Instrumentation And Process Control

by Bartelt, Terry L.M.

• ISBN13: 9781418041717
• ISBN10: 1418041718
• Edition: 1st
• Format: Paperback
• Copyright: 2006-11-28
• Publisher: Cengage Learning

Summary

This book provides comprehensive coverage of components, circuits, instruments, and control techniques used in today's process control technology field. It is ideal for students and technicians who will be installing, troubleshooting, repairing, tuning, and calibrating devices in a process control facility. Following an overview of an industrial control loop, each element of the loop is explored in detail.

Author Biography

Terry Bartelt is an instructor at Fox Valley Technical College

Table of Contents

Preface	p. xi
Industrial Control Overview
Introduction to Industrial Control Systems	p. 3
Introduction	p. 3
Industrial Control Classifications	p. 4
Motion and Process Controls	p. 4
Open- and Closed-Loop Systems	p. 5
Elements of Open- and Closed-Loop Systems	p. 8
Feedback Control	p. 10
Practical Feedback Application	p. 12
Dynamic Response of a Closed-Loop System	p. 13
Feed-Forward Control	p. 13
Problems	p. 15
Interfacing Devices	p. 17
Introduction	p. 17
Fundamental Operational Amplifiers	p. 17
Operational Amplifier Comparator	p. 18
Inverting Op Amp	p. 19
Summing Amplifier	p. 20
Noninverting Amplifier	p. 21
Difference Operational Amplifier	p. 21
Signal Processors	p. 22
Integrator Operational Amplifier	p. 22
Differentiator Operational Amplifier	p. 23
Wave-Shaping Schmitt Trigger	p. 24
Comparator Devices	p. 26
Digital Magnitude Comparator	p. 26
Optoelectronic Interface Devices	p. 27
Photodiodes	p. 29
Phototransistors	p. 29
Photo SCR	p. 29
Photo Triac	p. 30
Optoelectronic Packaging	p. 30
Digital-to-Analog Converters	p. 31
Integrated-Circuit Digital-to-Analog Converter	p. 34
Analog-to-Digital Converters	p. 34
Integrated-Circuit Analog-to-Digital Converter	p. 36
Timing Devices	p. 38
555 Astable Multivibrator	p. 40
555 Monostable Multivibrator	p. 42
Problems	p. 44
The Controller
The Controller Operation	p. 49
Introduction	p. 49
Control Modes	p. 50
On-Off Control	p. 50
Proportional Control	p. 53
Controller Amplification	p. 55
Steady-State Error	p. 56
Proportional-Integral Control	p. 59
Proportional-Integral-Derivative Control	p. 61
Time-Proportioning Control	p. 65
Time-Proportioning Circuit	p. 66
Problems	p. 68
Process Control and Instrumentation
Pressure Systems	p. 73
Introduction	p. 73
Pressure Laws	p. 74
Properties of a Liquid	p. 74
Height	p. 74
Weight	p. 75
Temperature	p. 75
Atmospheric Pressure	p. 75
Mechanical Machines	p. 76
Properties of a Gas	p. 76
Temperature of the Gas	p. 76
Volume of the Gas Container	p. 76
Gas Removal from a Container	p. 77
Pressure Measurement Scales	p. 77
Gauge Pressure Scale	p. 77
Absolute Pressure Scale	p. 78
Differential Pressure Scale	p. 79
Vacuum Pressure Scale	p. 80
Pressure Measurement Instruments	p. 80
Nonelectrical Pressure Sensors	p. 80
Liquid Column Gauges	p. 80
Mechanical Gauges	p. 83
Electronic Pressure Sensors	p. 85
Semiconductor Strain Gauges	p. 85
Transverse Voltage Strain Gauge	p. 85
Variable Capacitor Pressure Detector	p. 87
Pressure Control Systems	p. 87
Hydraulic Systems	p. 87
Pneumatic Systems	p. 89
Vacuum Systems	p. 89
Static Pressure Systems	p. 90
Steam Pressure Systems	p. 91
Problems	p. 92
Temperature Control	p. 93
Introduction	p. 93
Fundamentals of Temperature	p. 94
Thermal Control Systems	p. 94
Thermodynamic Transfer	p. 94
Thermal Energy Source	p. 95
Industrial Furnaces	p. 95
Cooling Systems	p. 96
Temperature Measurements	p. 97
Temperature Scales	p. 98
Differential Temperature	p. 99
Temperature Indicating Devices	p. 100
Crayons	p. 101
Paints	p. 101
Pellets	p. 101
Labels	p. 101
Liquid Crystal Indicator	p. 101
Liquid Filled Thermometers	p. 102
Electronic Sensors	p. 103
Thermistor	p. 103
Resistance Temperature Detectors	p. 105
Thermocouple	p. 106
Probe Assemblies	p. 111
Radiation Thermometry	p. 112
Problems	p. 115
Flow Control	p. 117
Introduction	p. 117
Systems Concepts	p. 118
Reasons for Control	p. 119
Flow Units of Measurement	p. 119
Volumetric Flow Rate	p. 119
Flow Velocity	p. 120
Mass Flow Rate	p. 120
Solid Flow Measurement	p. 120
Fluid Flow Measurement	p. 121
Pipe Flow Principles	p. 122
Fluid Flowmeter Classification	p. 123
Electronic Sensors	p. 129
Coriolis Meters	p. 129
Rotor Flow Detectors	p. 129
Electromagnetic Flow Detectors	p. 129
Thermal Flowmeters	p. 130
Vortex Flowmeters	p. 130
Ultrasonic Flowmeters	p. 131
Time-of-Flight Flowmeter	p. 132
Flowmeter Placement	p. 133
Selecting a Flowmeter	p. 133
Problems	p. 134
Level Control Systems	p. 135
Introduction	p. 135
A Level Control System	p. 136
Power Sources	p. 137
Transfer Systems	p. 137
Methods of Measurement	p. 137
Point Level Measurements	p. 138
Continuous Level Measurements	p. 138
Level Measurement Methods	p. 138
Float and Displacement Methods	p. 139
Electronic Sensors	p. 144
Conductive Probes	p. 144
Capacitive Probes	p. 144
Ultrasonic Sensors	p. 145
Selecting a Level Sensor	p. 147
Problems	p. 148
Analytical Instrumentation	p. 149
Introduction	p. 149
pH Measurement and Control	p. 150
pH Measurements	p. 152
Controlling pH	p. 154
Conductivity	p. 156
Conductivity Electrode Probe	p. 157
Conductivity Inductive Probe	p. 158
Conductivity Applications and Control	p. 158
Combustion Analyzers and Control	p. 160
Combustible Gases	p. 160
Hydrocarbon Gases	p. 161
Controlling Combustion	p. 162
Humidity	p. 163
Quantitative Measures of Humidity	p. 163
Absolute Humidity Sensor	p. 164
Relative Humidity Detectors	p. 165
Dew Point Measurements	p. 167
Controlling Humidity	p. 168
Sampling Measurement System	p. 169
Problems	p. 169
Industrial Process Techniques and Instrumentation	p. 171
Introduction	p. 172
Batch Processes	p. 172
Control Requirements	p. 173
Types of Batch Processes	p. 174
Chemical Reaction	p. 174
Continuous Processes	p. 175
Control Requirements	p. 175
Instrumentation	p. 178
Measurement Devices (Sensors)	p. 179
Dynamic	p. 179
Static	p. 179
Feedback Loop Interface Instruments	p. 182
Transmitters	p. 182
Transducers	p. 183
Controllers	p. 186
Pneumatic Controllers	p. 186
Panel-Mounted Controllers	p. 187
Personal Computers	p. 187
Programmable Logic Controllers	p. 188
Distributed Control Systems (DCS)	p. 188
Monitoring Instruments	p. 189
Indicators	p. 189
Alarms	p. 190
Recorders	p. 190
Manipulation Devices (The Final Control Element)	p. 191
The Control Valve	p. 191
DC and AC Motors	p. 199
Problems	p. 199
Instrumentation Symbology	p. 201
Introduction	p. 201
General Instrument Symbols	p. 201
Individual Instruments	p. 201
Tag Numbers	p. 202
Line Symbols	p. 205
Valve and Actuator Symbols	p. 206
Control Valves	p. 206
Actuators	p. 207
Reading a Single Loop	p. 207
Information Block	p. 208
Problems	p. 210
Process Control Methods	p. 213
Introduction	p. 214
Open-Loop Control	p. 214
Closed-Loop Control	p. 214
Process Behavior	p. 215
Single-Variable Control Loop	p. 216
Response Time of the Instruments	p. 216
Pure Lag of the Controlled Variable	p. 217
Dead Time	p. 218
Selecting a Controller	p. 219
On-Off Control	p. 219
Case Studies-Using Different Control Modes	p. 221
Continuous Control	p. 223
Proportional Mode	p. 223
Integral Mode	p. 229
Derivative Mode	p. 231
Advanced Control Techniques	p. 234
Cascade Control	p. 235
Feed-Forward Control	p. 237
Ratio Control	p. 238
Adaptive Control	p. 239
Problems	p. 241
Instrument Calibration and Controller Tuning	p. 245
Introduction	p. 245
Instrument Calibration	p. 246
Reasons for Performing Calibrations	p. 246
Calibration Preparation	p. 247
Standard Calibration Procedure	p. 248
Five-Point Calibration Procedure	p. 249
Calibration Check	p. 250
Calculating the Input Values	p. 250
Calculating the Output Values	p. 250
Analysis of Calibration Data	p. 250
Transmitter Zero and Span Adjustments	p. 250
Verification of Adjustments	p. 251
Tuning the Controller	p. 252
Trial-and-Error Tuning Method	p. 253
Ziegler-Nichols Tuning Methods	p. 254
Ziegler-Nichols Continuous Cycling Method	p. 254
Ziegler-Nichols Reaction Curve Tuning Method	p. 260
Controller Autotuning	p. 265
Problems	p. 265
Answers to Odd-Numbered Problems	p. 267
Glossary	p. 271
Index	p. 277
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