Chapter1-Basic Concepts of Measurements

EEB 5223/EAB4223EEB 5223/EAB4223Industrial Automation and Control Industrial Automation and Control SystemsSystemsyy• Process/Industrial Instrumentation and

Measurements• Automation• DCS and Fieldbus

Dr. Rosdiazli IbrahimDepartment of Electrical & Electronics Engineering Department of Electrical & Electronics Engineering Universiti Teknologi PETRONAS22.03.22Email: [email protected]

Topic 1.1Topic 1.1-- 11EEB5223/EAB4223 Industrial Automation & Control Systems

p yTel: 05-368 7821

1. Basic Concepts of Measurement System

Topics-Part 1: TopicsTopics--Part 2:Part 2:1. PLC: Featuresp y

2. Calibration3. Temperature Measurements4. Pressure Measurements

2. PLC programming languages: IEC1131

3. Sequential/batch/ 5. Flow rate Measurements6. Level Measurements7. Loop drawing/connections TopicsTopics--Part 3:Part 3:

continuous processes

p g/1. DCS2. Fieldbus

Assessments:

•50% - Final examination

•20% - Test (10% X 2).

•10 % - Assignments (5% x 2).

•15% - Lab reports: Each from Part 1 & 2


•15% - Lab reports: Each from Part 1 & 2.

•5% - Quizzes

The course syllabus is designed to provide students in the key and base areas of industrial automation, using mixed-mode delivery comprises of lecture-tutorial-lab activities that covers the technical, theory and practical.

This course cover topics related to measurements (PLTF) d t ti i th i d t Th i l d

SynopsisSynopsis Learning OutcomesLearning Outcomes

h d d hi f(PLTF) and automation in the process industry. These include a study on industrial sensors and actuators, industrial controllers such as computer-based control, PLC, DCS and FF.

that students are expected to achieve after successfully completing the course

The learning outcomes related to Industrial instruments and

The learning outcomes related to Automation and the implementation of

The learning outcomes related to DCS and Foundation Fieldbus use

Process , Industrial Instr.& Meas.Process , Industrial Instr.& Meas. AutomationAutomation DCS and Foundation FieldbusDCS and Foundation Fieldbus

Measurements

• Have knowledge and understanding of the various process industry instruments, concept of measurements, calibration and

Programmable logic controller

• Have knowledge and understanding of the PLC architecture and its i t i t ti

in process industries.

• Have knowledge and understanding of a DCS and its

i i d t i d th,configuration requirements and their applications.

• Be able to design and develop a control loop consisting the process instruments based on a prescribed

importance in automation.

• Be able to develop a PLC program to perform sequential, and batch control.

use in process industries, and the features and architecture of a Foundation Fieldbus system, and its improvement over the conventional DCS.


instruments, based on a prescribed requirement.

Learning OutcomesLearning OutcomesTo achieve the following Learning Outcomes:

Have knowledge and understanding of the various process

Assessment CriteriaAssessment Criteria

Assessment criteria:• Have knowledge and understanding of the various process

industry instruments, the concept of measurements, calibration and configuration requirements and their applications.

• Be able to design and develop a control loop consisting the i t t b d ib d i t

To demonstrate student has achieved the learning outcomes

• Describe the measuring principles, calibration and configuration requirements of different process industry instruments and their applications.

process instruments, based on a prescribed requirement.

.• Design and develop a control loop using the relevant

instruments to meet specifications

Assessment criteria:• Basic concepts of measurements

Lab experiences• Calibration,

fi i f

Assessment criteria:• Signal Conditioning

Process , Industrial Instrumentation & MeasurementProcess , Industrial Instrumentation & Measurement

• Process control terminologies

• Calibration

configuration of transmitters, controllers, recorders and other peripherals, wiring, selection

• P,T,L,F to mA, V

• V-V,V-mA,mA-V

and installation.

• Design and implementation of a simple control loop.

Assessment criteria:• Applications and selections of sensors and actuators

used in industries

• Pressure Level Temperature Flow

Assessment criteria:• Design and implement a simple control

loop.



Have knowledge and understanding of the PLC architecture

Assessment CriteriaAssessment CriteriaAssessment criteria:To demonstrate student has achieved the learning• Have knowledge and understanding of the PLC architecture

and its importance in automation.

• Be able to develop a PLC program to perform a sequential, and a batch control.


• Describe and discuss the architecture and input-output features of a PLC, and its importance in automation.

• Develop, design, and use the appropriate instructions t it t f ifi t k i ti l

.

.

to write a program to perform specific task in particular sequential process in automation/process plant, and a batch process.

Hardware structure of a PLC

• PLC architecture: CPU, I/O modules, peripheral i

Lab experiences• Sequential control,

l i

Sensors and actuators for automation

AutomationAutomation

equipments.

• Review PLC internal architecture: Timers, counters, arithmetic function, and logical operation.

• Advanced instruction sets.

electropneumatic systems, conveyor belt systems.

• Design and implementation of PLC system in

• Applications and selections of sensors and actuators used in industries

PLC system in automation/process control.Software structure of a PLC

• PLC internal architecture: Timers, counters, arithmetic function, and logical operation.

Ad anced inst ction sets

Programming

• Programming sequence function charts and Grafcet.

• Implementation of PLCs for


• Advanced instruction sets. Implementation of PLCs for sequential/batch control


Assessment CriteriaAssessment CriteriaAssessment criteria:To demonstrate student has achieved the learning

• Have knowledge and understanding of a DCS and its use in process industries, and the features and architecture of a Fieldbus system, and its improvement over the conventional DCS


• Explain the structure of a DCS and its use in process industries, its benefits and limitations.

• Describe the various components of a typical fieldbus hit t th t l fi ti d it

.

.

architecture, the control configurations and its improvement over the conventional DCS architecture.

DCS & Foundation FieldbusDCS & Foundation Fieldbus

MMI

• Explain the man-machine interface and the features of a control room.

DCS

• Describe the structure of a DCS and its use in process plant and other industries.

Fieldbus

• Describe the overall layout of a fieldbus system used in industry.

control room. plant and other industries.

• FF Topologies

• Interoperability, Reliability

• CIF


• Simple implementation example

References:

h ” lCurtis D. Johnson,”Process Control Instrumentation Technology”, Pearson.

D ll Ril & M C ll “I t t ti f Dally, Riley & Mc Connell, “Instrumentation for Engineering Measurements”, Wiley

E O Doebelin “Measurement Systems Application E. O. Doebelin, Measurement Systems Application and Design”, Mc Graw Hill.


Lab Part 1 (week 2- 7):Lab Part 1 (week 2- 7):•Process Instrumentation for T,P,L,F, using single station controller, recorder, transmitter etc.station controller, recorder, transmitter etc.

•Design and implementation of a simple control loop

Lab Part 2 (week 8 11):Lab Part 2 (week 8- 11):•PLC for sequential control – conveyor belt system, electropneumatic actuatorselectropneumatic actuators.

•Design and implementation of PLC in automation


Emphasize learning through the accessibility to lab-based activities using real instruments, formal reports and continuous assessments...

Calibration of transmitters (T)

Electro-pneumatic

Conveyor belt system

& PLC

Lab Briefing & Grouping

Calibration of transmitters

(P L F)

Configuration of Controller &

Recorder

LOOP design & interconnection

pneumatic actuators & PLC

Grouping (P, L, F) interconnection

1 w

eek

1 w

eek

3 w

eeks

2 w

eeks

2 w

eeks

TEST 1 TEST 2

ASSIGNMENT 1 ASSIGNMENT 2

Formal Lab Report Formal Lab Report


Calibration, Configuration

and Loop design

Formal Lab Report PLC and

Electropneumatic systems

Concepts of MeasurementsConcepts of Measurements

Basic Concepts of Measurement Systems

Obj i f• Objective of measurements

To establish the value or the tendency of someTo establish the value or the tendency of some variable based on the value or the tendency suggested by the measurement device.

• General Measurement SystemA measurement assigns a specific value to a physical variable measured variables


variable, measured variables.

A Measurement System

Sensor Stage

TransducerStage

SignalConditioning

Control Stage

ProcessOutputStage

Process


A general template for a measurement system

Components for Measurements

• Sensor


– Sensor is a physical element that uses some natural phenomenon to sense the variable being measured

– Sensor selection, placement, and installation are , p ,particularly important, because the input to the measurement system is the information sensed by the sensor

– The interpretation of all information passed through and indicated by the system depends on that which is actually sensed by the sensor



Transducer– The transducer converts the sensed information into

a detectable signal form, such as electrical, g , ,mechanical, optical or otherwise

– Convert the sensed information into a form that can be easily quantifiedy q

– The term “transducer” often used in reference to a packaged device, may contain a sensor, transducer, and even some signal conditioning elementsg g


Components for MeasurementsComponents for Measurements

• Signal Conditioning– It will take the transducer signal and modifies it to a desired

form– This optional intermediate stage might be used to perform

task such as• to increase the magnitude of the signal through g g g

amplification• to remove some portions of the signal through some

filtering techniqueg q• to provide mechanical/optical linkage between transducer

and output stage



• Output stage– This stage provides an indication of the value of the g p

measurement. – The equipment might be a simple readout display or a marked

scale or it might contain a device that can record the signal for g glater analysis.



• Control stage– This stage contains a controller that interprets the measured

signal and makes a decisions regarding the control of the process.

– This decision results in a change in a process parameter that effects the magnitude of the sensed value


In process controlIn process control …

• Puts emphasis on the four (4) major control variables in process control, P,L,F,T needed for implementation of automatic control.implementation of automatic control.

• Allows the application of transmitters, controller, and recorders in the control loop to achieve a required

lcontrol.• Allows investigation on the limitations of

instruments for process control and the importance instruments for process control, and the importance of correct measurements, in a control system.


Signal conditioning : Digital I/OsSignal conditioning : Digital I/OsSignal conditioning : Digital I/OsSignal conditioning : Digital I/Os

Output terminal4-20mA

DCS

Output terminalblock

To clientPC

24VDC

Digital output fromDCS

24VDC

alve Open command

Digital inputto DCS

24VDC

Input terminalblock

24VDC24VDC


Signal conditioning : Analog I/OsSignal conditioning : Analog I/Os

DCS

Signalconditioner

Input terminalblock

To clientPC

4-20mA

Pressure transmitter

0-10V4-20mA

Flow transmitter

4-20mA

SignalO t t t i l

Temperature transmitter

4-20mA

DCS

Signalconditioner

Output terminalblock

To clientPC

0-10V4-20mA

4-20mA

Control valve 14-20mA

Topic 1.1Topic 1.1-- 1919EEB5223/EAB4223 Industrial Automation & Control SystemsControl valve 2

S l i f P ISelection of Process Instruments

The influential factors that determine the selection of process instruments

• Size or Range

pfor process plant

• Certification by Government A i• Operating Conditions

• Cost• Compatibility

Agencies• Maintenance Capability• Confidence, Known Past

P fp y

• Standardisation• Delivery• Life Expectancy

Performance• Design Features• Supplier Backup. Credibility


p y

End of Lecture notes on Basic Concepts of Measurements

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Chapter1-Basic Concepts of Measurements

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