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Learning Outcomes
Upon completion of this module you will be
able to …
 Understand basic instrumentation terminology.
 Understand the Impact of automatic controls on the
primary areas of industry (e.g. Safety, efficiency,
manpower, demands, distance/time, hostile
environments, accuracy).
 Understand the importance of accurate measurement
of process variables such as; level, pressure, flow,
temperature, density and composition.
 State the five purposes of instrumentation in a process
plant (Measure, Control, Alarm, Record, and
Indicate). 2
Introduction
 A process plant is an arrangement of processing
units , such as heat exchangers , distillation
columns, reactors etc which are arranged in a
systematic order .
 The overall plants objective is to convert raw
materials into a desired product, by the
application of energy in a safe and cost effective
manner .

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The main criteria for process
Instrumentation
In a successful process plant design, the instrumentation
must address:
 Safety
the plant should allow for the safe containment of
process pressures, the construction materials should be
able to withstand designed temperatures and chemicals
concentrations. In addition the control system should be
capable of maintaining the process parameters at the
designed points , providing for safe shut down and fail
safe capability.
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 Production-
In order to maximize returns on investments the plant
should maintain quality and quantity. The designed
product must meet or exceed the original design
expectations

 Environmental Standards-
The process plant must comply with environmental
regulations concerning air pollution and plant effluent,
if the plant is to remain operational. Instrumentation
allows for the monitoring and controlling the discharge
from plants.

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 Main Components of a Control
Loop
 PROCESS

 MEASUREMENT

 CONTROL

 FINAL CONTROL ELEMENT

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 PROCESS
 The physical system we are attempting to
control or measure. It is a physical or chemical
change of matter or energy.
Examples: water filtration system, molten
metal casting system, steam boiler, oil refinery
unit, power generation unit.

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 MEASUREMENT
The function of this block is to determine the
current status of process parameters and to send
such information to the controller

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 CONTROL
The function of this block is to receive data from
a measurement instrument, compare that data to
a programmed setpoint or desired value and if
necessary, signals the final control element to
take corrective action.

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 FINAL CONTROL ELEMENT
This is the device which acts to physically change
the manipulated variable i.e. it controls the flow
of materials to the process.
 In most cases, the final control element is a
valve used to restrict or cut off fluid flow, but
pump motors, louvers (typically used to
regulate air flow), solenoids, and other devices
can also be final control elements.

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ACTUATORS
An actuator is the part of a final control device
that causes a physical change in the final control
device when signaled to do so.
 The most common example of an actuator is a
valve actuator, which opens or closes a valve in
response to control signals from a controller.
 Actuators are often powered pneumatically,
hydraulically, or electrically. Diaphragms,
bellows, springs, gears, hydraulic pilot valves,
pistons, or electric motors are often parts of an
actuator system.
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 PURPOSE OF INSTRUMENTATION
(I.C.R.A.M.)
Instrumentation in a process plant must be capable of
one or more of the following :
 Indicate
 Control
 Record
 Alarm
 Measure

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INDICATORS
While most instruments are connected to a
control system, operators sometimes need to
check a measurement on the factory floor at the
measurement point.
 An indictor makes this reading possible.
 An indicator is a human-readable device that
displays information about the process.

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CONTROLLER
A controller is a device that receives data from a
measurement instrument, compares that data to
a programmed setpoint, and, if necessary, signals
a control element to take corrective action.
 Local controllers are usually one of the three
types: pneumatic, electronic or programmable.
 Controllers also commonly reside in a digital
control system.

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 Controllers may perform complex
mathematical functions to compare a set of
data to setpoint or they may perform simple
addition or subtraction functions to make
comparisons.
 Controllers always have an ability to receive
input, to perform a mathematical function
with the input, and to produce an output
signal.

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Common examples of controllers
Programmable logic controllers (PLCs)—
 PLCs are usually computers connected to a set
of input/output (I/O) devices. The computers
are programmed to respond to inputs by
sending outputs to maintain all processes at
setpoint.
Distributed control systems (DCSs)—
 DCSs are controllers that, in addition to
performing control functions, provide readings
of the status of the process, maintain databases
and advanced man-machine-interface. 17
RECORDERS
A recorder is a device that records the output of a
measurement devices.
 Many process manufacturers are required by
law to provide a process history to regulatory
agencies, and manufacturers use recorders to
help meet these regulatory requirements.
 In addition, manufacturers often use recorders
to gather data for trend analyses.
 By recording the readings of critical
measurement points and comparing those
readings over time with the results of the
process, the process can be improved.

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ALARM INSTRUMENTATION
 The purpose of alarm instrumentation is to
detect process parameters that deviate outside
predetermined limits.
 The alarm instrument loop usually consists of a
switch or contact closure device and an end
device such as a horn, light or bell.
 The purpose of a switch is to turn on and off
with varying process conditions.
 Usually, switches are used to activate alarms to
alert human operators to take special action.
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MEASUREMENT INSTRUMENTATION
In all cases, some kind of instrument is used to
determine current status of process parameters
and report a process variable value.
Because sensing devices are the first element in
the control loop to measure the process variable,
they are also called primary sensing elements.
Within this block one would also find
Transmitters and Transducers

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Primary Sensing Elements (PSE)

A device that directly senses the process

variable and translates that sensed quantity
into an analog representation (electrical
voltage, current, resistance; mechanical force,
motion, etc.).

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Examples of primary elements include:
 Pressure sensing  Venturi tubes
diaphragms, strain  Magnetic flow tubes
gauges, capacitance  Coriolis flow tubes
cells
 Radar emitters and
 Resistance
receivers
temperature detectors
 Ultrasonic emitters
(RTDs)
and receivers
 Thermocouples
 Annubar flow
 Orifice plates
elements
 Pitot tubes
 Vortex sheddar 22
Transmitters
A transmitter is a device that converts a reading from
a sensor or transducer into a standard signal and
transmits that signal to a monitor or controller.
Transmitter types include:
Pressure transmitters
Flow transmitters
Temperature transmitters
Level transmitters
Analytic (O2 [oxygen], CO [carbon monoxide],
and pH) transmitters
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Transducers
 Transducers are used to convert the output of a
sensor into a signal that a controller can use.
 The output of a sensor may be a mechanical
movement, or a change in size or position, or a
nonstandard electrical signal.
 The output of a sensor may even be nonlinear.
 A transducer will convert the output of the
sensor into a standard signal that a controller
can use.
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Basic Terms in Process Control
 Process Variable, or PV: The specific quantity
we are measuring in a process. It is a condition
of the process fluid (liquid or gas) that can
change the manufacturing process in some
way.
Examples: pressure, level, temperature, flow,
electrical conductivity, pH, position, speed,
density, mass etc.

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 Setpoint, or SP: The value at which we desire
the process variable to be maintained at. In
other words, the “target” or “desired” value of
the process variable.

 Manipulated Variable, or MV: Another term

to describe the output signal generated by a
controller. This is the signal commanding
(“manipulating”) the final control element to
influence the process.

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Types of Control
 Open Loop
 Closed Loop

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 An open control loop exists where the process
variable is not compared, and action is taken
not in response to feedback on the condition of
the process variable, but is instead taken
without regard to process variable conditions.
 Manual mode: When the controller’s
decision-making ability is bypassed to let a
human operator directly determine the output
signal sent to the final control element.

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 For example, a water valve may be opened to
add cooling water to a process to prevent the
process fluid from getting too hot, based on a
pre-set time interval, regardless of the actual
temperature of the process fluid.
 Another example , driving a car.

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 A closed control loop exists where a process
variable is measured, compared to a setpoint,
and action is taken to correct any deviation
from setpoint.
 Automatic mode: When the controller
generates an output signal based on the
relationship of process variable (PV) to the
setpoint (SP).

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Example of closed loop control is a cruise control in a
car
Control Objective: maintain car speed at SP in spite of disturbances
Process Variable: car speed
Measurement Sensor: magnet and coil to clock drive shaft rotation
Measured Process Variable (PV) Signal: "click rate" signal from the
magnet and coil
Set Point (SP): desired car speed, recast in the controller as a desired
click rate
Controller Output (CO): signal to actuator that adjusts gas pedal
(throttle)
Final Control Element (FCE): gas pedal position
Manipulated Variable: fuel flow rate
Disturbances (D): hills, wind, curves, passing trucks…

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Transmission media
The transmission media transmit a signal from one
location to another.

The transmission media must;

 Be instantaneous or very nearly
 Be compatible with the controller, transmitter and
final control element .

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Three common types of media
used :
 Pneumatic – 3-15 psig or 20-100 kPa
 Electronic – 4-20mA
 Optical – light beams modulated with
digital codes.

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Questions
1. List the most important operation criteria of process
plant instrumentation .
2. Indicate the most common process parameters
measured in a typical process plant .
3. Identify the four major elements in a simple control
loop.
4. What the difference between open loop control and
closed loop control?

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References:
 Course notes CNTR 110D located in library.
 Instrumentation for Process Measurement and
Control by: N. Anderson (Chilton)

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