INSTRUMENTATION AND

CONTROL
Presented By

ENGR. DR. ANIUGO V.O

MECHATRONICS ENGINEERING DEPARTMENT

FUTO, OWERRI
70/20/10 Philosophy in execution
 70/20/10 Philosophy in execution
10% Learning Consultant
Tutoring (theory level) Employee
Reading (Instrumentation Manuals) TLC Classroom & Workshops
E-learning (Web) Self-study (home/work)

20% Employee
Understudying, process analysis, questioning, Shop floor shadowing
Laboratory works and assignments Best practice visits
Feedback specialists
70%
Manager Coach
Shadowing, hands on practice, relief work and
Relief work and practice
attachments, Maintenance and
Troubleshooting Projects
Assignments
Maintenance
Troubleshooting
 AIMS AND OBJECTIVE
At the end of this Training Participants should be
able to:
Know the types of instruments used in the brewery

Know why instruments are used in brewery

Identify and know the functions of each instrument

Identify faulty instrument on the plant

 Instrumentation
• Instrumentation can be defined as "the art and
science of measurement and control".
• Instrumentation is used to refer to the field in
which Instrument technicians and engineers
work.
• Instrumentation also can refer to the available
methods of measurement and control
 INSTRUMENT

Instrument is a device or combination of

devices used directly or indirectly to measure,
display and / or control process variables.
 Processes
– Process is an event in which materials undergo
physical or chemical change or energy is converted
Inputs from
of one form to another Outputs of material
material or
or energy, B
energy, A

Process
PROCESSES
In the brewery, operations involved in the conversion of grains to bottled
beverage can be broken down into thousands of processes, each with
process variables to be measured or controlled. In order to properly
design the required control loop, the system designer needs to know the
characteristics of each process.
PROCESS VARIABLES
The Process Variables includes:
1. Temperature
2. Pressure
3. Level
4. Flow; etcetera.
 Need for Instruments
• To ensure safety of personnel and equipment
• To ensure a high and consistent product quality
• To optimize costs
 TYPES OF INSTRUMENT
There are different types of Instruments which include:

 Measuring and indicating Instruments, also known as

Indicators like Temperature indicators; Pressure Indicators;
Level indicators; Flow indicators; etc.
Examples are:

Sanitary Pressure
Gauge

Liquid in glass
Thermometer
Temperature Gauge

Pressure Gauge

Flow Rate Indicator Flow Rate Indicator Flow Rate Indicator

TYPES OF INSTRUMENT cont’d
 Measuring and Transmitting Instruments also known as
Transmitters like Temperature transmitters; Pressure
Transmitters; Level Transmitters; Flow Transmitters; etc.

Electronics Pressure Transmitters

Electronics Level
Electronics Level Transmitter
Transmitter Magnetic Flow Transmitter
 TYPES OF INSTRUMENT cont’d
 Indicating and Controlling Instruments also known as
Controllers like Temperature Controllers; Pressure
Controllers; Level Controllers; Flow Controllers; etc.

FGH 560 Electronics FGH 2000 Electronics Sipart Electronics

Controller JUMO Electronics Controller
Controller Controller
TYPES OF INSTRUMENT cont’d
 Final Correcting Instruments also known as Final
Correcting Element like Valves; pumps; etc.

Pump

Keystone Control Samson Control Valve

Valve Cam flex Control Valve
 Temperature measurement
Temperature is the degree of hotness or coolness of a body,
and the units of measurement are: °C; °F; Rankin; and
Kelvin.
Methods of Temperature measurement:

 Body Contact
 Filled thermal systems
 Bimetallic temperature measurement
 Resistance Temperature Detectors (RTD)
 Thermistors
 Thermocouples
 Temperature Switch
Methods of Temperature measurement cont’d
Filled thermal systems
The filling liquid or gas of this types of temperature sensors can be found
in a reservoir, connected with a narrow tube (the capillary). When the
temperature rises, the filling liquid or gas will increase in volume. This
increase in volume will cause a proportional rise in the level height in the
capillary which results in temperature measurement.

Example of Filled thermal systems

Liquid in glass Temperature Gauge Temperature Switch

Thermometer
Methods of Temperature measurement cont’d

Bimetallic temperature measurement

This work with the principle of two de-similar metals joint together and a
rise in temperature on the joint metals caused the metals to bend
towards the weaker metal and which results in the measurement.

Temperature Gauge
Methods of Temperature measurement cont’d

Resistance Temperature Detectors (RTD) – A

resistance-temperature detector (RTD) is a temperature
sensing device whose resistance increases with
temperature.
PT 100 sensors offer excellent accuracy over a wide
temperature range (from -200 to +850ºC

RTD Temperature
Probe
Methods of Temperature measurement cont’d
Thermistors
A thermistor is similar to an RTD in that it is a passive resistance device;
however thermistors are generally made of semiconductor materials
giving them much different characteristics.
Thermistors usually have negative temperature coefficient, their
resistance decreases as the
temperature increases.
Methods of Temperature measurement cont’d
Thermocouples

Thermocouple is a Temperature-measuring device:

a device for measuring temperature in which two
wires of different metals are joined. The potential
difference between the wires is a measure of the
temperature of something they touch.

Thermocouple
Temperature Probe
Methods of Temperature measurement cont’d

 Temperature Switch:
This is a switch operating by
changes in temperature.

Temperature Switch
 Pressure Measurement
 Pressure is force per unit area perpendicular to a surface

 Types of pressure

 Atmospheric pressure
 Absolute pressure: sum of atmospheric pressure and
pressure due to an object
 Gauge pressure: pressure on a surface due to an object
 TYPES OF PRESSURE

GAUGE PRESSURE OR
OVER PRESSURE

ATMOSPHERIC PRESSURE
(ZERO REFRENCE)

ABSOLUTE PRESSURE

VACCUM PRESSURE

ABSOLUTE ZERO OR
ABSOLUTE VACCUM
 Methods of Pressure measurement
 Pressure sensors
 Pressure gauges
 Pressure transmitters
 Pressure switches
Electronics Pressure Transmitters

Sanitary Pressure Danfoss Pressure

Manocomb Switch Differential
Pressure Gauge Gauge
Pressure Switch Pressure Switch
 Level measurement

 Some simple level measurement methods include:

 Dip stick
 Sight glass method
 The float level meter
 Hydrostatic pressure method
 Buoyancy method
 Conductivity probes
 Capacitive probes
 Ultrasonic level measurement
 Level switches
 Flow measurement
 Differential pressure flow meters
 Positive displacement flow meters
 Turbine flow meters
 Electromagnetic flow meters Flow
Electronics
Switch
 Flow switches Flow Switch

Flow
Switch
Magnetic
Water Meter Water Flow Meter
Meter

Flow Rate Indicator Flow Rate Indicator

Flow Rate Indicator Flow Rate Indicator Flow Rate Indicator
 Final Control Elements

 The final control element is made up of two components

 The actuating element
 The correcting element
• The actuating element receives the ‘control signal’ from the controller and
converts it into a physical force. This force is used to move the correcting element.
• The correcting element is in direct contact with the process. It is acted upon by
the actuating element and alters the manipulated variable like the flow of a
cooling medium in order to bring the controlled variable closer to the desired
value.

actuating element

Keystone
Control Valve Cam flex
Control Valve correcting element
Samson Control
Valve
 Types of Actuating elements
• Diaphragm and spring actuator
• Piston actuator
• Pilot valve (3/2 or 5/2) combined with diaphragm and spring or piston
• Solenoid

Diaphragm and spring actuator

Piston and spring actuator

5/2 Tebel Solenoid Valve

3/2 Joucomatic Solenoid 3/2 Lucifer Solenoid

Valve Valve Lucifer Solenoid
Valve
 What is a Control Valve?
The most common final control element in process industries is
the control valve. Control valves manipulate the flow of utilities
(such as steam, air, water or glycol), ingredients or in process
streams, compensating for load or Set Point changes to keep
the regulated process variable as close as possible to the
desired Set Point.

A control valve is an inline device in a flow stream that

receives commands from a controller and manipulates the
flow of a gas or fluid in one of three ways:
1) Interrupt flow (shut-off service)
2) Divert flow to another path in the system (divert service)
3) Regulate the rate of flow (throttling service)
 Shut-Off Service

Control valves for flow shut-off service have two positions. In the
open position flow is allowed to exit the valve. In the closed
position flow is blocked from exiting the valve.
 Divert Service

Control valves for divert service also have two positions,

however flow is never blocked. In the one position flow is allowed
from the common port to port A. In the other position flow is
allowed form the common port to port B.
 Throttling Service

Control valves for throttling service have many positions. The

position of the valve determines the rate of flow allowed through
the valve.
 P/I Converter I/P Converter

CONVERTERS
P/I Converter is a Device which has the capability of
converting pneumatic signal of 0.2 - 1 Bar to an electronics
signal of 4 - 20 mA. While I/P Converter is a Device which
can convert an electronics signal of 4 - 20 mA to
pneumatic signal of 0.2 - 1 Bar.
 An inductive proximity sensor

Inductive proximity sensor is the sensor which detects metal object

without physical contact with metal.

The sensor incorporates an electromagnetic coil which is used to detect

the presence of a conductive metal object. The sensor will ignore the
presence of an object if it is not metal.
 Characteristics of Level detections
DN 2 1

Conductive
65
 sensitive
for conductive foam and
contamination
 need more maintenance and checking

Vibration
 more reliable
 no adjustments

 for foam special option

♦Product, CIP, water, etc.

 Characteristics of Level detection

 Conductive
 liquids, foam

 Vibration
 liquids, solids, foam
Schuim R1

R2 < R1
 Capacitive R2

Bier
 solids, spent grains, yeast

 Ultrasonic:- Ultrasonic makes use of sound waves. A

transducer mounted in the top of a tank transmits sound waves
on to the surface of the material to be measured. Echoes are
reflected back from the surface of the material to the transducer
and the distance to the surface is calculated from the timing to
determine the material level in the tank. -barely applied
Switch 2
Measuring Pointer

Set Point 1

Set Point 2

Switch 1

Switch
Contact
Manocomb Pressure
Switch
 Characteristics of Magnetic Flow measurement
Characteristics of Magnetic Flow meter
 Conductive fluids
 Compact or remote converter Flow
Indicating
 No obstructions Transmitter

 No pressure loss
Primary
 No moving parts Element

 Fast response
 Acc. Meter ± 0.4 / 0.2 % rate
 Beer, water, wort, dosings
 Steam Pressure Regulator

Pilot Valve
Main Valve
 Cold Water
Hot Water Valve (HIC)
Control Valve

Water Mixer
Temperature
Transmitter

Water Mixer Control Loop

20 -100 kpa
 INSTRUMENT CALIBRATION

CALIBRATION—this is an arrangement made to correct

an inherited error on instrument, it involves checking the
measuring device against a known standard and
correction takes place on the instrument.

NEED FOR CALIBRATION

 To correct error or deviation

 To maintain uniform standard among devices
 To maintain good quality of products
 TYPES OF INSTRUMENT ERROR
ZERO ERROR

Zero Error is a constant error on an instrument reading.

The error can be positive or negative along the scale reading.

OUTPUT

INPUT

ZERO ERROR
 TYPES OF INSTRUMENT ERROR

SPAN ERROR

Span error is an increasing or decreasing error along the

reading scale of an instrument.
 TYPES OF INSTRUMENT ERROR

LINEARITY ERROR

Linearity error is an increasing or decreasing ununiformed

error along the reading scale of an instrument.