Chapter 06 - Instrumentation Control Systems Documentation by Frederick A. and Clifford A. Meier. An ISA Publication. This is Rev. 02. It is my own personal opinion that the A. Meier textbook does a horrible job with the Binary Logic Systems and I have therefore supplemented the chapter with other information.
2. Why Binary Logic Systems?
• Documents need to be understood by people with very different
backgrounds. People who could need the documentation are:
• Management
• Process Designers
• Operations Staffs
• Maintenance Technicians
• Electrical and Control System Professionals
• Logic Device Programmers
• Supervisory Control and Data Acquisition (SCADA) System Configurators
3. Binary Logic Diagrams
• ISA-5.2-1976 (R1992) Binary Logic
Diagrams for Process Operations and
Scientific Apparatus Makers Association
(SAMA) PMC 22.1 Functional
Diagramming of Instrument and Control
Systems. Both address binary logic
diagrams.
• Elements of these standard are now
included in ANSI/ISA-5.1
4. Terms You Should Know Before Proceeding
• Discrete Control
• “On/off control. One of the two output values is equal to zero.” (International
Society of Automation, 2003, p. 150)
• A better definition would be: A signal that is either fully ON or fully OFF with
no values in-between.
• Binary
• “1. A term applied to a signal or device that has only two discrete positions or
states. When used in its simplest form, as in “binary signal” (as opposed to
“analog signal”), the term denotes an “on-off” or “high-low” state, that is, one
that does not represent continuously varying quantities. [ANSI-ISA-5.1-1984
(R1992)].” (International Society of Automation, 2003, p. 49).
5. Terms You Should Know Before Proceeding
• Analog
• “1. Having the form of continuously variable physical quantities, as in data.
Contrast with digital. 2. The representation of numerical quantities by means
of physical variables, such as translation, rotation, voltage or resistance. 3. A
waveform is analog if it is continuous and varies over an arbitrary range.
Contrast with digital.” (International Society of Automation, 2003, p. 21).
• Another way to define Analog is: A continually varying signal that can be fully
ON, fully OFF or any level in between. (International Society of Automation,
2003, p. 21).
6. Terms You Should Know Before Proceeding
• Process Variable
• “1. Any variable property of a process. The term process variable is used in
the relevant standard to apply to all variables other than instrument signals
[ANSI/ISA-5.1-1984 (R1992)]. 2. In the treatment of material, any
characteristic or measurable attribute whose value changes with changes in
prevailing conditions. Common variables are flow, level, pressure and
temperature.” (International Society of Automation, 2003, p. 392).
• Control Variable (Controlled Variable)
• “1. The variable that the control system attempts to keep at the set point
value. The set point may be constant or variable. 2. The part of a process to
be controlled (flow, level, temperature, pressure, etc.).” (International Society
of Automation, 2003, p. 109).
7. Combining Analog and On-Off Control
• Combining analog and on/off control schemes can be defined by
using:
• Process control descriptions
• Instrument diagrams
• Functional diagrams
• Electrical schematic diagrams
• These documents can be used independently or together depending
upon the phase of design, construction or operation.
8. Process Control Descriptions
• The more complex the process, the more detail that is required in a
Process Control Description. The following are areas to be included,
but not limited to, in a Process Description:
• Process Description
• Title of the system
• General description
• Form
• Control Description
• More specific data on how the system will perform
• Loop-by-loop descriptions
• Format
9. The Binary Concept – Multiple Input
• This two-state binary concept, applied to gates, can be the basis for
making decisions in ladder logic.
• The gate is a device that has one or more inputs and one output.
• The gate will perform a logical decision based on the status of its
inputs and produce a result at its one output.
10. Using Gates to Make Decisions
• The logical AND gate or function.
• All inputs must be true to obtain an output.
AND
Gate
Air Conditioner
Switch
Blower Switch
Cold Air
The automotive air conditioning to work,
the Air Conditioner must be turned on and
the Blower must be turned on.
11. Using Gates to Make Decisions
• The logical OR gate or function.
• Any one input must be true to obtain an output.
OR
Gate
Passenger
Door Switch
Driver Door
Switch
Dome Light
The automotive dome light will be on when
the passenger door OR the driver door or
both door switch(s) is activated.
12. The AND Function
• The AND function has two or more
inputs and one output. The input
signals are labeled A, B, C, etc. and
the output signal is labeled Y.
• A binary 1 represents the presence
of a voltage (signal). A binary 0
represents the absence of voltage
(no signal, 0 V or ground).
• Logic functions can be represented
using a truth table. The truth table
lists all possible input status
conditions with the corresponding
output status for each set of input
condition.
AND
Gate
A
B
YInputs
Output
Two input AND gate
13. An AND Gate Application
• An AND gate functions like switches in series.
• The light will only be ON when switch A AND switch B are both
closed.
AND
Gate
PB1 = 1
LT1 ON
PB2 = 1
14. The OR Function
• The OR function has two or more
inputs and one output. The input
signals are labeled A, B, C, etc. and
the output signal is labeled Y.
• A binary 1 represents the presence
of a voltage (signal). A binary 0
represents the absence of voltage
(no signal, 0 V or ground).
• Logic functions can be represented
using a truth table. The truth table
lists all possible input status
conditions with the corresponding
output status for each set of input
condition.
OR
Gate
A
B
YInputs
Output
Two input OR gate
15. An OR Gate Application
• An OR gate functions like switches in parallel.
• The light will be ON when either or both switch A OR switch B are
closed.
OR
Gate
PB3 = 1
PB4 = 0
LT2 ON
16. The NOT Function (Inverter)
• The NOT function gate, also
called an inverter, has one input
and one output.
• The NOT gate functions like its
name states, it inverts the input
signal status.
• If the input is a 1 the output is a
0.
• If the input is a 0, the output is a
1.
Input Input
A A
(not A)
17. A NOT Gate Application
• The NOT gate functions like a normally closed switch.
• The light will be ON if the switch is NOT being activated and OFF
when the switch IS being activated.
Input Input
PB5 PB5
(not PB5)
18. The NAND Function
• The NAND gate functions like an
AND gate with an INVERTER on
its output.
• The only time that the output of
a NAND gate is a 0 is when all
the inputs are a binary 1.
NAND
Gate
PB6
PB7
Light
Two input NAND gate
19. The NOR Function
• The NOR gate functions like an
OR gate with an INVERTER on its
output.
• The only time that the output of
a NOR gate is a 1 is when all the
inputs are a binary 0.
NOR
Gate
PB8
PB9
LT5
Two input NOR gate
20. The XOR (Exclusive- OR) Function
• The XOR gate has two inputs and
one output.
• The output of this gate is a 1
when the two inputs are
opposite to each other.
Therefore, one input a 1 and the
other a 0.
• The output of this gate is a 0
when both inputs are the same,
either two 0’s or two 1’s.
XOR
Gate
PB10
PB11
LT6
30. Control Description (From ANSI/ISA-5.1)
• Control system design for:
• Small volumes for long and short periods should allow tank to fill to a high level to
automatically start the pump and then to stop the pump at a low level.
• Large volumes for long periods should allow the pump t run continuously and
maintain a fixed level with a level-to-flow cascade control loop.
• Pump (run, or operation) control is selected by a three-position Hand-Off-
Auto (H-O-A) selector switch:
• Selector switch is in “HAND” position.
• Selector switch is in “AUTO” position.
• Pump should be stopped at any time:
• Automatically if low level is exceeded.
• By operation the stop pushbutton.
• Switching the H-O-A selector to “OFF” position.
ISA 5.1 (2009).pdf
32. Functional Diagram Symbols
(*)
Measuring, Input, or Readout Device
[*] = Instrument Tag Number
Symbols from Table 5.5 in the ANSI/ISA-
5.1-2009 Standard
(*)
(*)
Automatic single-mode controller
(*)
(*) (*)
Automatic two-mode controller
(*) Automatic single controller
(*) Manual signal processor
(*) Final control element
Control valve
(*)
Final control element with positioner
Control valve with positioner
33. Binary Logic – AND & OR Gates
A
N
D
OR
A
B
C
A
B
C
Y Y
A
B
A
B Y
AND
OR
A B C Y
0 0 0 0
0 0 1 0
0 1 0 0
0 1 1 0
1 0 0 0
1 0 1 0
1 1 0 0
1 1 1 1
A B C Y
0 0 0 0
0 0 1 1
0 1 0 1
0 1 1 1
1 0 0 1
1 0 1 1
1 1 0 1
1 1 1 1
A
N
D
OR
A
B
C
A
B
C
Y Y
A
B
C
A
B
C
Y
34. Binary Logic – NOT & Memory
A
A
B
C
NOT A A A
S
R D
NOT
Memory
A
A
B
C
NOT A A A
S
R D
A A
0 1
1 0
A B C D
1 0 0 0 1
2 1 0 1 0
3 0 0 1 0
4 0 1 0 1
5 0 0 0 1
6 1 1 1 0
7 0 0 1 0
8 1 1 0 1
35. Electrical Schematic – Ladder Diagram
M1
M2
LSH*02
HS*02-A
HS*02-B LSL*02
M
OL
STOP
START
H
O
A
36. Logic Diagram Example
STARTSTOP COIL OVERLOAD
RELAY CONTACTS
Pump
Stop
Motor Starter,
Pump Motor
Overload
Motor Starter,
Reset Pump
Motor
NOT
S
R
NOT
A
N
D
Pump
Start
Pump
Starts
Electrical
Logic
39. Δ
P I
Δ
P I
TA TA A
T
A
(*)f(x)
FT
*01
LT
*02
FV*01
H
LSH*02
L
LSL*02
A
N
D
A
N
D
HS
*02-B
STOP
NOT
A
N
DHS
*02-A
HS
*01 H-O-A
A
N
D
A
N
D
OR
S
Ro
S
Ro
OL
OL
PUMP
P-1
START
H
A
‘1’ when
NOT at
Low Level
‘1’ when
at High
Level
This diagram literally
sucks – SU QU E
Functional Diagram
40. Δ
P I
Δ
P I
TA TA A
T
A
(*)f(x)
FT
*01
LT
*02
FV*01
H
LSH*02
L
LSL*02
‘1’ when
NOT at
Low Level
‘1’ when
at High
Level
HS
*02-B
STOP
HS
*02-A
START
HS
*01 H-O-A
H
A
M2
M1
OL
Pump
Functional Diagram
45. Summary
• This chapter discussed discrete control (on/off control) in a process
plant.
• Logic diagrams will aid in the understanding of how Safety
Instrumented Systems (SIS) work.
• Functional diagram symbols were discussed along with an example of
how they are used.
• Basic logic gates have been discussed, along with the symbols used to
represent them.
46. References
CEmark.com & European.Authorized-Representative.eu. (1996-2015). What is CE Marking (CE Mark)?
Retrieved June 17, 2015, from Welkang Tech Consulting: http://www.ce-marking.org/what-is-ce-
marking.html
International Society of Automation. (2003). Automation, Systems, and Instrumentation Dictonary (4th ed.).
Research Triangle Park: International Society of Automation. Retrieved from
http://app.knovel.com/hotlink/toc/id:kpASIDE005/automation-systems-instrumentation/automation-
systems-instrumentation
International Society of Automation. (2009, September 18). ANSI/ISA-5.1-2009 Instrumentation Symbols and
Identification. American National Standard. Research Triangle Park, North Carolina: International Society
of Automation.
Kirk, W. F., Weedon, A. T., & Kirk, P. (2014). Instrumentation and Process Control (6th ed.). Orland Park,
Illinois: American Technical Publishers.
Lipták, G. B. (Ed.). (1995). Process Measurement and Analysis (3rd ed.). Radnor, Pennsylvania: Chilton Book
Company.
McAvinew, T., & Mulley, R. (2004). Control System Documentation Applying Symbols and Identification (2nd
ed.). Research Triangle Park, North Carolina, USA: International Society of Automation.
Meier, F. A., & Meier, A. C. (2011). Instrumentation and Control Systems Documentation (2nd ed.). Research
Triangle Park, North Carolina: International Society of Automation.
Thomas, E. C. (2015). Introduction to Process Technology (4th ed.). Boston, MA: Cengage Learning.
Editor's Notes
Introduce the students as to why a Binary Logic System and it’s documents are needed.
Discuss the ISA-5.2-1976 (R1992) and SAMA PMC 22.1 standard and how important elements of them are now in the ISA-5.1 standard. They have been listed in the ISA-5.1 standard because of their importance to the documentation package.
Review these terms with the class. These terms will be needed when further discussing how to read P&ID’s and other instrument and process drawings.
Give some examples of each.
Review these terms with the class. These terms will be needed when further discussing how to read P&ID’s and other instrument and process drawings.
Give some examples of each.
Review these terms with the class. These terms will be needed when further discussing how to read P&ID’s and other instrument and process drawings.
The students should be somewhat familiar with PV and CV from the home heating exercise that was done in a previous chapter.
Give some examples of each.
Discuss the four basic documents as listed on this slide. Mention that these are listed and described in Annex B of ANSI/ISA-5.1-2009.
Process Description
Title – Provide a title for the control system being documented
General Description – A written description of what the system does including system limits (Where in the document starts and ends in the system). A description of the major equipment is provided and how this equipment is suppose to work. Discussion should include the conversion of material inputs to the product output. If this is a design project, the scope of the project should be included.
Form – The process description is an executive summary. It should be assumed that a large number of people will be reading the document and will need to understand its content. Setpoints and ranges for loops should not be included in this document. The overall system range and limits should be listed.
Control Description
System operation in more specific form and data.
A detailed loop-by-loop description should be provided.
Format – This is a well written section that contains specific logic steps or modules in the program. Some process, process control and/or experience is typically required to read this section.
Addition information that can be included:
P&ID drawing number references
A list of motors and interlocks
A list of analog and discrete loops affected by the on/off control elements
Open the file “ISA 5.1 (2009).pdf” and review the simple control description in Annex B, Paragraph 13 of the ANSI/ISA-5.1-2009 standard. Clicking the link on the slide will open a PDF with only the simple process description from paragraph 13.
Then review the Instrument Diagram, Functional Diagram and the electrical diagram. For the Functional Diagram, slides are included that define Functional Diagramming Symbols.
Review this Instrument Diagram and how it relates to the simple process description in Annex B, Paragraph 13 of the ANSI/ISA-5.1-2009 Standard.
Review the Functional Diagram Symbols and their meaning according to the ANSI/ISA-5.1-2009 Standard
Discuss the operation of the AND and OR gates and the various symbols that represent them. There are other symbols and they could/should be mentioned; however, the Functional Diagram Symbols are the important ones at this time.
Discuss the operation of the NOT gate and Memory and the various symbols that represent them. There are other symbols and they could/should be mentioned; however, the Functional Diagram Symbols are the important ones at this time.
Output C and D are always opposite
If input A = 1 then output C = 1 and output D = 0
If input A changes to 0, output C remains 1 until input B = 1 then output C = 0 and output D = 1
If input B= 1 then output D = 1 and output C = 0
If input B changes to 0 output D remains 1 until input A = 1 then output D = 0 and output C = 1
If inputs A and B are simultaneously = 1 then outputs C and D change state
Discuss the relationship between the Instrument Diagram, the Functional Diagram and the Ladder Diagram and how they all describe the basic process description in paragraph 13.
Review the logic example on this slide.
The electrical ladder logic requires that the overload relays are closed, the Stop push button is closed and the Start push button is pressed to get the motor to start. If the Stop push button is pressed or if either one of the overload relays open the circuit is interrupted and the motor coil is de-energized stopping the motor.
The Logic diagram shows the same function. The diagram shows a 3-input AND gate with the output controlling the pump motor. All 3-inputs of the AND gate must be true (a logic 1) for the pump motor to start. The Start push button is normally open in the field and when the operator presses it, it closes placing a logic 1 on the top input of the AND gate. The Stop push button is normally closed in the field and is depicted as a push button with a NOT gate. In this case, the NOT gate is creating a logic 1 at the center input of the AND gate when the Stop push button is not being pressed. The memory logic has the 2-overload relays as the top input (S) and the motor starter reset as the bottom input (R). When both of these overloads are closed, a logic 1 is on the input side of the Memory. This creates a logic 0 out and therefore under normal operating conditions, the NOT gate is required to get a logic 1 on the bottom input of the AND gate.
If a small letter o is placed around or next to the S in the Memory it means that the Overload overrides the Motor Reset. This means that if the overload(s) opens, the motor will not start with the reset.
Review the correlation of this Functional Diagram to the simple process description and the Instrument Diagram. Be sure to show the student that they represent the same process description.
Review the correlation of this Functional Diagram to the simple process description and the Instrument Diagram. Be sure to show the student that they represent the same process description.
Draw the ladder logic on the white board and then convert it to logic gates.
On the white board, convert this ladder logic to logic gates.
On the white board, convert this ladder logic to logic gates.
On the white board, convert this logic to a rung of ladder.