Process Control Instrumentation Technology

by Johnson, Curtis D.

• ISBN13: 9780131194571
• ISBN10: 0131194577
• Edition: 8th
• Format: Paperback
• Copyright: 2005-06-21
• Publisher: Pearson

Summary

This manual is designed to provide users with an understanding and appreciation of some of the theoretical concepts behind control system elements and operations, without the need of advanced math and theory. It also presents some of the practical details of how elements of a control system are designed and operated, such as would be gained from on-the-job experience. This middle ground of knowledge enables users to design the elements of a control system from a practical, working perspective, and comprehend how these elements affect overall system operation and tuning.This edition includes treatment of modern fieldbus approaches to networked and distributed control systems. Generally, this guidebook provides an introduction to process control, and covers analog and digital signal conditioning, thermal, mechanical and optical sensors, final control, discrete-state process control, controller principles, analog controllers, digital control and control loop characteristics.For those working in measurement and instrumentation and with control systems and PLCs.

Table of Contents

Introduction to Process Control	1	(52)
Instructional Objectives	1	(1)
Introduction	1	(1)
Control Systems	2	(4)
Process-Control Principles
Servomechanisms
Discrete-State Control Systems
Process-Control Block Diagram	6	(4)
Identification of Elements
Block Diagram
Control System Evaluation	10	(4)
Stability
Steady-State Regulation
Transient Regulation
Evaluation Criteria
Analog and Digital Processing	14	(8)
Data Representation
ON/OFF Control
Analog Control
Digital Control
Programmable Logic Controllers
Units, Standards, And Definitions	22	(14)
Units
Analog Data Representation
Definitions
Process-Control Drawings
Sensor Time Response	36	(4)
First-Order Response
Second-Order Response
Significance and Statistics	40	(13)
Significant Figures
Statistics
Summary
Problems
Supplementary Problems
Analog Signal Conditioning	53	(62)
Instructional Objectives	53	(1)
Introduction	53	(1)
Principles of Analog Signal Conditioning	54	(4)
Signal-Level and Bias Changes
Linearization
Conversions
Filtering and Impedance Matching
Concept of Loading
Passive Circuits	58	(25)
Divider Circuits
Bridge Circuits
RC Filters
Operational Amplifiers	83	(6)
Op Amp Characteristics
Op Amp Specifications
Op Amp Circuits in Instrumentation	89	(13)
Voltage Follower
Inverting Amplifier
Noninverting Amplifier
Differential Instrumentation Amplifier
Voltage-to-Current Converter
Current-to-Voltage Converter
Integrator
Differentiator
Linearization
Design Guidelines	102	(13)
Summary
Problems
Supplementary Problems
Digital Signal Conditioning	115	(60)
Instructional Objectives	115	(1)
Introduction	115	(1)
Review of Digital Fundamentals	116	(9)
Digital Information
Fractional Binary Numbers
Boolean Algebra
Digital Electronics
Programmable Logic Controllers
Computer Interface
Converters	125	(30)
Comparators
Digital-to-Analog Converters (DACs)
Analog-to-Digital Converters (ADCs)
Frequency-Based Converters
Data-Acquisition Systems	155	(5)
DAS Hardware
DAS Software
Characteristics of Digital Data	160	(15)
Digitized Value
Sampled Data Systems
Linearization
Summary
Problems
Supplementary Problems
Thermal Sensors	175	(48)
Instructional Objectives	175	(1)
Introduction	175	(1)
Definition of Temperature	176	(4)
Thermal Energy
Temperature
Metal Resistance versus Temperature Devices	180	(9)
Metal Resistance versus Temperature
Resistance versus Temperature Approximations
Resistance-Temperature Detectors
Thermistors	189	(4)
Semiconductor Resistance versus Temperature
Thermistor Characteristics
Thermocouples	193	(11)
Thermoelectric Effects
Thermocouple Characteristics
Thermocouple Sensors
Other Thermal Sensors	204	(7)
Bimetal Strips
Gas Thermometers
Vapor-Pressure Thermometers
Liquid-Expansion Thermometers
Solid-State Temperature Sensors
Design Considerations	211	(12)
Summary
Problems
Supplementary Problems
Mechanical Sensors	223	(62)
Instructional Objectives	223	(1)
Introduction	223	(1)
Displacement, Location, or Position Sensors	224	(8)
Potentiometric Sensors
Capacitive and Inductive Sensors
Variable-Reluctance Sensors
Level Sensors
Strain Sensors	232	(14)
Strain and Stress
Strain Gauge Principles
Metal Strain Gauges
Semiconductor Strain Gauges (SGs)
Load Cells
Motion Sensors	246	(12)
Types of Motion
Accelerometer Principles
Types of Accelerometers
Applications
Pressure Sensors	258	(9)
Pressure Principles
Pressure Sensors (p > 1 atmosphere)
Pressure Sensors (p > 1 atmosphere)
Flow Sensors	267	(18)
Solid-Flow Measurement
Liquid Flow
Summary
Problems
Supplementary Problems
Optical Sensors	285	(48)
Instructional Objectives	285	(1)
Introduction	285	(1)
Fundamentals of EM Radiation	286	(10)
Nature of EM Radiation
Characteristics of Light
Photometry
Photodetectors	296	(15)
Photodetector Characteristics
Photoconductive Detectors
Photovoltaic Detectors
Photodiode Detectors
Photoemissive Detectors
Pyrometry	311	(5)
Thermal Radiation
Broadband Pyrometers
Narrowband Pyrometers
Optical Sources	316	(6)
Conventional Light Sources
Laser Principles
Applications	322	(11)
Label Inspection
Turbidity
Ranging
Summary
Problems
Supplementary Problems
Final Control	333	(54)
Instructional Objectives	333	(1)
Introduction	333	(1)
Final Control Operation	334	(2)
Signal Conversions
Actuators
Control Element
Signal Conversions	336	(6)
Analog Electrical Signals
Digital Electrical Signals
Pneumatic Signals
Power Electronics	342	(16)
Switching Devices
Controlling Devices
Actuators	358	(13)
Electrical Actuators
Pneumatic Actuators
Hydraulic Actuators
Control Elements	371	(16)
Mechanical
Electrical
Fluid Valves
Summary
Problems
Supplementary Problems
Discrete-State Process Control	387	(52)
Instructional Objectives	387	(1)
Introduction	387	(1)
Definition of Discrete-State Process Control	388	(1)
Characteristics of the System	389	(14)
Discrete-State Variables
Process Specifications
Event Sequence Description
Relay Controllers and Ladder Diagrams	403	(10)
Background
Ladder Diagram Elements
Ladder Diagram Examples
Programmable Logic Controllers (PLCs)	413	(26)
Relay Sequencers
Programmable Logic Controller Design
PLC Operation
Programming
PLC Software Functions
Summary
Problems
Supplementary Problems
Controller Principles	439	(42)
Instructional Objectives	439	(1)
Introduction	439	(1)
Process Characteristics	440	(2)
Process Equation
Process Load
Process Lag
Self-Regulation
Control System Parameters	442	(6)
Error
Variable Range
Control Parameter Range
Control Lag
Dead Time
Cycling
Controller Modes
Discontinuous Controller Modes	448	(9)
Two-Position Mode
Multiposition Mode
Floating-Control Mode
Continuous Controller Modes	457	(9)
Proportional Control Mode
Integral-Control Mode
Derivative-Control Mode
Composite Control Modes	466	(15)
Proportional-Integral Control (PI)
Proportional-Derivative Control Mode (PD)
Three-Mode Controller (PID)
Special Terminology
Summary
Problems
Supplementary Problems
Analog Controllers	481	(32)
Instructional Objectives	481	(1)
Introduction	481	(1)
General Features	482	(1)
Typical Physical Layout
Front Panel
Side Panel
Electronic Controllers	483	(17)
Error Detector
Single Mode
Composite Controller Modes
Pneumatic Controllers	500	(4)
General Features
Mode Implementation
Design Considerations	504	(9)
Summary
Problems
Supplementary Problems
Computer-Based Control	513	(46)
Instructional Objectives	513	(1)
Introduction	513	(1)
Digital Applications	514	(5)
Alarms
Two-Position Control
Computer-Based Controller	519	(14)
Hardware Configurations
Software Requirements
Other Computer Applications	533	(7)
Data Logging
Supervisory Control
Control System Networks	540	(10)
Development
General Characteristics
Fieldbus Types
Computer Controller Examples	550	(9)
Summary
Problems
Supplementary Problems
Control-Loop Characteristics	559	(40)
Instructional Objectives	559	(1)
Introduction	559	(1)
Control System Configurations	560	(4)
Single Variable
Cascade Control
Multivariable Control Systems	564	(4)
Analog Control
Supervisory and Direct Digital Control
Control System Quality	568	(7)
Definition of Quality
Measure of Quality
Stability	575	(5)
Transfer Function Frequency Dependence
Stability Criteria
Process-Loop Tuning	580	(19)
Open-Loop Transient Response Method
Ziegler-Nichols Method
Frequency Response Methods
Summary
Problems
Supplementary Problems
Appendixes	599	(37)
References	636	(1)
Glossary	637	(4)
Solutions to the Odd-Numbered Problems	641	(46)
Index	687