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ISAThe Instrumentation, Systems, and Automation Society
Automation
Introduction to Marine Automation
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ISAThe Instrumentation, Systems, and Automation Society
Learning Objectives
Define what is meant by Instrumentation
Define: Process control Measurement Accuracy Repeatability Resolution Hysteresis Sensitivity Precision Reproducibility
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ISAThe Instrumentation, Systems, and Automation Society
Learning Objectives
Explain the three (3) variables involve in process control Manipulative variable Disturbance Controlled variable
Describe simple process control loops using a blockdiagram
Explain the difference between open and closed loop
State the essential requirement for automatic operationof machinery
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ISAThe Instrumentation, Systems, and Automation Society
Short History of Instrumentation and
Control
3 BCfloat valve on a water clock is the first control devicerecorded being used
1750-1850Scottish Engineer James Watt devised the flyball
governor for steam engine was the 1
st
significant controlinvention
1850-1900 - Siemens invented first dynamo machine. BrownInstrument Co., Honeywell and Fisher governor companies wereestablished
1900-1920Ervin Bailey invents Bailey Boiler Meter,pneumatically operated instruments are made available and On-off controllers are widely used in the process industry
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Short History of Instrumentation and
Control (Continued)
1920-1940
Bailey Controls introduces the 1stmulti-pointer guage and installs1strecording instrument on a marine boiler.
Leeds & Northrup introduces the 1stconductivity recorder andpioneered the development of glass pH electrodes.
Foxboro begins marketing the 1stproportional plus resetrecorder/controller. Instrumentation grows with over 600companies selling instruments.
Taylor Instrument Co. markets its Model 56R the 1stadjustableproportional controller.
Leeds & Northrup introduces the first conductivity gas analyzer
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ISAThe Instrumentation, Systems, and Automation Society
Short History of Instrumentation and
Control (Continued)
1940-1960 Coleman B. Moore fouds Moore Products. G.B.
Hoadley receives a patent or LVDT.
Lead sulphide infrared detectors are develop by Gudden inGermany.
Taylor Instruments develops the Fulscope 100 which has threerespnse sensitivity, automatic reset and a pre-act (PID).
John Ziegler and Nathaniel Nichols of Taylor Instruments developthe Ziegler-Nichols method of basic controller tuning.
The ISA was born.
First all-electronic instrument was manufactured by Foxboronamed Dynalog.
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ISAThe Instrumentation, Systems, and Automation Society
Short History of Instrumentation and
Control (Continued)
1940-1960
Miniature pneumatic controls were develop.
Computers were use in instrumentation and controls.
Electro-magnetic and ultrasonic flowmeters weredevelop.
Capacitance pressure sensors was develop andBeckmen Instruments markets the 1stgas
chromatograph. The 1sttransistorized temperature controller was
develop by Honeywell.
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ISAThe Instrumentation, Systems, and Automation Society
Short History of Instrumentation and
Control (Continued)
1960-Present
Solid state electronics experience tremendous growth whilepneumatic controllers lose their dominance in the market.
Computers are used more often for industrial applications. The vibrating viscocity meter is develop by Tough, McCormick
and Dask.
Bailey install 1stautomated boiler control system aboard the S.S.
Wiliam G Mather and the S.S. CapeBreton Miner. Fuzzy logic was termed and applied. Micro-miniaturization
started a revolution in the manufacturing industry.
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Short History of Instrumentation and
Control (Continued)
1960-Present
Chance Pilkington release 1stfiber optic and HP introducesLEDs.
Honeywell begins development of DCS.
Maturation of computer technology dramatically advances thefield of instrumentation and control.
Masoneilan revolutionizes control valves with the invention of theCamflex the 1stgeneral rotary stem valve.
First in-situ oxygen sensor was introduced by WestinghouseElectric.
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ISAThe Instrumentation, Systems, and Automation Society
Short History of Instrumentation and
Control (Continued)
1960-Present
Honeywell and Yokogawa introduced the 1stindustrial applicationof distribution digital electronics in process control.
Texas Instruments markets the 1stPLC with true processcapabilities.
Applications of microprocessors, telemetry, ultrasonics andmodeling techniques lead to major advances in biomedical
instrumentation.
Leeds & Northrrup develops the 1stself-tuning automaticcontroller and fiber-optic data highway.
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ISAThe Instrumentation, Systems, and Automation Society
Short History of Instrumentation and
Control (Continued)
1960 to Present
Honeywell introduces the St 3000 Smart transmitters.
USDATA introduces FactoryLink the 1stPC-based
application enabler software product for SCADA. FieldBus becomes the talk of the town.
SAAB tank Control pioneers a new non-contact radarmethod measurement for levels of liquid in LPG and
LNG tanks. ISO 900X certification for Instrumentation
Manufacturers
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Properties of Matter
Physical Propertiesthe qualities of substances usuallyidentified to our senses of sight, sound, smell, touch andtaste Color Smell Insolubility
Chemical Propertiesdefined as how a substance
reacts during chemical change Oxidation (rust) Reduction Corrosion
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Matter
Elementsa substance that cannot be broken downinto simpler chemical form
Atomthe smallest possible quantity of an element
Moleculesare the smallest quantity of a materialmade up of multiple atoms/elements that still retains theproperties of that substance
Molecules can be broken down chemically in toelemental atoms that have completely differentcharacteristics from the original molecule
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Matter
No matter what form , all molecules within a substance are inconstant motion
The higher the level of energy the higher the motion
The amount of space that a substance occupies is called volume
Solids have a definite shape and definite volume
Liquids have a definite volume but do not have a definite shape
Gasses do not have a definite volume and do not have a definite
shape. Its volume and shape is defined by its container Fluids is a liquid or a gas substance that can flow
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Energy
Energy is define as the capacity to do work
Potential energy is energy due to position
Kinetic energy is energy of motion
Kinetic energy of a process fluid can be determined bymeasuring its flow rate
Internal energy comes from the motion of molecules
within the material Internal energy will flow from a warmer body to a cooler
body until equilibrium is reached
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Measurement
Regardless of its use, every measurement musthave a number and a unit or label to have ameaning
Measurement are made by comparingsomething to a scale
Industry around the world uses either English,Metric or International System of units (SI).
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efinitions Instrumentat iona collection of instruments
or their applications for the purpose ofobservation, measurement or control (ISA)
Measurementis the extraction of signalsfrom physical and chemical systems orprocesses which represents parameters orvariables
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efinitions Process
a natural progressively continuing operation ordevelopment marked by a series of gradualchanges that succeeds one another in a relativelyfixed way and leads towards a particular result or
end (Webster) consist of an assembly of equipment and material
that relates to some manufacturing operation orsequence (ISA)
Process Contro l is a technique of balancing supply and demand
over a period of time at a pre-determined level ofoperation called set point
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efinitions Accuracy
conformity of an indicated value to an acceptedstandard value or true value
Repeatabi l i ty the closeness of agreement among a number ofconsecutive measurements of the output for the
same value of input under identical operatingconditions
Resolut ion the smallest interval between two adjacent
discrete details which can be distinguished onfrom the other
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efinitions Hysteresis
the maximum difference obtained as an output forthe same input between the upscale anddownscale output values during a full rangetransverse in each direction
Sensi t iv i ty the ratio of change in output to the change in
input magnitudes
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The Instrumentation, Systems, and Automation Society
efinitions Precis ion
the closeness of agreement between test results
Reproducib i l i ty the ability of a system of elements to maintain its
output/input precision over a relatively long periodof time
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The Instrumentation, Systems, and Automation Society
Examples of a Process:
1. Mixing of fluids.
2. Heating or cooling of substances.
3. Pumping out of water.
4. Canning food.
5. Deriving gasoline from crude.6. Many more..
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The Instrumentation, Systems, and Automation Society
Difference between a
Systemand a Process:Often in the past, the term process wasapplied to a plant, that is, to the process
itself as well as all of the piping, valves,and equipment need to manufacture aproduct. In order to use the term
accurately, process should describe whatis occurring within a system.
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The Instrumentation, Systems, and Automation Society
Process Variable
Instrumentation systems are a group ofinstruments or their application for thepurpose of observation, monitoring, or
control The system has the necessary
measurement and control components to
maintain the process within the properlimits. In most cases, process parametersare referred to as Process Variables.
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The Instrumentation, Systems, and Automation Society
Process Variable
A variable is a property of a substance that may change
The devices used to measure and control process variables are calledprocess instruments
A measuring instrument may: Determine if a particular process variable exist in a material Determine value for that material
A control instrument may: Cause a variable to be maintained at a set value or within set limits
Cause a change in the process that changes the value of thevariable in a known way Cause another mechanism such as a valve to control process
variable
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The Instrumentation, Systems, and Automation Society
Process Variable
A variable is a property of a substance that may change
The devices used to measure and control process variables are calledprocess instruments
A measuring instrument may:
Determine if a particular process variable exist in a material Determine value for that material
A control instrument may: Cause a variable to be maintained at a set value or within set limits Cause a change in the process that changes the value of the
variable in a known way Cause another mechanism such as a valve to control process
variable
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The Instrumentation, Systems, and Automation Society
Typical Process iagram
MANIPULATIVE
VARIABLE
CONTROLLED
VARIABLEPROCESS
DISTURBANCE
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The Instrumentation, Systems, and Automation Society
Simple Process Control Loop
CONTROLLER
CONTROL ELEMENT
MEASUIREMENT
PROCESS
DISTURBANCES
INPUT
SET-POINT
OUTPUT
Dist rbances
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The Instrumentation, Systems, and Automation Society
PROCESSinput output
Disturbances
FCE
PrimaryMeasuring
Element
Secondary
Element
Feedback(control loop)
Correction
Comparison
Measurement
The figure shows the relationship of the 4 Basic Functions of an
Automatic Control System and its 3 Control Elements
Computation
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The Instrumentation, Systems, and Automation Society
Elements of a Control Loop
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The Instrumentation, Systems, and Automation Society
Elements of a Control Loop
Measurementconversion of the process variable in toan analog or digital signal that can be use by the controlsystem
Evaluationmeasurement value is examined, comparedwith a desired value or set-point, and the amount ofcorrective action needed to maintain proper control isdetermined
Controlis the device in the control loop that exerts directinfluence on the process or the manufacturing sequence
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1. SELF REGULATING
HOT H2O
COLD H2O
STM HEATER
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The Instrumentation, Systems, and Automation Society
2. MANUAL CONTROL W/ INDICATING
INSTRUMENT
HOT H2O
COLD H2O
STM HEATER
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3.AUTOMATIC CONTROL
HOT H2O
COLD H2O
STM HEATER
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The Instrumentation, Systems, and Automation Society
Pneumatic Control Systems
Less expensive initially in spite of tubing and air supplycost
No heat generation and safe in explosive atmosphere
Less susceptible to power supply variation but do havetime lag
Direct applications, without transducers to large finalpower actuators
Simple system design Short commissioning and set-up period
Higher maintenance cost
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The Instrumentation, Systems, and Automation Society
Pneumatic Control Systems
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The Instrumentation, Systems, and Automation Society
Hydraulic Control Systems
Similar to the advantages of pneumatic controlsystems
More appropriate for high pressure, power or work
requirements
Generally more restricted in application
Requires hydraulic oil compared to pneumaticswhich uses air which is free
Recovery-storage system is required for notallowing fluid to escape
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The Instrumentation, Systems, and Automation Society
Hydraulic Control Systems
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The Instrumentation, Systems, and Automation Society
Electro-Technical Control System
Small and adaptable with cheap flexible transmissionlines
No moving parts, can however generate heat
Stable, generally accurate and very short time lag Low power consumption, direct application to
computers, but often need final control element ortransducers
Lower maintenance cost Better suited for long distance transmission
Superior dynamic response
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Definitions
Digital A term applied to a signal or device that uses binary
digits to represent continuous values or discretestates
Analog A term applied to a physical signal or variable which
remains similar to another variable in so far as theproportional relationship are the same over some
specific range (McGraw-Hill Dictionary) a signal or a device that represents a variable which
may be continuously observed or continuouslyrepresented over a range
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Difference Between Analog and
Digital DeviceAnalog
Takes an infinite numbervalues
More accurate in reproducinga quantity, variable or signal
May be transmitted overgreater distance but subjectto energy loss
Operator error is more likely
Instantaneous representationof measured variable
Digital
Variables are limited todefined states
Less susceptible to noise
May be transmitted over longdistance at greater efficiency
Operator error is less likely
Conversion of signal mayincur error depending onsampling rate
Uses Binary Number system