Installing process control apparatus

and associated equipment

LEARNING OUTCOMES:
LO1: Prepare process control apparatus and associated equipment
LO2: Install process control apparatus and associated equipment
LO3: Complete and report installation activities
 MODULE CONTENTS:
LO1: Prepare process control apparatus and
associated equipment

1. Identification of OH&S procedures

2. Preparing installation apparatus
3. Determining the nature & location of the work
4. Preparing process control apparatus
5. Identifying tools, equipment and testing devices
LO2: Install process control apparatus and associated
equipment
1. Reading and interpreting drawings accurately
2. Terminate wiring and tubing at process control
apparatus
3. Installing process control apparatus in accordance
with manufacturers specification
4. Checking the quality of installed apparatus
 LO3: Complete and report installation
activities
1. Following OH&S risk control measures
2. Preparing documentation for installation activities
3. Reporting the final result
4. Cleaning the work area
OH&S Policies and procedures
Occupational health and safety is an aspect of public health program.
Creating a healthy workplace and a healthy work force in any occupational
environment is the best way to position that occupation to better delivery
of service.
There are some general points which can be noted:
 Safety equipment, e.g. goggles, gloves, etc., should be provided and
must be used where they are appropriate.
 Safe working practices are part of any job and you should always learn
and adopt them as a natural way of working.
 Don’t take shortcuts which compromise your safety, or that of anybody
else.
 You should make yourself aware of the procedures used at your place of
work to prevent Accidents.
 You should know how to isolate electric supplies and how to work safely
on electrical circuits.
5
What equipment is covered by the
Generally, any equipment which is used by an employee at work is
Regulations?
covered, for example hammers, knives, ladders, drilling machines,
power presses, and circular saws, photocopiers, lifting equipment
(including lifts), dumper trucks and motor vehicles.
Examples of uses of equipment which are covered by the Regulations
include starting or stopping the equipment, repairing, modifying,
maintaining, servicing, cleaning and transporting.
Safety and reliability of control systems
• Control systems should be designed and constructed
 Particular attention should be paid to the following points:
a) the machinery should not start unexpectedly;
b) the parameters of the machinery should not change in an
uncontrolled way;
c).the machinery should not be prevented from stopping if the
stop command has already been given;

d). no moving part of the machinery or piece held by the

machinery should fall or be ejected unintentionally;
e). automatic or manual stopping of the moving parts,
whatever they may be, should be unimpeded;
f). Protective devices should remain fully effective or give a
stop command; and
g). Safety-related parts of the control system should apply in a
coherent way to the whole of an assembly of machinery and
partly completed machinery.
Control devices
 Clearly visible and identifiable and readily distinguishable
from one another by their separation, size, shape, colors
or feel, and by labelling controls either with words.
a) Designed in such a way that controls for starting or
stopping are clearly marked;
b) Positioned in such a way as to be safely operated
without hesitation or loss of time and without ambiguity;
c) Designed in such a way that the movement of the control
device is consistent with its effect;
d) Located outside danger zones, except where necessary
for certain control devices such as an emergency stop or
a teach pendant;
e) Positioned in such a way that their operation cannot
cause additional risk;
Starting
Machinery should be fitted with a specific start control device.
The same requirement applies:
a) when restarting the machinery after a stoppage,
b) when effecting a significant change in the operating
conditions.
 For machinery functioning in automatic mode, the
starting of the machinery, restarting after a
stoppage, or a change in operating conditions, may
be possible without intervention, provided this does
not lead to a hazardous situation.
 Where machinery has several starting control
devices and operators can therefore place one
another in danger, additional devices should be
fitted
Stopping
Normal stop
a). Machinery should be fitted with a reliable control
device allowing the machinery to be brought safely
to a complete stop.
b). Each workstation should be fitted with a control
device to stop some or all of the functions of the
machinery.
C). The machinery’s stop control should have priority
over the start controls.
D). Once the machinery or its hazardous functions
have stopped, the energy supply to the actuators
concerned should be cut off.
a) Where, for
Operational operational reasons, a stop controls that does
stop
not cut off the energy supply to the actuators is required,
the stop condition should be monitored and maintained.
 Emergency stops
Emergency stop controls should be:
a) colored red; and
b) positioned in such a way as to be safely operated
without hesitation or loss of time and without ambiguity.
c) be clearly identifiable, clearly visible and quickly
accessible, so that they can be used to stop the
hazardous process as quickly as possible, without
creating additional risks
Failure of the energy source
The fluctuation, interruption and re-establishment after an interruption of
the energy source to the machinery should not lead to a dangerous
situation (e.g. fails-to-safe).
a) The machinery should not start unexpectedly;
b) The parameters of the machinery should not change
in an uncontrolled way when such change can lead to
hazardous situations;
c) The machinery should not be prevented from stopping
if the command has already been given;
d) No moving part of the machinery, or piece held by the
machinery, should fall or be ejected unintentionally;
e) Automatic or manual stopping of the moving parts,
whatever they may be, should be unimpeded; and
f) The protective devices should remain fully effective or
give a stop command
Personal protective equipment (PPE) and OH&S

Hazards exist in every workplace in many different

forms: sharp edges, falling objects, flying sparks,
chemicals, noise and a myriad of other potentially
dangerous situations. The Occupational Health
and Safety Administration (OSHA) requires that
employers protect their employees from workplace
hazards that can cause injury.
 Performing a "hazard assessment" of the workplace to identify
In
andgeneral, employers
control physical are responsible for:
and health hazards.
Identifying and providing appropriate PPE for employees.
Training employees in the use and care of the PPE.
Maintaining PPE, including replacing worn or damaged PPE.
Periodically reviewing, updating and evaluating the
effectiveness of the PPE program.

In general, employees should:

Properly wear PPE,
Attend training sessions on PPE,
Care for, clean and maintain PPE, and
Inform a supervisor of the need to repair or replace PPE.
potential hazards in the following basic hazard
Impact,
categories:
Penetration,
Compression (roll-over),
Chemical,
Heat/cold,
Harmful dust,
Light (optical) radiation, and
Biologic.
 Types
• Safety of EyeThese
spectacles. Protection
protective eyeglasses have safety frames constructed
of metal or plastic and impact-resistant lenses. Side shields are available on
some models.
• Goggles. These are tight-fitting eye protection that completely cover the eyes,
eye sockets and the facial area immediately surrounding the eyes and provide
protection from impact, dust and splashes. Some goggles will fit over
corrective lenses.
• Welding shields. Constructed of vulcanized fiber or fiberglass and fitted with a
filtered lens, welding shields protect eyes from burns caused by infrared or
intense radiant light; they also protect both the eyes and face from flying
sparks, metal spatter and slag chips produced during welding, brazing,
soldering and cutting operations.
• Laser safety goggles. These specialty goggles protect against intense
concentrations of light produced by lasers. The type of laser safety goggles an
employer chooses will depend upon the equipment and operating conditions in
the workplace.
• Face shields. These transparent sheets of plastic extend from the eyebrows to
below the chin and across the entire width of the employee's head. Some are
polarized for glare protection.
 HeadProtection

Protecting employees from potential head injuries is a key element of any

safety program.

In general, protective helmets or hard hats should do the following:

• Resist penetration by objects.
• Absorb the shock of a blow.
• Be water-resistant and slow burning.

Foot and LegProtection

Employees who face possible foot or leg injuries from falling or rolling objects or from
crushing or penetrating materials should wear protective footwear.

Special Purpose Shoes

Electrically conductive shoes provide protection against the buildup of static

electricity. Employees working in explosive and hazardous locations such as explosives
manufacturing facilities

Electrical hazard, safety-toe shoes are nonconductive and will prevent the wearers'
feet from completing an electrical circuit to the ground. These shoes can protect against
open circuits of up to 600 volts in dry conditions
Care of Protective Gloves
Hand and
Protective Arm
gloves Protection
should (Glove
be inspected )
before each use to ensure that
they are not torn, punctured or made ineffective in any way.
Body Protection
Employees who face possible bodily injury of any kind that cannot be
eliminated through engineering, work practice or administrative
controls.
examples of workplace hazards that could cause bodily injury:
•  Temperature extremes;
•  Hot splashes from molten metals and other hot liquids;
•  Potential impacts from tools, machinery and materials;
•  Hazardous chemicals.
Protective clothing comes in a variety of materials, each
effective against particular hazards, such as:
 Paper-like fiber used for disposable suits provide protection
against dust and splashes.
 Treated wool and cotton adapts well to changing
temperatures, is comfortable, and fire-resistant and protects
against dust, abrasions and rough and irritating surfaces.
 Duck is a closely woven cotton fabric that protects against
cuts and bruises when handling heavy, sharp or rough
materials.
 Leather is often used to protect against dry heat and flames.
 Rubber, rubberized fabrics, neoprene and plastics protect
against certain chemicals and physical hazards.
Identifying Materials, Tools, Equipment’s and Testing Devices

Instruments are devices which are used to

measure attributes of physical systems.
The variable measured can include practically
any measurable variable related to the physical
sciences.
These variables commonly include:- pressure, flow,
temperature, level, density, viscosity, radiation, current,
voltage, inductance, capacitance, frequency, chemical
composition, chemical properties, various physical
properties, etc. Instruments can often be viewed in terms
of a simple input-output device.
Principles of Instrumentation
Measurement is the process of determining the amount, degree or capacity
by comparison with the accepted standards of the system units being used.
Instrumentation is a technology of measurement which serves sciences,
engineering, medicine and etc.
Instrument is a device for determining the value or magnitude of a quantity

or variable.

3 phases of instruments
a. Mechanical,
b. Electrical and
c. Electronic Instruments

Electronic instrument is based on electrical or electronic principles for its

measurement functions.

The 3 basic functions of instrumentation:

 Indicating – visualize the process/operation
 Recording – observe and save the measurement reading
Mechanical Instruments
 These instruments are very reliable for static and stable conditions.
Basic Measurement and Control Concepts
The basic set of units used on this course is the SI unit
system.
 Process Control Theory
A process is broadly defined as an operation that uses
resources
to transform inputs into outputs.
It is the resource that provides the energy into the process
for the transformation to occur.
Process industries include the chemical industry, the oil and
gas industry, the food and beverage industry,
the pharmaceutical industry, the water treatment industry,
and the power industry.
Control is used to modify the behavior of a system so it behaves
in a specific desirable way over time.
Process Control
Process control is the act of controlling a final control
element to change the manipulated variable to maintain
the process variable at a desired Set Point. For example,
factors such as the proportion of one ingredient to
another, the temperature of the materials
Manufacturers control the production process for three
reasons:
 Reduce variability
 Increase efficiency
 Ensure safety
Standard Instrumentation Signals

There are three kinds of signals that exist for the

process industry to transmit the process variable
measurement from the instrument to a centralized
control system.
1. Pneumatic signal
2. Analog signal
3. Digital signal
Manual and Automatic Control
Control operations that involve human action to make an adjustment are called
manual control systems. Conversely, control operations in which no human
intervention is required, such as an automatic valve actuator that responds to a
level controller, are called automatic control systems.
Basic Elements of Process Control?
Controlling a process requires knowledge of four basic elements,
1. process itself, a dynamic behavior that is determined by physical properties;
2. sensor that measures the process value, measure are temperature, pressure,
mass, flow and level.
3. final control element that changes the manipulated variable, and physical
device that receives commands from the controller to manipulate the resource.
Typical Final Control Elements used in these processes are valves and pumps.
4. controller which provides the signal to the final element.
A controller can be a person, a switch, a single loop controller, or DCS / PLC
 Closed-loop
Closed control
and Open Control Loops system A closed control
loop exists where a process variable is measured,
compared to a set point, and action is taken to
correct any deviation from set point.
An open control loop
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.
 GroupedAlgorithms
Controller by control mechanism function, the three
types of controllers are:
1. Discrete controllers
2. Multistep controllers
3. Continuous controllers
Discrete Controllers
Discrete controllers are controllers that have only two modes or
positions: on and off. A common example of a discrete controller
is a home hot water heater.
Multistep Controllers
Multistep controllers are controllers that have at least one other
possible position in addition to on and off. Multistep controllers
operate similarly to discrete controllers, but as setpoint is
approached, the multistep controller takes intermediate steps.
Controllers automatically compare the value of the PV to the SP
Continuous Controllers
to determine if an error exists. If there is an error, the controller
adjusts its output according to the parameters that have been set
in the controller. The tuning parameters essentially determine:
 How much correction should be made? The magnitude of the
correction (change in controller output)
 How long should the correction be applied? The duration of the
adjustment to the controller output
 How fast should the correction be applied? The speed at which
a correction is made is determined by the derivative mode of
the controller.
Thermometer – measures absolute temperature (discussed in the previous section)

Thermal Sensors
Thermocouple gauge– measures temperature by its affect on two dissimilar metals
A thermocouple is a device that directly converts thermal energy into electrical energy.


Mechanical Sensors
Pressure sensor – measures pressure
Barometer – measures atmospheric pressure
Altimeter – measures the altitude of an object above a fixed level
Liquid flow sensor – measures liquid flow rate
Gas flow sensor – measures velocity, direction, and/or flow rate of a gas

Accelerometer – measures acceleration



Electrical Sensors
Ohmmeter – measures resistance
Voltmeter – measures voltage
Galvanometer – measures current
Watt-hour meter – measures the amount of electrical energy supplied to and used by a

residence or business
 Light sensors (photodetectors) – detects light and electromagnetic energy
Optical Sensors
Photocells (photoresistor) – a variable resistor affected by intensity changes in
ambient light.
 Infra-red sensor – detects infra-red radiation
 
Key terms/terminologies

 Electroacoustic: The interaction between electrical and acoustic phenomena.

 Electrochemical: The transfer of electric charge between matter.
 Electromagnetic: Objects made magnetic by an electric current.
 Electromechanical: A mechanical device which is controlled by an electronic
device.
 Electrostatic: Of or related to electric charges at rest or static charges.
 Optical: Referring to the behavior and properties of light and the interaction of
light with matter.
 Photoelectric: Relates to the electrical effects caused by light.
 Reading and understanding electrical drawings
.
Electrical drawings can represent anything from a single-
line power distribution, to a power or control circuit, and
are prepared using various symbols for electrical devices
and their interconnections with lines representing
conductors or wires used for interconnections. To read and
understand electrical drawings, it is necessary to know the
following:
 Symbols used for representing electrical devices
 Their interconnections, legends, terminology, and
abbreviations
 Sheet numbering and column format for each sheet
 Wire and terminal numbering (an important aspect in
understanding electrical drawings)
Basic Electrical Devices
Manually actuated push button switches: a
switch used to close or open an electric control circuit. They are primarily used for
starting and stopping of operation of machinery
Limit switches: Any switch that is actuated due to
the position of a fluid power component (usually a
piston rod or hydraulic motor shaft or the position of
load is termed as limit switch.
1. two types of Limit switches

a) Lever actuated contacts

b) Spring loaded contacts
Pressure switches:
is a pneumatic-electric signal converter. Pressure
switches are used to sense a change in pressure,
and opens or closes an electrical switch when a
predetermined pressure is reached.
Solenoids
Electrically actuated directional control valves
form the interface between the two parts of an
electro-pneumatic control. 12 V DC, 12V AC, 12
V 50/60 Hz, 24V 50/60 Hz, 110/120V 50/60 Hz,
220/230V 50/60 Hz.
Relays: an electro magnetically actuated switch.

Timers: Timers are required in control systems to effect time

delay between work operations.
Temperature switches
automatically senses a change in temperature and
opens or closes an electrical switch when a

predetermined temperature is reached.

1. Proximity sensors: Reed switches are

magnetically actuated proximity switches. Reed
switches are similar to relays, except a
permanent magnet is used instead of a wire coil.
Indirect Control of single acting cylinder
ድቡል ቡል አምፖ ል (inca de ce ns t

la mp)………………………………………………………………….........................

የሸንበቆአምፖ ል (floure ce ntla mp)…………..……………………........….......

ነጠላ ማብሪያ ማጥ ፊያ(s ingle pole s ingle throughs witch …………...................………

ባለሁ ለት /ባለሶስት አቅጣጫ ማብሪያ ማጥ ፊያ(s ingle pole double through s witch )......

ባለ አራት አቅጣጫ ማብሪያ ማጥ ፊያ(four wa y s witch)………………………….......

መ ንታ /ድር ብ ማብሪያ ማጥ ፊያ(double pole s ingle through s witch )....................

ባለ ሁ ለት ቀዳዳ ሶኬ ት (s ocke t without ground)…………....................................

ባለ ሶስት ቀዳዳ

ሶኬ ት (s ocke t)……………………..……………………………………......................

ደወል (be ll)…………………………………………………………………….............…

የደዎ ል ማብሪያ ማጥ ፊያ(pus h button)..............................................................

የአየር ማቀዝቀዣ (ve te la tor)………………………………………………………………
የኤሌክት ሪክ ሀ ይ ል ማከፋፈያ(ma in dis tributionboa rd)...........................................

ከፊል የኤሌክትሪክ ሐ ይ ል ማከፋፈያ(s ub dis tribution boa ....................................

የዉ ሀ ማሞቂያ(wa te r

he a te r)......................................................................... ......................................
የኤሌክት ሪክ

ምድጃ(s tove )…………….............................................................................................

ማብሪያ ማጥ ፊያ ያለዉ ሶኬ ት (s ocke t a nd s witch)………………………….………….

የስል ክ መ ስመ ር ሶኬ ት (te ll s ocke t)…………………………………………………..

የቴል ቪዥንአንቴና(tva ntte na )………………………………………………………………..

የል ብስማጠቢያ(wa s hingma chine )………………………………………………..…..

የሣህንማጠቢያ(dis hwa s he r)……………………………………………………………..

መ ከላከያ(ground)…………………………………………………………………………
Terminate wiring and tubing plicing
1. Reading and interpreting drawings accurately
Common tube fitting types and names
 Tube fittings designed to connect a tube to
pipe threads are called connectors.
 Tube fittings designed to connect one tube to
another are called unions
Test
For Equipment
all low voltage electrical installation verification
and condition reporting work, electrical contractors
and installers should, as a minimum, have the
following range of test instruments:
• Continuity test instrument
• Insulation resistance test instrument
• Loop impedance test instrument
• Residual current device test instrument
• Earth electrode resistance test instrument
• Voltage indicating instrument**
Check and monitor tools and equipment
Managing the Risks of Electrical Work
What is electrical work?
Electrical work means:

 Connecting electricity supply wiring to electrical

equipment or disconnecting electricity supply
wiring from electrical equipment
 Installing, removing, adding, testing, replacing,
repairing, altering or maintaining electrical
equipment or an electrical installation.
 Work that involves connecting electrical equipment to an
Electrical work does not include:
electricity supply by means of a flexible cord plug and socket
outlet
 Work on a non-electrical component of electrical equipment if
the person carrying out the work is not exposed to an electrical
risk
 Replacing electrical equipment or a component of electrical
equipment if that task can be safely performed by a person
who does not have expertise in carrying out electrical work
(e.g. Replacing domestic fuses or light bulbs)
 Assembling, making, modifying or repairing electrical
equipment as part of a manufacturing process
HAZARD ASSESSMENT
Certain areas of the building will require different types

of cleaning due to differences in the types of hazards. For

example, areas requiring differential housekeeping
attention include:
 Entryways and lobbies
 Bathrooms
 Hallways and corridors
 Kitchen and cafeteria
 Offices
 Warehouse
HOUSEKEEPING
Supervisors andAREAS—SAFE WORK PRACTICES
workers will implement the following safe
work practices for housekeeping in all areas of the facility.
All Working Surfaces

 Keep all walking and working surfaces clean, sanitary,

and orderly.
 Keep work surfaces dry.
 Clean up small spills immediately; report large spills to a
supervisor.
 Ensure that all walking and working surfaces and
passageways are free from protruding nails, splinters,
holes, or loose boards.
Final Inspection
Inspection list shall include at least the
following items where applicable:
1. Tray installation; satisfactory testing (where
required).
2. Internal draw off piping.
3. Catalyst supports and screens.
4. Internal distributors.
5. Liquid entrainment separators.
6. Internal risers and vortex breakers.
Thermos well location and length.
 Field visual
Visual inspection shall ensure that each instrument:
Inspection
- has the correct tag number, range, etc.;

- is in the proper place;

- is correctly and rigidly installed;

- is properly earthed where necessary;

- is suitably protected against adverse environmental

conditions.

 Attention shall also be paid to the final accessibility of

the instrument and the free space necessary for removal
or partial disassemble.
1. Ensure all devices to be checked out are properly
Recording and notifying document
installed and powered.
2. Perform a device Scan operation by right-clicking
the interface icon in AMS Device Manager.
3. FOUNDATION field bus devices will appear
automatically without a scan operation,
4. Run the AMS Device Manager Tag Naming Utility
to transfer the HART device tag to the AMS device tag.
5. For FOUNDATION fieldbus devices you should
name the devices as they appear.
6. AMS Device Manager Audit Trail will automatically
document these events,
The following steps complete the loop check work
process with AMS Device Manager:
7. Verify device configuration with the device
Documentation
An essential requirement for an inspection system is to
keep up to date, precise and detailed records of all
inspection, testing and calibration activities.
blue leak test completed.
 yellow pressure test completed.
 orange cable test. completed
green calibration test. completed
red: incomplete. components are
missing
pink calibration fault. in temporary use only.
white test failed. waiting for further action
Procedures of writing report
Many project teams utilize the reporting options and
tools available in their collaborative project site to track
work, identify risks and issues, and keep stakeholders
informed about the project. 1. 1. 1.Decide the Objective
2. Understand Your Audience
3. Report Format and Type
4. Gather the Facts and Data
5. Structure the Report
 Executive Summary
 Introduction
 Body
6. Readability
7. Edit
 !! !
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