Unit Description and General Aims

The objective in presenting this unit is to introduce students to the basic principles of process instrumentation and control. The subject matter covered in this unit will include: the underlying principles of measurement science, in conjunction with the principles of measurement of pressure, level, temperature, and flow; the fundamentals of control, including tuning loops; and, an overview of advanced process control principles. The student will learn how identify, select and size control valves and to also have the knowledge to apply MATLAB/SIMULAB tools for different applications.

Learning Outcomes

On successful completion of this Unit, students are expected to be able to:

1. Evaluate and apply the principles of measurement science.
   Bloom's level 5
2. Specify, design, install, commission, and troubleshoot a range of instrumentation systems.
   Bloom's Level 6
3. Identify, select, size and maintain control valves for different applications.
   Bloom's Level 4
4. Evaluate the fundamentals of control and control systems.
   Bloom's Level 5
5. Assess and apply MATLAB and SIMULINK tools in control applications.
   Bloom's level 5
6. Examine the procedures used in loop tuning.
   Bloom's Level 4

Student assessment

Overall requirements: Students must achieve a result of 50% or above in the exam itself to pass the exam and must pass the exam to be able to pass the unit. An overall final unit score of 50% or above must be achieved to pass the unit once all assessment, including the exam, has been completed.

Prescribed and Recommended Readings

Suggested Textbook

• Manesis, S and Nikolakopoulos, G 2018, Introduction to Industrial Automation, ISBN: 13: 978-1-3510-6908-3.
• Singh, SK 2010, Industrial Instrumentation and Control, 3rd edn, Tata McGraw, ISBN-13: 978-0070678200.

Reference Materials

• Raymond F. Gardner, 2020, Introduction to Plant Automation and Controls, 1st edn, CRC Press, ISBN: 9781000204360.
• Frank Lamb, 2013, Industrial Automation, Hands-on, ISBN: 978-0-07-181647-2.
• Whitt, MD 2012. Successful Instrumentation and Control Systems Design, 2nd edn, ISA, ISBN 978-1-62198-550-1 Online version available at: http://app.knovel.com/hotlink/toc/id:kpSICSDE06/successful-instrumentation/successful-instrumentation.
• Meier, FA. Meier, CA. 2011. Instrumentation and Control Systems Documentation, 2nd edn. ISA. Online version available at: http://app.knovel.com/hotlink/toc/id:kpICSDE006/instrumentation-control/instrumentation-control.

Peer reviewed Journals

Knovel library: http://app.knovel.com

IDC Technologies publications

Other material and online collections as advised during the lectures

Unit Content

One topic is delivered per contact week, with the exception of part-time 24-week units, where one topic is delivered every two weeks.

Topic 1

Introduction to Measurement Science

1. Fundamentals of measurement science (static characteristics calibration, accuracy, precision, repeatability; dynamic characteristics (response speed, lag, dynamic error, etc.)
2. Statistical analysis
3. Units and standards (unit conversion and some fundamental mathematics such as errors, correction factors, curve fitting, and so on)

Topic 2

Pressure measurement and analytical analysis

1. Pressure units, characteristics, and types of pressure (Gauge, absolute, vacuum, etc.)
2. Methods of pressure measurement, calibration (manometers, force balance, etc.)

Topic 3

Temperature measurement and analytical analysis

1. Temperature and Level measurement (direct and indirect methods, sight glass, float-type air bellows, calibration, maintenance, and repair, etc.)
2. Temperature scales, fixed points
3. Methods, characteristics, calibration (Thermometers, electrical temperature measurement, Pyrometers, fibre optic systems, etc.)

Topic 4

Flow measurement and analytical analysis

1. Flow measurement (inferential, quantity, mass)
2. Inferential flow methods and characteristics (variable head, magnetic, target, turbine, thermal, ultrasonic, etc.)
3. Quantity methods and characteristics (positive displacement, metering)
4. Mass flow methods and characteristics, calibration, maintenance and repair

Topic 5

Control Valve Sizing, Selection and Maintenance

1. Control valves theory
2. Valve types, materials and characteristics
3. High-pressure drop applications, and sizing
4. Actuators and positioners
5. Installation and maintenance
6. Quality standards (ASME, NACE, ISO9000, etc.)

Topic 6

Fundamental of Process Control

1. Process control (on/off, modulation, feed-forward, feedback, PID: P, I, D, and PID actions)

Topic 7

Tuning Control Loops (1)

1. Fundamentals of tuning loops (PID controllers and modes, load disturbances and offsets, speed, and stability issues, etc.)
2. Tuning control loops (PID controller (ZN, Simplified lambda))
3. Automated tuning (Self tuning and Adaptive control)
4. Tuning value controllers (Hysteresis, striction)

Topic 8

Tuning Control Loops (2)

1. Tuning complex systems (Multivariate, ratio, feed-forward, cascade and interactive loops)
2. Tuning valve controller

Topic 9

Introduction to Matlab Control Toolbox and Simulink

1. Principles of Matlab and exercises in scripting
2. Block diagram models and transfer function manipulation
3. Frequency response testing methods

Topic 10

Signal conditioning and error

1. Characteristics and linearization
2. Pneumatic signal conditioning
3. Electrical signal conditioning

Topic 11

Other sensors

1. Humidity, Density and Viscosity
2. pH measurement devices and applications
3. Gas and chemical sensors and smoke detectors in industry
4. Position sensors
5. Force, torques, load cells and balances

Topic 12

Instrumentation standard (safety instrumented systems), documentation and Symbols (Alarm and trip systems and documentation, PFD, and P&ID diagrams)

Software/Hardware Used

Software

• Software: MATLAB/SIMULINK
• Version: Student version
• Instructions: N/A
• Additional resources or files: N/A

Hardware

• N/A

Unit Changes Based on Student Feedback