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Industrial Control System Czemplik PDF
Industrial Control System Czemplik PDF
Control System
Instrumentation of a technological process
1
Introduction
2
Contents
3
Topics
I. Measurement devices
Ia. Sensors
Ia-1. Thermometers: a) Expansion thermometer; b) Pressure spring thermometer; c) Resistance thermometer; d) Thermoelectric thermometer;
e) Optical thermometer. Selection of thermometer and measuring circuit
Ia-2. Displacement and force sensors: a) Resistance displacement sensor; b) Piezoelectric displacement sensor; c) Piezomagnetic
displacement sensor; d) Inductive displacement sensor; e) Capacitive displacement sensor; f) Hall effect displacement sensor
Ia-3. Manometer: a) Hydrostatic manometer; b) Hydraulic manometer; c) Elastic manometer; d) Electronic manometer (strain gauge, inductive,
capacitive); e) Manometer with a force sensor. Selection of manometer
Ia-4. Level indicator: a) Water-level indicator; b) Float level gauge: c) Hydrostatic level gauge; d) Displacer level gauge; e) Ultrasonic level
gauge; f) Radar level gauge; h) Another l.g. (capacitive, eletrical, thermometer). Selection of level gauge
Ia-5 Flowmeter: a) Differential pressure flowmeter; b) Rotameter; c) Velocity-type flowmeter; d) Positive displacement flowmeter; e) Inductive
flowmeter; f) Ultrasonic flowmeter; g) Calorimetric flowmeter; h) Vortex flowmeter; i) Coriolis flowmeter; j) Open channel flowmeter. Selection of
flow meter
Ia-6. Speed: a) Tachometer; b) Digital speed sensor
Ia-7. Relays: a) Non electrical relays; b) Electrical relays and switches
Ia-8. Physico-chemical properties: a) pH meter, ...
Ia. Sensor selection
Ib. Converters
Ib-1. Measuring converters types and selection
Ib-3. Separating converters
Ib-4. Analog-to-digital converters
Ib-5. Digital-to-analog converters
Measuring devices; Instrumentation and control tag
II. Actuating elements
IIa. Final control element
IIa-1. Valves
IIa-2. Pumps
IIb. Actuators
IIb-1. Pneumatic actuator
IIb-3. Electric actuator - Electric motors: a) Brushed DC electric motor; b) Synchronous motor; c) Inductive motor 4
Electro-mechanical drive system
Fundamental definitions
Block diagram of a control system
supervisor system
communication system
controller
A/D D/A
converter control devices converter
measuring actuator
converter (actuating driver)
measurement actuating
devices sensor final control equipment
(sensing element) element
plant
5
Part I. Measurement devices
I. Measurement devices
a) Sensors
1 - temperature, c
supervisor system
2 - displacement, communication system
3 - pressure, controller
4 - level, A/D D/A
converter converter
5 - flow,
6 - rotational speed, measuring actuator
7 - relays, converter (actuating driver)
1 - measuring, plant
2 - signaling,
3 - separating,
4 - A/D,
5 - D/A
c) Control engineering design
I. Measuring devices/ 6
Ia. Sensors
manometer
(spring-type pressure gauge)
capillary
thermometric
bulb
platinum
nickel R
copper
Metal resistance increases under the influence of temperature PTC
thermistor (semiconductor)
NTC, PTC, CTC NTC
platinum
ceramic T
PTC
Temperature dependence of resistance
Ia. Measuring devices/ 10
Ia-1d. Thermoelectric thermometer
(thermocouple, thermoelement)
Principle: Thermoelectric effect - if junctions of two different metal have a different
temperatures than a voltage is generated.
metal A E 1) Fe-konstantan
[mV] 2) NiCr Ni
T1 T2 3) PtRh - Pt
1
metal B
2
E=f(T1-T2)
3
C
measuring junction connecting
(hot junction) head 500 1000 1500
Measuring area
Non-contacting measurement
based on an optical system and a detector
2) Contact or non-contact
R1 R2
2-wire circuit
Uz R0 Rw Rt
The connecting wiring
are added to
R3 connecting wiring
the measured resistance
R1 R2
3-wire circuit
Uz R0 Rw Rt
The connecting wiring
connecting wiring occur in
R3 two legs of the bridge
hot
e t0
junction
R1 R2
mV
Rt R3
Uz
Circuit with the cold junction compensation
A e3 C
e1 cold junctions
hot
junction B A C
e2 e4 mV
t0
thermostat e=e1-e2 (e2=const), e3 = - e4 Ia. Measuring devices/ 15
Ia-2. Displacement and force sensors
Measurements of displacement (position) and force are similar on account of that the
displacement is a result of some force.
Principle: The resistance depends on the geometry of the resistor (and the resistivity of
the material)
potentiometer
The linear or angular motion of a wiper
linear l is converted into a changing resistance of potentiometer
rotary
R=rl R=r
strain gauge
Principle: Piezoelectric effect - some materials (e.g. quartz) generate a voltage under
influence of a mechanical stress.
[http://www.americanpiezo.com/knowledge-center/piezo-theory/piezoelectricity.html]
F Measurement of inductance
transformer-type sensor
Measurement of current in the secondary circuit
mA consisting of two push-pull winding
F (a differential measurement)
s s
Ls0W2/
x
x
differential parallel-plate c.
Target
Principle: Hall effect an electric current in the conductor placed in a magnetic field
causes a voltage difference (the Hall voltage)
N -
UH=kIB
I+ x UH
S
h
1
2
The pressure causes a change of liquid
p1-p2=gh(1-2) level and the float transfers it to an
indicator
The pressure is indicated by the difference in levels in
the two arms of the tube
p
p1 p2
p cy+mg=pA
ring differential manometer
The force of pressure (ring balance)
is in balance with the spring p1
p1 p2
p2
p2
p1-p2=gh
Ia. Measuring devices/ 24
Ia-3c. Elastic manometer
(Spring-type pressure gauge)
Principle: Equilibrium of the pressure and a spring force
Bourdon tube
diaphragm pressure gauge
(tube pressure gauge,
spiral pressure gauge)
bellows pressure gauge
p
The curved tube is open to external p p
pressure input on one end and is
coupled mechanically to an indicating Sensor uses the deflection
needle on the other end. The external of a flexible membrane The bellows is stretched on
pressure is guided into the tube and that separates regions of pressure influence
causes it to flex. different pressure
p2 p1
p
4) Process connection 1 2
A 1 2 A
h2-h1 h2-h1
h2 h2
h1 h1
p1=p2 p1>p2
h2-h1 the pressure arisen from a liquid flow
Assumption: no pipe resistance
Ia. Measuring devices/ 28
Ia-4a. Water-level indicator
Principle: Liquid level float is buoyant in liquid and indicates the level
inductive
resistance
Float moves
on a linear resistor
Sensor
Intelligent level transmitters based on without
Archimedes buoyancy principle are chamber
designed to measure liquid level,
interface and density. Sensor
in a side-and-bottom chamber
Ia. Measuring devices/ 32
Ia-4e. Ultrasonic level gauge
The sensors emit waves (20 kHz to 200 kHz) that are reflected
back to and detected by the emitting transducer. The elapsed time
period between transmission and reception of the signal - at the
speed of sound - is measured and calculated as a distance and
computed into level or volume.
Example applications
The sensors emit waves (1 GHz to 30 GHz ) and measure the time
period between transmission and reception of the signal.
Capacitive l.g.
Sounder is a long capacitor and his capacity depends on draught
p
Pressure sensor measures the differential pressure before and within the constriction
flow nozzle Venturi tube
(Venturi meter)
Nozzle and tube offer advantages over orifice plates in that they require less
upstream piping and incur lower permanent pressure loss. Ia. Measuring devices/ 37
Ia-5b. Rotameter
Principle: Balance between the flowing force and the weight of the float
The rotameter consists of a vertically oriented glass (or plastic) tube with a larger
end at the top.
The substance flows through the meter vertically from bottom to top and lifts the
float proportionally to the flow quantity.
plastic
metal
glass
Ia. Measuring devices/ 38
Ia-5c. Velocity-type flowmeter
(Rotating meter)
Principle: The fluid flow actuates the movement of blades, screw or turbine-type impeller
proportionally to flow rate.
blade f.
screw f.
counter The flow is calculated by counter
measuring and integrating
the flow speed over the
flow area
1 2 impeller impeller
turbine f.
Principle: Counting repeatedly the filling and discharging of known fixed volumes
A typical positive displacement flowmeter comprises a chamber that obstructs the
flow. Inside the chamber, a rotating/reciprocating mechanical unit is placed to
create fixed-volume discrete parcels from the passing fluid.
piston
four-way
valve
Piston is operated to fill a cylinder with the fluid
and then discharge the fluid. Each stroke
represents a finite measurement of the fluid
electromagnet
electrode
scheme
Z V
Two temperature sensors are in close contact with the fluid but thermal insulated from each
other. The flowing fluid cools both sensors but one of the two sensors is constantly heated.
The temperature difference between the two sensors is proportional to the flow rate.
Animation: http://www.emersonprocess.com/micromotion/tutor/42_densityoperatingprincipal.htm
Ia. Measuring devices/ 45
Ia-5j. Open channel flowmeter
The rotor of the tachometer is mechanically connected, directly or indirectly, to the load .
dc generator ac generator
U1
Uzasil eg
eg
1
The dc rate generator often has The ac rate generator field is excited
permanent magnetic field excitation. by a constant ac supply
The phase or polarity of output voltage (eg) depends on the rotor's direction of rotation
photoelectric transformer-type
fn
fn
fz Uz
relay-type magnetoresitive
.
(rotational speed
(reed swich)
sensor) S N
NS
reed switch
N S N S
N S
close relation turn tern
tern
limit switch
a) pH pH meter
b) redox potential (oxidation/reduction potential, ORP) ORP meter
c) humidity hygrometer
d) oxygen (proportion of O2 in the gas or liquid ) oxygen meter, lambda sensor
e) conductivity conductometer
f) suspension densitometer, suspension turbidity meter
g) water hardness
h) concentration refractometer
....
Requirements:
measurement value (temperature, pressure, ..)
range
accuracy class
mounting of the instrument (process connection, location)
frequency response
environmental condition (e.g. Ex, dustiness, moisture)
operational reliability (e.g. periodical calibration)
dimensions, weight
complexity of additional equipment
qualification of service staff (method of calibration or programming)
price of sensor and an additional apparatus
resolution of the measured signal
Iout
Us
Rs Us
Us
Rb Rr Rb Rr
Rf Rf
generating
modulating
tachometer generator
T
UA
Uout
UX
ULG
ULG U
LG C UX
UA
UC
Uout
ti
LG linear generator (g. of linear signal)
UA activation; C - comparator
Ux input voltage
Uout output voltage
Ib. Measuring devices/ 59
Ib-1. Measuring converter selection
The main directions
Requirements:
a suitable static characteristic (linear or non-linear)
stability of characteristic
a small conversion error (e.g.<1%)
no hysteresis
galvanic separation of input and output circuits
easy modification of conversion range
low level of noise
small influence onto the source of signal
low sensitivity to a change of load
dynamic properties (time response, pass band)
service conditions
Ux
U1
Uw U1
K U2 U3 L
T1 T2 t
US GW U2
U t
Nx = Nmax x U3
Uw
Nmax Nx t
Ux Uw
Uout counting fx
Pulse generator
t for a determinate
ti time period
1 1 1 22R Uout
0 X0 0 X1 0 Xi
voltage ladder
U
2R 2R
2R 2R 2R 2R
Uout
U
2R 2R
1 1 1 Uout
0 X0 0 X1 0 Xi
...
A controller
D
A P controller
D
US Standards:
ANSI Y32.2.3 Graphical Symbols for Pipe Fittings, Valves and Piping
ANSI Y32.2.11 Graphical Symbols for Process Flow Diagrams
ISA 5.5 Graphical Symbols for Process Displays
British Standards:
BS: 1646 1-4 Symbolic Representation for Process Measurement, Control
Function and Instrumentation
German Standards:
DIN 19227 P1-P3 Graphical Symbols and Identifying Letters for Process
Measurement and Control Functions
Polish Standards:
PN-M-42007 (archive)
More: http://enormy.pl
http://www.samson.deServicesTechnical Information Ic. Measuring devices/ 69
Part II. Actuating equipment
c
supervisor system
II. Actuating equipment communication system
a) Final control element controller
1 valve A/D D/A
converter converter
2 - pump
b) Actuator measuring actuator
1 - electrical motors converter (actuating driver)
controling
2 - pneumatic actuator system
sensor final control
3 - hydraulic actuator (sensing element) element
plant
controlled system
Examples:
Actuating equipment (final control equipment): Control valve:
- final control element - valve (closure element, body of valve)
- actuator - actuating driver
- positioner (measuring element)
Body of valve manipulates the mass and energy flow.
The opening or closing of control valve is usually done by electrical, hydraulic or pneumatic actuator.
Positioner is used to control the opening or closing of the actuator based on electric, or pneumatic signals.
IIa. Actuating equipment/ 70
IIa. Final control element
Final control element a part of the controlled system that manipulates the mass and
energy flow.
Basic type of final control element:
1) valves 2) pumps
butterfly valve
(quarter-turn valve) knife gate valve
Inside a metal disc mounted on a rod
and positioned in the center of the pipe
Features: low cost, light
Pomp a device used to move fluids (liquids, gases, slurries) by mechanical actions
(often a reciprocating or rotary mechanism).
positive displacement pump velocity pump
(rotodynamic pump, dynamic pump)
The pump moves a fluid by trapping a fixed The pump increases the flow velocity thereby
amount of it and then forcing (displacing) that kinetic energy and this energy is converted to
trapped volume into the discharge pipe pressure
screw centrifugal
lobe
impulse pump
The pump use pressure created by gas (usually air) and pushing part of the liquid upwards
IIa. Actuating equipment/ 73
IIb. Actuators
(effectors, servomotor)
Actuator - a type of motor for moving or controlling a mechanism (final control element).
It is operated by a source of energy (an electric current, hydraulic fluid pressure,
pneumatic pressure) and converts this energy into some kind of motion.
Actuator processes and amplifies the output signal of controller
Principle: Pneumatic actuator converts energy of compressed air into a mechanical motion
diaphragm actuator bellow actuator
Definitions:
actuator - a device converting a low-power signal into a large-force displacement
(linear or rotary )
motor a device converting a heat, electrical energy, mechanical energy into energy
to drive machines (usually electrical energy into energy of rotational motion)
Actuator Motor
a large force a small torque
a small velocity a high velocity
Classification:
stator
rotor
[http://www.allaboutcircuits.com/vol_2/chpt_13/1.html]
IIb. Actuating equipment/ 77
IIb-3a. Brushed DC electric motor
Principle: Stator with a stationary magnets and the rotor powered from a DC power by
brushes and commutator.
Magnetic fields of the stator and the rotor interact and a generated torque causes a turn of the rotor.
The commutator consisted of a split ring reverses the current each half turn of the rotor.
permanent magnets electromagnets
+ - + - + + -
brushes M N S M M M
-
series m. shunt m. separately excited m.
The type of connection determines the characteristics of the motor
Control:
- the sense of rotation depends on the polarity of the excitation winding control by change of the polarity
- the rotational speed is proportional to the EMF in its coil - control by variable supply voltage, resistors or
electronic controls (e.g. PWM)
- the torque is proportional to the current
Advantages: low initial cost, high reliability, simple control of motor speed
Disadvantanges: sparking and wear of the electric contact commutator-brushes IIb. Actuating equipment/ 78
IIb-3b. Synchronous motor
Principle: Rotor with a stationary magnets and the stator powered from the AC power
and generating a rotating magnetic field.
Electromagnets on the stator create the magnetic field which rotates in time with the oscillations of the
line current and the rotor turns in step with this field, at the same rate (the motor speed is synchronized
with the frequency the AC supply current )
three-phase s.m. single phase s.m. stepper m.
M M
N
S
Control:
- sense of rotation depends on the direction of rotating magnetic field control by change of the phase order
- motor speed is synchronized with the supply frequency control by a variable-frequency driver
------------------------------------------
I. Field devices - controllers
II. Communication networks
III. SCADA & DCS
} 15 hours
82