The document discusses the fundamentals of instrumentation and control (C&I) in process industries, emphasizing the importance of automation for safety, efficiency, and productivity. It outlines various instruments and systems used for measuring and controlling physical parameters such as pressure, flow, temperature, and level, as well as components like sensors, controllers, and valves. Additionally, it covers control system definitions, operation principles, and various calibration and communication protocols in industrial applications.

1. Basics of Instrumentation
& Control
Shridhar A.Kulkarni
C&I Engineer

2. General introduction to C&I
Now a days all the process industries are going
for automation for safe and efficient operations to achieve
maximum productivity and to maintain quality.
There are many advanced instruments and
automation techniques have come-up due to the innovative
research and development made in this field.
As the name itself tells us that C&I is
responsible for smooth operation, control and
maintaining of the process parameters in a
production area through various instruments.

3. This is a technique to measure certain field
parameters or physical variables. Such as
 Pressure: Static or Differential
 Flow
 Temperature
 Level
 Density and Viscosity
 Electrical Variables
 Chemical Properties and compositions.
 Vibration and Speed.
What is an Instrumentation.

4.  Efficient operation of the plant.
 Economic operation of the plant.
 Safe operation.
 Pollution Control.
 Correct utilization of Manpower.
Objectives of Instrumentation &
Control

5.  Measurement
 Control
 Operation
 Monitoring
 Protection
Instrumentation System Includes

6.  Very Accurate
 Reliable
 Delays should be as small as possible.
 Should be switched on manually when a
overall control system fails.
Plant Measurement system and user
Requirements:

7.  A Transmitter which responds to a measured
variable by means of a sensing element, and
converts it into a standardized transmission signal.
 A Solenoid Valve is a Primary Device used to
ON/OFF the Pneumatic or Hydraulic Valve.
 A Limit Switch is used to detect the position of
any physical part of the machinery or position of
valve stem.
Briefly about some instruments

8. Pressure:
Pressure Gauge:
Bellow type PG

9. Pressure Transmitters:

10.  Temperature gauges
 RTDs( 260 to 50 °C)
−
 Thermocouple(-180 to 1700 °C)
 Thermistors(-20 to 120 °C)
Temperature Measurement
instruments

11.  Magnetic Flow metes
 Ultrasonic Flow meters
 DP type Flow meters/Transmitters
 Vortex Flow meter
 Positive Displacement
 Mass flow meter
Flow:

12.  DP type Level transmitters
 Ultrasonic Level transmitters
 Displacer type Level transmitters
 Radar type Level transmitters
Level:

13. Level Switches: RF type
Works on oscillation differences

14. Control Features
 Speed Control
 Auxillary Control
 Extraction/Admission Control
 Valve Limiter
 TWO Actuators
 Remote communication
 Overspeed protection
 PC based programmable software
Governor- Woodward 505E

15.  Non contact Vibration and Displacement
Sensors.
Vibration:

16. Fig: Water analysis instruments
pH,ORP,Conductivity:

17. Oxygen analyzer
The zirconium dioxide, or zirconia sensor is based on a solid-state
electrochemical fuel cell. Its two electrodes provide an output voltage
corresponding to the quantity of oxygen in the flue gas.

18.  Zero speed switches
 Belt sway switches
 Pull cord switches
Conveyor Safety Switches

19. A control system can be defined as an interconnection of
several components all working together to perform a
certain function. In most cases this function is the control of
physical variable, such as temperature, voltage, frequency,
flowrate, current, position, pressure, speed, illumination,
altitude etc., These are called controlled variables.
 Regardless of what type of control system we have, the
basic ingredients of the system can be described by
 Objectives of the control
 Control system components
 Results
Control System

20. Basically Control System consists
Control System
 Sensors
 Transducers
 Medium
 Controller
 Final Control Element
Controllers provide the required control action to position the FCE
at a point necessary to maintain the PV at the desired SP.
PV – Process Value
SP – Set Point
MV – Manipulated value

21.  Sensor: A device for sensing a physical variable in
the Process or environment.
 Transducer: One form of signal into another form.
 Medium: Through which the signal is passing.
Ex: Fiber optic cable, Co axial cable.
 Controller: Gets Feedbacks and Gives an Output
and Controls Process variables as per
requirements.
 Final Control Element: Receives signal from
Controller and changes or makes corrections in the
process. Such as control valve.
Definitions

22. Block Diagram of the Control System

24.  Analog Input Signals(4-20 mA in)
 Analog Output Signals(4-20 mA Out)
 Digital Input Signals(0 and 1 in)/ON&OFF
 Digital Output Signals(0 and 1 out)/ON&OFF
Signals:

25.  Pneumatic Control Valves:
 Motorised Valves:
 VFDs.
Final Control Elements

26.  Valve Body
 Actuator
 Air Filter Regulator
 Air Lock Relay
 Positioner
 Solenoid Valve(For on/OFF only)
Pneumatic control valve:

27.  A Positioner is like a proportional controller. The
set point is the control signal from the primary
controller and the controlled variable is the
valve position.
 The Positioner compensates for disturbances
and nonlinearities.
 It can be used to reverse the action of the
actuator from air to open to air to close and vice
versa.
 To minimize the response time for the valve.
Positioner

28. TYPES OF CONTROL VALVES
Depends on the construction, the valves are classified in
different names. Valves are classified into two general types based on
how the valve closure member is moved: by linear motion or rotary
motion.
The types of the valves as follows:
• Globe valves /
• Butterfly valves
• Ball valves
• Gate valves
• Slide valves
Based on Valve Operation:-
1. Air Fail to Open
2. Air Fail to Close
3. Stay put (Air fail to Lock in the same Position.)

29.  Relays and Contactors.: Hard wired logic.
 Controller Algorithm/PID Controller: Controller to
control a Single loop.
 PLC: Programmable logic controller.
 SCADA: Supervisory control and data acquisition
system.
 DCS: Distributed control systems.
Controlling Masters:

30. DCS

31.  Power Supply module
 Controllers(FCS)
 Interfacing Modules
 Input output modules
 Remote node Communicators.
 HIS/HMI
 Ethernet Switches/D links
DCS Consists of

32. DCS: Yokogawa Centum VP.

33.  Single chair control.
 Online changes can be done.
 Low maintenance cost.
 Protections for safe operation of the plant.
 Sequence logics to avoid Jamming.
 Interlocking for smooth operation of the plant.
Advantages of DCS

34.  Calibration: The process of adjusting an instrument or compiling a
deviation chart so that its reading can be correlated to the actual value
being measured.
 Accuracy: The closeness of an indication or reading of a
measurement device to the actual value of the quantity being
measured. Usually expressed as ± percent of full scale.
 Error: The difference between the value indicated by the transducer
and the true
value of the measurand being sensed. Usually expressed in percent of
full scale output.
 Repeatability: The ability of a transducer to reproduce output
readings when the
same measurand value is applied to it consecutively, under the same
conditions, and in the same direction. Repeatability is expressed as the
maximum difference
between output readings.
 Range: Those values over which a transducer is intended to measure,
specified by its upper and lower limits.
Calibration

35.  What is HART?
 HART ("Highway Addressable Remote
Transducer") is a communication protocol
designed for industrial process measurement
and control applications.
HART COMMUNICATOR

36. HART

37. Dead weight tester:
A dead weight tester (DWT) is a
calibration standard method that uses a
piston cylinder on which a load is
placed to make an equilibrium with an
applied pressure underneath the
piston.

38. Druck calibrator

39. Temperature Calibrator

40. Automation in plant is like a Man
with so many eyes and so many
hands.
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