Date post: | 10-Oct-2014 |
Category: |
Documents |
Upload: | analtina-goncalves |
View: | 235 times |
Download: | 4 times |
Instrumentation and Controls
CNTR 252
Credits: 1.5
Total Modules: 31
Prerequisite(s): None
Corequisite(s): None
Description: An introduction to process measurement and control, explaining
how instrumentation and processes interact. These processes could
be in any area of study, such as the oil/gas sector, chemical
manufacture, agriculture, and mining, building systems or utilities.
Areas of study will include measurement and control of variables
such as fluid flow, level and pressure. Specific applications to apply
the knowledge to design, operate, troubleshoot measurement and
control systems.
Effective: January 2008
Course Outline
www.sait.ca
1
CNTR 252
Instrumentation and Control
Course Evaluation Exams Weighting Time Required To Complete
Theory Mid-Term 30% 3 Hours
Theory Final 35% 3 Hours
Laboratory Write-ups 35% 32 Hours (10 Hours on simulator)
Total 38 Hours
All work submitted for evaluation is expected to be of "industry acceptable
standard." All assignments and laboratory write-ups are expected to be word
processed, and presented in a "Duotang" type cardstock folder. Deadline to have
a mark credited will be seven days from the date set, or as directed by the
instructor. A major part of the mark will be awarded for presentation, remainder
based on data collected, observations and conclusions. Laboratory teams, and
study groups are encouraged to work together, but independent reports and
assignments are required. Plagiarism will be dealt with severely.
Percentage Grade
Letter Grade
Grade Points
90-100 A+ 4.0
85-89 A 4.0
80-84 A- 3.7
77-79 B+ 3.3
73-76 B 3.0
70-72 B- 2.7
67-69 C+ 2.3
63-66 C 2.0
60-62 C- 1.7
55-59 D+ 1.3
50-54 D 1.0 Minimal Pass
0-49 F 0.0
According to Policy AC.3.10, SAIT will normally return students’ work to the
students. However, in certain courses, SAIT retains the right to keep physical
possession of the student’s work. Your instructor will discuss this with you at the
start of the course.
2
Course Attendance
Effort and involvement are as essential for learning as they are for success in your
career. To help assure your success, participation in all activities of this course is
expected. The academic department offering this course will identify any specific
requirements applicable to this class and delivery method. Reference: Procedure
AC.3.8.1 - Attendance Requirements (available on http://www.mysait.ca)
Time Guidelines Subject to change the following section times are a suggested guide in order to
meet learning goals…
Theory Instructional Time 48 Hours
Laboratory Time 16 Hours
Laboratory / Assigned Homework Time 38 Hours
Assigned Total Time 102 Hours
Expected supplemental study time 54 Hours
Expected Total Student Commitment Time 156 Hours
OUTLINE
Theory and recommended student time per module:
Module Title
Hours/Module
Instrumentation Drawing Symbols
Introduction to Process Instrumentation
The Feedback Control Loop
The Feedback Control Loop and its Dynamics
Pressure Measurement Standards
Basic Instrument Calibration
Pressure Measurement
Protection of Gages
Basic Transmitter Principles
Level Measurement
Level Measurement II
Flow Measurement-Orifice Plates
Flow Measurement-Orifice Plate Installation
Flow Measurement-Orifice Transmitter
Installation
Differential Pressure Flowmeters
Positive Displacement and Other Flowmeters
Temperature Measurement Devices
The Control Valve
Final Control Element Actuators
3
Control Valve Actuator Accessories
Control Valve Sizing
Pneumatic Controllers I On-Off Control
Pneumatic Controllers II Proportional Control
Automatic-Manual Transfer Stations
Introduction to Process Control Strategies I
Introduction to Process Control Strategies II
Electronic & Pneumatic Control Systems
Electronic Instruments
Computers in Process Control I
Computers in Process Control II
4
Course Text(s) Instrumentation for Process Measurement and Control by N. Anderson (Chilton)
Fisher Control Valve Handbook by: Fisher Valve Company.
Supplimental Reference Text:
Instrumentation Symbols and Identification, ANSI/ISA-S5.1
Process Instrumentation Terminology, ANSI/ISA-S51.1
Process/Industrial Instruments & Controls Handbook - Considine
Instrument Engineers Handbook (Meas. & Cont.) - Liptak
Materials CNTR 252 Module Package – (see time guidelines for module listing)
Lab Exercises
1. Transmitter calibration - Foxboro 13a DP cell, correct use of a calibration
sheet and graphing of results, illustrating gain, (Bias) zero and linearity.
2. M1 Bridge - Analyze Negative feedback / Gain / Bias / Direct and Reverse
Acting.
3. M1 Bridge - Compare On-Off controller with laboratory number three.
4. M1 Bridge - Compare PI controller with laboratory number three(possibly
demonstrate PID controller)
5. Valve positioner calibration and inspection (stroke, air to open / air to close,
characterization, piston actuator)
6. IBM computer Boiler Sim™ (Analyze P, PI, PID Controllers & Practice
Controller Tuning) (Flex Time)
7. IBM computer (introduction to DCS type control) Boiler Sim™ simulation.
(Examine Lead/Lag, P & P+I) (Flex Time)
8. IBM computer Boiler Sim™ simulation (examine 1 & 3 Element Drum Level
Control) (Flex Time)
5
Course Content Below is presented a list of the learning modules used to achieve the learning
outcome(s) for this course….
1. Instrumentation Drawing Symbols
Learning Outcome:
Know how a simple closed loop control system is arranged, identify its
major components, and employ the correct ISA drawing symbols.
Objectives:
1.1 List and describe the job of the following control system parts;
controller, transmitter, final control element (FCE) and process.
1.2 Sketch how the components listed in 1.1 would be correctly
arranged in a typical control system.
____________________________________________________________
2. Introduction to Process Instrumentation
Learning Outcome:
Describe the importance of automation in relation to industry.
Objectives:
List and describe how the primary areas of industry are impacted
by automatic controls. (e.g.. safety, efficiency, manpower,
demands, distance/time, hostile environments, accuracy.)
2.2 Explain the importance of accurate measurement of process
variables such as; level, pressure, flow, temperature, density and
composition
2.3 State and describe the five purposes of instrumentation in a process
plant. (Measure, Control, Alarm, Record, Indicate)
____________________________________________________________
6
3. The Feedback Control Loop
Learning Outcome:
Describe the basic closed loop control system, and its four main parts.
Objectives:
3.1 Sketch and label a simple closed loop control system, label and
describe the controller, transmitter, final control element and
process.
3.2 Compare the relationship between process capacity and the
controller.
____________________________________________________________
4. The Feedback Control Loop and its Dynamics
Learning Outcome:
Explain, with sketches, the feedback control loop and its dynamics.
Objectives:
4.1 Describe with the aid of sketches how increasing gain will lead t
instability and decreased gain to over damped conditions.
4.2 Show how phase relationships can affect stability.
4.3 Explain the relevance of process capacity on the selection of
controller gain.
____________________________________________________________
7
5. Pressure Measurement Standards
Learning Outcome:
Describe the principles of operation and the limitations of various pressure
measurement standards.
Objectives:
5.1 Define a pressure standard.
5.2 Describe the principle of operation of manometers, mercury
barometers, dead weight testers, and comparison gauge testers and
perform relative calculations.
5.3 Describe desirable characteristics of manometer fluids and
describe factors that may introduce errors into manometer
readings.
5.4 Describe limitations of manometers.
5.5 Describe factors that may introduce errors into dead weight tester
measurements and calibrations.
____________________________________________________________
6. Basic Instrument Calibration
Learning Outcome:
Explain the procedure for calibrating some basic instrumentation devices.
Objectives:
6.1 Briefly define the following terms: span, range, linearity,
hysteresis, and repeatability.
6.2 Perform calculations to convert ranges, spans, and standard signals
into percentages and back again.
6.3 Briefly describe the method for the calibration of a pressure gage.
6.4 Briefly describe a method of calibrating a pneumatic transmitter.
6.5 Briefly describe a method of calibrating an electronic transmitter.
6.6 Sketch and describe the transmitter connections to open tanks,
closed tanks, and tanks containing pressurized condensing vapours
and liquids (wet and dry leg).
____________________________________________________________
8
7. Pressure Measurement
Learning Outcome:
Describe the operation and application of pressure gages.
Objectives:
7.1 Define absolute, gage, vacuum, and atmospheric pressure.
7.2 Describe the operation of a C-type, spiral, and helix Bourdon tube
pressure gage.
7.3 Describe the application of bellows and diaphragms to pressure
measurement.
7.4 Describe the operation of an absolute pressure gage including an
Aneroid barometer.
____________________________________________________________
8. Protection of Gages
Learning Outcome:
Discuss the hazards that gages are exposed to in industry.
Objectives:
8.1 Identify the hazards that gages are exposed to in industry.
8.2 Briefly describe the following methods of gage protection:
snubbers, location, oil filled, needle valves, seal pots, chemical
seals, and purging.
____________________________________________________________
9
9. Basic Transmitter Principles
Learning Outcome:
Discuss the basic principles of pneumatic and electronic transmitter
operation.
Objectives:
9.1 Describe the operation of a pneumatic transmitter.
9.2 Describe the basic principle of operation of an electronic
transmitter.
9.3 State the purpose of a pneumatic relay.
9.4 Define negative feedback and proportional output with respect to
pneumatic and electronic transmitters.
9.5 Compare the basic principle of operation of electronic transmitter
sensors.
9.6 Calculate the input of a transmitter when given the output.
9.7 State the purpose of current to pneumatic (I to P) transducers.
____________________________________________________________
10. Level Measurement
Learning Outcome:
Discuss the application and installation of float operated bubbler systems,
diaphragm boxes, and level switches related to level measurement and
control.
Objectives:
10.1 Discuss the application of Archimedes’ principle to level
measurement using floats.
10.2 Sketch and describe float and cable and float and tape level
measurement devices.
10.3 Describe a control valve and linkage arrangement used with float
systems.
10.4 Sketch and describe a bubble pipe system for open and closed
tanks.
10.5 Describe the characteristics of a bubble pipe or purge system and
its application.
10.6 Sketch and describe a diaphragm box type of level measuring
system.
____________________________________________________________
10
11. Level Measurement II
Learning Outcome:
Discuss the application of level measurement by electrical capacitance,
conductance, mass, radiation, ultrasonic, and thermal methods.
Objectives:
11.1 Briefly describe level measurement using the following methods:
(a) electrical capacitance
(b) conductance
(c) mass
(d) radiation
(e) ultrasonic
(f) thermal sources
(g) rotating paddles
(h) vibrating paddles
(i) laser, microwave, and optical devices
____________________________________________________________
12. Flow Measurement – Orifice Plates
Learning Outcome:
Discuss the purpose of orifice plates and describe the most commonly
used types.
Objectives:
12.1 State the theory involved in the use of differential pressure flow
meters.
12.2 Describe the types of orifice plates and their applications.
12.3 Discuss the mechanical requirements that are followed to ensure
accuracy when using orifice plates.
12.4 Calculate the permanent pressure loss caused in a pipe by the
orifice plate.
____________________________________________________________
11
13. Flow Measurement – Orifice Plate Installation
Learning Outcome:
Describe orifice plate installations.
Objectives:
13.1 Describe the reasons and requirements for straightening vanes.
13.2 Describe the types and locations of pressure taps.
13.3 Describe the procedure to change orifice plates under pressure
using a slide valve plate changer.
____________________________________________________________
14. Flow Measurement – Orifice Transmitter Installation
Learning Outcome:
Discuss the installation requirements of secondary elements to provide
accurate and maintenance free operation.
Objectives:
14.1 State the installation requirements of the transmitter for measuring
flow of steam, liquids, and gases.
14.2 Describe the purpose of a sealing liquid.
14.3 State the function of condensing pots or reservoirs used in the
measurement of steam flow.
14.4 Describe the operation of a manifold.
14.5 Discuss winterizing a transmitter and the connecting sensing lines.
____________________________________________________________
12
15. Differential Pressure Flowmeters
Learning Outcome:
Discuss the basic operation of differential pressure meters other than
orifice plate meters.
Objectives:
15.1 Briefly describe the principle of operation of the following
differential pressure flowmeters: venturi tube, flow nozzle, pitot
tube, elbow tap, and target meter.
15.2 Briefly describe the operation of the weir and flume types of open
channel flowmeters.
15.3 State the advantages and disadvantages of each of these devices.
____________________________________________________________
16. Positive Displacement and Other Flowmeters
Learning Outcome:
Briefly explain the operation of positive displacement type flowmeters and
variable area meters.
Objectives:
16.1 Explain the difference between metering pumps and meters.
16.2 Sketch and describe the following types of positive displacement
flowmeters: nutating disc, bellows, reciprocating piston, rotating
piston, sliding vane, rotary lobe, rotary gear.
16.3 Sketch and describe the operation of a variable area meter.
____________________________________________________________
13
17. Flow Measurement – Velocity Flowmeters
Learning Outcome:
Discuss the basic principle of operation of various velocity type
flowmeters and state suitable process applications.
Objectives:
17.1 State the basic flow equation that relates velocity to area of the
pipe.
17.2 Describe the basic principle of operation of the turbine, vortex
shedding, magnetic, ultrasonic, and mass flowmeters.
17.3 Define meter “K-factor”.
17.4 Describe a process application for each type of velocity flowmeter.
____________________________________________________________
18. Temperature Measurement Devices
Learning Outcome:
Discuss the basic principle of operation and the application of the various
common temperature measuring devices.
Objectives:
18.1 Describe the operation and application of bimetallic thermometers.
18.2 Describe the operation, classes, and application of filled thermal
element systems.
18.3 Describe the operation and application of thermocouples.
18.4 Describe the operation and application of resistance thermometers.
18.5 Describe the operation and application of radiation pyrometers.
____________________________________________________________
14
19. The Control Valve
Learning Outcome:
Describe the various valve body types and determine which type of valve
body is most practical for a particular application.
Objectives:
19.1 Describe the various control valve bodies and seats.
19.2 Describe the different types of control valve end connections.
19.3 Indicate the type of control valve body which should be used for a
given application, and explain the reasons for the choice.
19.4 State the different valve flow characteristics.
____________________________________________________________
20. Final Control Element Actuators
Learning Outcome:
Describe the components of a typical actuator, list the different types of
actuators, and select the proper actuator for a specific application.
Objectives:
20.1 Describe the operation of a typical actuator and list the major
components.
20.2 Describe the different types of actuators and where they are used.
20.3 Explain how an actuator is sized, based on valve and process
requirements.
20.4 Explain the criteria for selecting a safe fail position of an actuator.
____________________________________________________________
21. Control Valve Actuator Accessories
Learning Outcome:
List the accessories available for actuators, describe their function, and
explain their operation.
Objectives:
21.1 List the accessories available for valve actuators.
21.2 Explain the function and construction of each accessory.
21.3 Describe the operation of each general type of accessory.
____________________________________________________________
15
22. Control Valve Sizing
Learning Outcome:
Describe why control valve sizing is important, and to determine the size
of control valve required for particular flow rate applications.
Objectives:
22.1 Define valve coefficient (Cv).
22.2 List the three basic formulas for Cv.
22.3 Perform basic calculations for sizing of control valves.
22.4 Explain the terms flashing and cavitation.
____________________________________________________________
23. Pneumatic Controllers I – On-Off Control
Learning Outcome:
Discuss the principles and terms that apply to basic on-off control and
explain the action of a pneumatic on-off controller.
Objectives:
23.1 Describe the operation of on-off control.
23.2 Differentiate between direct action and reverse action control.
23.3 Describe the action of a flapper-nozzle relay.
23.4 Sketch and describe the action of a flapper-nozzle based on-off
pneumatic controller.
____________________________________________________________
16
24. Pneumatic Controllers II – Proportional Control
Learning Outcome:
Explain the principle of proportional control and the basic terms of the
three-mode controller equation.
Objectives:
24.1 State how an on-off controller is made into a proportional
controller.
24.2 Define the term offset.
24.3 State the purpose of the integral mode in a controller.
24.4 State the purpose of the derivative mode in a controller.
24.5 Sketch and describe a three mode pneumatic controller.
24.6 Explain the terms for proportional, reset, and rate in the equation.
24.7 Describe the basic concept of the equation.
____________________________________________________________
25. Automatic-Manual Transfer Stations
Learning Outcome:
Discuss the principles, functions, and operation of automatic-manual
transfer stations.
Objectives:
25.1 Explain why processes are often run on manual control.
25.2 Describe the operation of an automatic-manual transfer station.
25.3 Sketch and describe the basic components of any automatic-
manual transfer station in a process loop.
25.4 Describe the purpose of automatic-manual transfer stations.
25.5 Describe the term balanced transfer.
____________________________________________________________
17
26. Introduction to Process Control Strategies I
Learning Outcome:
Discuss ratio, auto-select and split-range control theory, the interaction of
each pertaining to a control loop and practical applications of each
method.
Objectives:
26.1 Describe the difference between a multiplier and divide function
used in a ratio control loop.
26.2 Sketch a ratio control application.
26.3 Define an auto-select loop.
26.4 Describe typical auto-select loops.
26.5 Describe special applications of auto-select loops.
26.6 Employ a split-range control system to improve loop response of a
controlled variable.
____________________________________________________________
27. Introduction to Process Control Strategies II
Learning Outcome:
Discuss cascade and feedforward control theory, the interaction of each
within a control loop, and practical applications of each method.
Objectives:
27.1 Describe the effective use of a cascade control on both supply and
demand disturbances.
27.2 Give the general definition of feedforward control.
27.3 Sketch a typical cascade control loop.
27.4 Describe the general block diagram of a feedforward control
system.
27.5 List four problems of feedback control.
27.6 Describe under what conditions cascade can improve loop
performance.
27.7 Describe a general method of feedforward control design.
27.8 State the reasons for feedback trim on a feedforward system.
27.9 Discuss primary and secondary control loop tuning.
____________________________________________________________
18
28. Electronic & Pneumatic Control Systems
Learning Outcome:
Compare electronic and pneumatic instrumentation as applied to typical
industrial control systems.
Objectives:
28.1 Describe the advantages and disadvantages of pneumatic vs.
electronic instrumentation and control system.
28.2 Sketch and describe the equipment and components necessary to
form a pneumatic control system.
____________________________________________________________
29. Electronic Instruments
Learning Outcome:
Discuss how electronics is applied to different measurement and control
techniques.
Objectives:
29.1 Explain the fundamental difference between analog and digital
electronics.
29.2 Sketch and describe the fundamental components of a typical
electronic control loop.
29.3 Describe the fundamentals of a smart transmitter, and explain its
advantages and disadvantages as compared to conventional
transmitters.
29.4 Sketch and describe the components of a typical electronic flow
measurement/computing system.
____________________________________________________________
19
30. Computers in Process Control I
Learning Outcome:
Explain the role computers play in the process control industry, describe
the components and architecture of the computer, and use the language
associated with computers.
Objectives:
30.1 Describe the historical evolution of the computer and the criteria
used to define a computer.
30.2 Define and describe the architecture and components that make up
the computer.
30.3 Describe the use of software to accomplish tasks using the
computer.
30.4 List the applications of the computer to the process control
industry.
____________________________________________________________
31. Computers in Process Control II
Learning Outcome:
Describe the major components of process control computer systems
(console) operations, and describe the hardware and software requirements
for a typical computer control console. The student will also be able to
describe a simple Supervisory Control and Data Acquisition (SCADA)
system, major components of the system, and appropriate forms of
communication between sites.
Objectives:
31.1 Define the terms hardware and software, and state the difference
between the two.
31.2 List the minimum hardware requirements for a process control
computer system.
31.3 Define various input/output devices in a console, and describe the
functions of these devices.
31.4 List various software functions found on a process control
computer system.
31.5 Describe the functions of various software features found in
control consoles.
____________________________________________________________
S
AIT
Cours
e O
utlin
e
SAIT’s vision is sharply focused – to be recognized as Canada’s premier polytechnic, one of the world’s finest, setting the standard in education, training and innovation. SAIT shall be an innovative organization equipping people to compete successfully in the changing world of work by providing relevant, skill-oriented education.
ALL RIGHTS RESERVED: This material may not be reproduced in whole or part
without written permission from the Director, Centre for Instructional Technology and Development.
Southern Alberta Institute of Technology, 1301 16 Ave. N.W. Calgary AB T2M 0L4
Printed in Canada
on Recycled Paper