Basic understanding and concept Industrial Process Control-1

Student Course Workbook
Presented by:
Honeywell Automation College
2500 West Union Hills Drive
Phoenix, AZ 85027
800-852-3211
FAX [phone]
www.automationcollege.com
5725

Notices and Trademarks
Copyright 2000 by Honeywell International Inc.
Revision 03 Date March 2003
Honeywell International Inc courseware is subject to change without notice.
FLEXTRAINING courseware is copyrighted and all rights are reserved by Honeywell International Inc.
These materials are intended solely for use in conjunction with Honeywell products. The materials
comprising the courseware may not, in whole or in part, be copied, photocopied, reproduced,
translated, or reduced to any electronic medium or machine-readable form with out the prior,
express written consent of Honeywell International Inc.
FLEXTRAINING , Honeywell and TotalPlant are trademarks of Honeywell
International Inc.
Other brand or product names are trademarks of their respective owners.
This module supports TotalPlant Solution (TPS) system network.
TPS is the evolution of TDC 3000X.
The information contained in this workbook consists of facts, concepts, and principles of
processes. Honeywell Automation College assumes no liability for the information
beyond its intended purpose of providing general information about troubleshooting.
DO NOT attempt to operate any plant, unit, process, system, or equipment based solely
on the information provided in this workbook. Refer to the appropriate operating
procedures, equipment descriptions, operating limits, safety and health considerations,
etc.
Honeywell
Industrial Automation and Control
Automation College
2500 W. Union Hills Drive
Phoenix, AZ 85027
www.automationcollege.com
1-800-852-3211 FAX: [phone]

Contents
PROCESS CONTROL FOR OPERATORS.............................................................................................................1
COURSE OBJECTIVE....................................................................................................................................................1
COURSE INTRODUCTION .............................................................................................................................................1
LESSON 1 INTRODUCTION TO PROCESS CONTROL ...................................................................................3
LESSON OBJECTIVES ..................................................................................................................................................3
BASIC CONCEPTS OF PROCESS CONTROL ...................................................................................................................3
Basic Instrumentation............................................................................................................................................5
Transmitters......................................................................................................................................................................... 5
Transducers ......................................................................................................................................................................... 5
Valves.................................................................................................................................................................................. 5
Dampers............................................................................................................................................................................... 5
Motors ................................................................................................................................................................................. 5
Characteristics of Instruments...............................................................................................................................6
Static Characteristics ........................................................................................................................................................... 6
Dynamic Characteristics...................................................................................................................................................... 6
INSTRUMENTATION DIAGRAMS AND SYMBOLS ..........................................................................................................7
The Identification System.......................................................................................................................................7
General ................................................................................................................................................................................ 7
Functional Identification...................................................................................................................................................... 8
Loop Identification ............................................................................................................................................................ 10
Symbols............................................................................................................................................................................. 10
P&IDs..................................................................................................................................................................14
Control Diagrams................................................................................................................................................15
LESSON SUMMARY...................................................................................................................................................22
LESSON 2 TEMPERATURE MEASUREMENT AND CONTROL ..................................................................23
LESSON OBJECTIVES ................................................................................................................................................23
INTRODUCTION: EVIDENCES OF HEAT......................................................................................................................23
Example: Change 77qF to qC............................................................................................................................................ 24
Changing from Celsius to Fahrenheit scale. ...................................................................................................................... 24
Example: Change 10qC to degrees Fahrenheit.................................................................................................................. 24
SENSORS...................................................................................................................................................................26
Mechanical Sensors.............................................................................................................................................27
Chemical Sensors ................................................................................................................................................28
Electrical Sensors ................................................................................................................................................28
Principle of Operation.........................................................................................................................................29
Thermistors..........................................................................................................................................................30
Thermocouples.....................................................................................................................................................31
TWO BASIC LAWS OF THERMOELECTRICITY ............................................................................................................32
Law of Intermediate Temperatures......................................................................................................................32
Law of Intermediate Metals.................................................................................................................................34
CONSTRUCTION AND OPERATION .............................................................................................................................35
Thermocouple Accessories ..................................................................................................................................36
LESSON SUMMARY...................................................................................................................................................40
LESSON 3 PRESSURE MEASUREMENT...........................................................................................................41
LESSON OBJECTIVES ................................................................................................................................................41
PRESSURE MEASUREMENT .......................................................................................................................................41
PRESSURE MEASUREMENT SCALES ..........................................................................................................................43
Absolute Pressure................................................................................................................................................43
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IMPORTANCE OF PRESSURE MEASUREMENT IN INDUSTRY .......................................................................................45
PRESSURE INSTRUMENTATION .................................................................................................................................46
Gages...................................................................................................................................................................46
Helix and Spiral Gages ...................................................................................................................................................... 46
Bourdon Tube Gages ......................................................................................................................................................... 47
Spring and Bellows Gages................................................................................................................................................. 48
Diaphragm Capsule Gages ................................................................................................................................................ 50
Inverted Bell Pressure Gages............................................................................................................................................. 51
Absolute Pressure Gages ................................................................................................................................................... 53
ELECTRONIC TRANSMITTERS ...................................................................................................................................54
Principles of Transmitter Operation....................................................................................................................55
LESSON SUMMARY...................................................................................................................................................60
LESSON 4 LEVEL MEASUREMENT ..................................................................................................................61
LESSON OBJECTIVES ................................................................................................................................................61
LIQUID LEVEL MEASUREMENT.................................................................................................................................61
INFERENTIAL METHOD .............................................................................................................................................61
PRESSURE GAGE METHOD........................................................................................................................................61
Diaphragm Box Method ......................................................................................................................................63
AIR PURGE METHOD ................................................................................................................................................66
METER BODY METHOD ............................................................................................................................................67
OPEN TANK APPLICATIONS ......................................................................................................................................68
Direct Measurement ............................................................................................................................................68
Indirect Measurement (Air or Gas Purge)...........................................................................................................71
CLOSED TANK APPLICATIONS ..................................................................................................................................73
Direct Measurement ............................................................................................................................................73
INDIRECT MEASUREMENT (AIR OR GAS PURGE) ......................................................................................................76
Flange-Mounted Liquid Level Transmitters ........................................................................................................78
Float Operated Method .......................................................................................................................................82
Electrode Type.....................................................................................................................................................83
Electrical Capacitance Type................................................................................................................................85
Radiation Type.....................................................................................................................................................87
Ultrasonic Type ...................................................................................................................................................88
LESSON SUMMARY...................................................................................................................................................89
LESSON 5 FLOW MEASUREMENT ...................................................................................................................91
LESSON OBJECTIVES ................................................................................................................................................91
FLOW MEASUREMENT..............................................................................................................................................91
FLOW MEASUREMENT INSTRUMENTATION ..............................................................................................................92
Positive Displacement Meters .............................................................................................................................92
General Features................................................................................................................................................................ 92
Metering Tank......................................................................................................................................................92
Bellows Meters ....................................................................................................................................................92
Nutating Disk Meters...........................................................................................................................................93
TURBINE FLOW METERS ..........................................................................................................................................94
Principle of Operation.........................................................................................................................................94
Receivers and Accessories...................................................................................................................................96
Area Meters .........................................................................................................................................................97
Vortex Flowmeters...............................................................................................................................................99
MAGNETIC FLOWMETERS.......................................................................................................................................101
Principles of Operation .....................................................................................................................................101
Receivers and Accessories.................................................................................................................................105
Differential Pressure............................................................................................................................106
Principles of Differential Flow Metering......................................................................................................................... 106
Example:.......................................................................................................................................................................... 110
Solution: .......................................................................................................................................................................... 110
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COMPONENTS OF A FLOW METER INSTALLATION ..................................................................................................112
The Primary Element.........................................................................................................................................113
The Connecting Piping ......................................................................................................................................113
The Meter Body .................................................................................................................................................114
The Recorder, Indicator, or Controller .............................................................................................................114
PRIMARY ELEMENTS FOR DIFFERENTIAL FLOW METERING ...................................................................................114
Orifice Plate ......................................................................................................................................................114
Concentric ....................................................................................................................................................................... 116
Eccentric.......................................................................................................................................................................... 117
Segmental ........................................................................................................................................................................ 117
High Hat .......................................................................................................................................................................... 118
Venturi Tubes .................................................................................................................................................................. 120
Flow Nozzles................................................................................................................................................................... 121
Calculation of Flow From Differential Pressure...............................................................................................122
Differential Pressure Flow Meters ....................................................................................................................124
Diffused Silicon Differential Pressure Transmitters..........................................................................................125
Principles......................................................................................................................................................................... 125
Meter Body Operation ..................................................................................................................................................... 126
Open Channel Flow Elements ......................................................................................................................................... 129
Ultrasonic Flowmeters ......................................................................................................................................131
Principles of Operation.................................................................................................................................................... 131
Application Factors.......................................................................................................................................................... 132
Conclusion.........................................................................................................................................................133
LESSON SUMMARY.................................................................................................................................................134
LESSON 6 ANALYTICAL MEASUREMENT...................................................................................................135
LESSON OBJECTIVES ..............................................................................................................................................135
PH MEASUREMENT ................................................................................................................................................135
OXIDATION REDUCTION POTENTIAL (ORP) MEASUREMENT .................................................................................138
SPECIFIC ION MEASUREMENT.................................................................................................................................141
CONDUCTIVITY/RESISTIVITY MEASUREMENTS ......................................................................................................143
Types of Cells.....................................................................................................................................................145
Electrode Cells................................................................................................................................................................. 145
Inductive (Toroidal) Cells..................................................................................................................................146
DISSOLVED OXYGEN MEASUREMENT ....................................................................................................................147
Diffusion-Type Sensor .......................................................................................................................................147
THERMAL CONDUCTIVITY GAS MEASUREMENT ....................................................................................................151
HUMIDITY MEASUREMENT.....................................................................................................................................152
Measurement Methods.......................................................................................................................................153
Chilled Mirror.................................................................................................................................................................. 153
Wet Bulb.......................................................................................................................................................................... 154
Salt Cells............................................................................................................................................................156
Capacitive Sensors ............................................................................................................................................158
Guarded Layer Moisture Sensor........................................................................................................................159
LESSON SUMMARY.................................................................................................................................................161
LESSON 7 FINAL CONTROL ELEMENTS......................................................................................................163
LESSON OBJECTIVES ..............................................................................................................................................163
GENERAL................................................................................................................................................................163
Control Valves ...................................................................................................................................................163
The Valve Body..................................................................................................................................................164
Valve Body Types...............................................................................................................................................165
Globe style....................................................................................................................................................................... 165
Angle Valve..................................................................................................................................................................... 166
Split-Body Valve ............................................................................................................................................................. 167
Cage Valve ...................................................................................................................................................................... 167
Saunders Patent Valve ..................................................................................................................................................... 168
Butterfly Valve ................................................................................................................................................................ 168
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