Level Gauges
 Directing Level reading device
 Types : Transparent and Reflux
 Transparent type is used for:
– Caustic, Acidic, Heavy HC services, High pressure
– Coated with protective Mica
 Reflux type is used for light services:
– Non-corrosive, non-viscous, Clear HC
– It has special optical property for clear demarcation
 Level Gauges

 While commissioning, open the Jerguson

valve partially till the gage is pressured up /
warmed up.
 While in service, jerguson valve shall be
fully in open condition
 Quarter turn valves for quick isolation
 Have special ball-checks for auto shut-off in
case of glass breakage
 Closed Vessels – Differential
Pressure Approach
 h = P /ρg
 In closed vessles, pressure above the liquid affects
the pressure measured at the bottom
 To measure the true level, the vessel pressure must
be subtracted.
 Making a pressure tap at the top of the vessel and
connecting this to LP side accomplishes this
 Dry Leg: If gas is non-condensable
 Wet leg: Condensed Liquid introduces error.
Hence calibrated with a reference liquid.
Level Measurement in Closed
Vessels
 Temperature Measurement

 Temperature is degree of hotness/coldness

on a definite scale
 oC = 5/9 (oF – 32)
 Most reliable methods of measurement:
– Bimetallic
– Thermocouples
– RTD
 Temperature Measurement
 All temperature gages uses bimetallic principles
 Bimetallic Principles:
– Metals change in volume in response to temperature
– and different metals respond differently to change in
temperature
 Its accuracy is not as good as a glass thermometer
 Temperature Measurement
Bimetallic Gage
 Bimetallic Principles:
– Metals change in volume in response to temperature
– and different metals respond differently to change in temperature
 All temperature gages uses bimetallic principles
 Most reliable methods of measurement:
– Bimetallic
– Thermocouples
– RTD
 Thermocouples
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company’s
competitive advantage
 Thermocouples
 It is a thermoelectric temperature measuring
device
 It is formed by pressing two dissimilar metals in
series
 When the junctions are at different tempertures,
emf is generated
 Measuring junction/hot junction is inserted into
the medium of which temperature is inserted
 Cold Junction/Reference junction is inserted in the
measuring device
 Thermocouples -Types
 J type:
– Iron-Constantan
– Low Range
 K Type:
– Chromel -Alumel
– Clean and oxidizing services
 E Type:
– Chromel-Constantan
– Vacuum, mildly oxidising, inert services
 T type:
– Copper-Constantan
– Sub zero termperatures
 Others include: B, R, S, W
 Resistance Temperature
Detectors
 Uses the change in resistance in response to
change in temperature
 Resistance depend on metal size and
resistivity of the metal
 Flow Measurement

 Most commonly used methods for flow

measurement:
– Head type
– Area Type
– Mass Flow Meters
 Flow Measurement

 Head Type:
– A restriction of known dimension is introduced
in the flow line
– Thus, pressure drop created, which is measured
– Sub-Type:
• Orifice &
• Venturi
 Flow Measurement

 Orifice
– Orifice may be concentric or eccentric
– Orifice plats constricts the flow to produce a
differential pressure
– The result is a high pressure upstream and a
low pressure down stream
– Dp is proportional to the flow
– Orifice meters are inexpensive
 Flow Measurement
 Venturi
– Low Pressure
– Highly accurate
– Big Size Pipe
 Annubar
 Uses Pitot Tube
Principle
 Flow is proportional
to pressure drop
 Uses multiple ports
 Flow Measurement

 Area Meters:
– In head flow meters, the restriction area kept
constant generating a pressure differential
– Where as in area meter, a variable area holds
differential pressure constant
– Change in area is a measure of flow rate
– Ex.: Rotameter
Rotameter- Suitable for low flows
 Valves – Valve is a variable
Orifice !
 Valve Types:
– Plug-in-seat
– Rotatable Plug
– Rotating Vane
– Eccentric Rotation
– Cage-guided
– Deformable Flow Passage
Globe Valve – Plug-in-seat
 Ball Valve/Plug Valve
- Rotatable Plug
 Plug/ball rotated
Through a quarter
of a turn
 The ball has a passage
 Butterfly valve/ Dampers –
Rotating Vane
 Quarter turn operated
 Leakage prone
 Valve Accessories

 Actuators: Translates control signal into

action, eg.:Motors, Diaphrams, solenoids,
cylinders
 Transducers and Positioners: Convert
electronic signals into pneumatic/hydraulic
pressures that control actuators/valves
 Positioner is used when more accurate
positioning of valve steam is required
There are two basic designs of gate valves, inside
screw stem and outside screw stem.
Seating is perpendicular or at right angles to the line
of flow - meets it head on.
Repeated movement of the wedge near the point of
closure, under high velocity flow, may create a drag on
the seating surfaces and cause galling or scoring on
the downstream side.
A slightly opened wedge may also cause turbulent
flow with vibration and chattering of the wedge.
Globe valve seating is parallel to the line of
flow. All contact between seat and disc ends
when flow begins. These are advantages for
more efficient throttling of flow, with minimum
wire drawing and seat erosion.
Globe valves are generally ideal for throttling,
and preferable for frequent operation.
Butterfly Valves are of the quarter turn
family and are so designed because a 90
degree turn of the operator fully opens or
closes the valve.
. In some cases, they may be used for
non-critical throttling applications. They
are lighter in weight than conventional
valves.