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ADVANCE        INSTRUMENTINSTRUMENT

M.HAROONI

WELCOME TO ADVANCE INSTRUMENT TRAINING COURSETRAINING COURSE

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TITLE TRAINING COURSE

MEASURING PARAMETER

CONTROL VALVE

CONTROL LOOPS

FEEDBACK CONTROL

FEEDFORWARD CONTROL

CASCADE CONTROL

RATIO CONTROL

TYPE OF CONTROL SYSTEM

LAYER CONTROL

SAFETY IN CONTROL

MEASURING PARAMETERFLOW MEASURMENTFLOW MEASURMENT

PRESSURE MEASURMENT

LEVEL MEASURMENT

TEMPRATURE MEASURMENT

SPEED MEASUREMENT

DENCITYDENCITY

MOVEMENT , VELOCITY, ACCELERATION 

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FLOW MEASURMENT

WHY  MEASURE FLOW?CUSTODY TRANSFERCUSTODY TRANSFER

FISCAL MEASURMENT

LEAK DETECTION 

CONTROL

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TYPE OF FLOW METERS

DP FLOW METER

VELOCITY FLOW METER

MASS FLOW METER

POSITIVE DISPLACEMENT FLOW METER

DP FLOW METER

ORIFICE PLATE

VENTURI TUBE

FLOW NOZZLE

PITOT TUBE

ANNUBAR

ELBOW

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VELOCITY FLOW METER

VOTEX FLOW METER

TURBINE FLOW METER

ULTRA SONIC FLOW METER

MAGNETIC FLOW METERMAGNETIC FLOW METER

MASS FLOW METER

CORIOLOIS FLOW METER

TERMAL FLOE METER

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IMPORTANT PARAMETER FOR SELECING FLOW METER

How much does the fluid cost? Is the fluid to be measured liquid or gas? Is there just one fluid, or are there many? In the case of liquid is it exceptionally viscous or

exceptionally thin? Will there be extremes of temperature and pressure? What is the range of flow rate? How much pressure loss can the system tolerate?How much pressure loss can the system tolerate? Is the fluid conductive? Do we have to meet any specific rules? Is there an on-site prover? What about maintenance?

IMPORTANT PARAMETER FOR FLOW METER

REPEATABILITY

UNCERTAINTY(ACCURACY)

RANGEABILITY(TURNDOWN RATIO)

LINEARITY

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INDUSTRIAL FLOWMETER MARKET

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PRESSURE MEASURMENT

TYPE OF PRESSURE MEASURMENT

ABSOLOTE PRESSURE MEASUREMENT

GAUGE PRESSURE MEASURMENT

DIFFRENTIONAL PRESSURE MEASURMENT

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MEASURABLE PRESSURE TYPE

HAED PRESSURE(HYDROSTATIC)

STATIC  PRESSURE (LINE)

VACCUM PRESSURE

LEVEL MEASURMENT

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TYPE OF LEVEL MEASURMENT

MANUAL/ MECHANICAL

ELECTRO MECHANICAL

ELECTRONIC CONTACTING

ELECTRONIC NON CONTACTING

MANUAL/ MECHANICAL

FLOAT SYSTEM

ROD GAUGING/ DIP PROB

SIGHT /GAUGE GLASS

TAPE SYSTEMS

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ELECTRO MECHANICAL 

DISPLACER

MAGNETOSTRICIVE

RESISTANSE TAPE

SERVO

ELECTRONIC CONTACTING

CAPACITANCE

CONDUCTIVITY

OPTICAL

PRESSURE‐BASED LEVEL TECHNOLOGI

BUBBLER SYSTEM

THERMAL

VIBRATING LEVEL(TUNING FORK)

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ELECTRONIC NON CONTACTINGELECTRONIC NON CONTACTING

RADAR

ULTASONIC

NUCLEAR

INITIAL / MENTENANCE COST. 

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TYPE OF TEMPRATURE MEASURMENT

RTD (RESISTANCE TEMPRATURE DETECTOR)

T/C (THERMOCUPLE)

WHY MEASURE TEMPRATURE ?PROUCT QUALITYPROUCT QUALITY

EFFICENCY

SAFETY

MONITORING

CUSTUDY TRANSFER

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COMPARISON OF T/C TYPE

COMPARISON OF RTD

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TYPE OF MEASURING SPEEDOPTICAL TYPE 

MAGNETIC PICK UP

TACHOMETER

CONTROL VALVE

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FAIL OPEN

FAIL CLOSE

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TYPE OF ACTUATORS DIAPHRAGM PISTON ELECTRIC ELECTROHYDROLIC MANUAL MANUAL

SEVER SERVICE ITEMS NOISE  NOISE  DELTA P CAVITATION  CHEMICAL ATTACK MATERIAL  EROSION FLASHING FLASHING SELECTION HIGH PRESSURE  VIBRATION HIGH / LOW TEMPRETURE

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TYPE OF CHARCTRISTIC LINEAR LINEAR

EQUAL PERCENTAGE

QUICK OPENING 

VALVE CHARACTRISTIC

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TYPE OF BONNET

EXTENTION BONNET

BELLOWS SEAL BONNET

TYPE OF PACKING

TFE                 UP TO 450°F

GRAPHITE     UP TO 1200°F

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DATA NEEDED FOR SELECTION OF CONTROL VALVE  TYPE OF FLUID  TEMP OF FLUID  VISC OF FLUID  S.G  OF FLUID Q MAX / MIN P1 MAX / MIN  DELTA P MAX / MIN/ NOISE LEVEL PIPE SIZE VALVE ACTION  TYPE OF PACKING  TYPE OF ACTUATOR ACCESORIES 

DOUBLE ACTING CONTROL VALVE

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SPLIT RANGE CONTROL VALVE

CONTROL VALVE

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CONTROL VALVE WITH SOLENOIED

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INSTRUMENTATION DESIGHN CRITERIA

STANDARD AND RECOMMENDED PRACTICE

PROTECTION AND CERTIFICATE

CONTROL SYSTEM DESIGHN PHILOSOFY

PROVISION OF INSTRUMENTS ON PACKAGE O O O U O C GUNIT

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CONTROL  SCHEMATIC

TYPES  OF CONTROL

CONTINIUS CONTROL

BATCH CONTROL 

SEQUENCE CONTROL

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CONTROL  LOOPS

OPEN LOOP CONTROL

CLOSE LOOP CONTROL

OPEN LOOP

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CLOSE  LOOP

ADVANTAGE OF CLOSE CONTROL LOOP

INCREASED  PRODUCTIVITY

ON SPEC PRODUCTS

ENERGI AND MATERIAL CONVERSATION 

SAFETY

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ACTING ELEMENTS

DIRECT ELEMENT

REVERSE ELEMENT

DIRECT ACTING ELEMENT(INCREASE/INCREASE)

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REVERSE ACTING ELEMENT(INCREASE/DECREASE)

INSTRUMENT SIGNALS

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CONVENTIONAL CONTROL LOOPr

Set Point

mI / P

TRC

b

Fs

Steam

TT

CProcess Fluid

F  Ti

Steam Trap

Condensate

FEEDFORWARD  CONTROL

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FEED FORWARD CONTROL LOOP

FEEDBACK  CONTROL 

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RATIO  CONTROL

RATIO  CONTROL

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VOUTING 2 OUT OF 3

P‐T COMPENSATION 

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OVER RIDE 

CASCADE CONTROL 

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VOUTING 2 OUT OF 3

SPLIT‐ RANGE

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TYPE OF CONTROL SYSTEM MANUAL

SELF ACTUATED

PNUMATIC

ELECTRONIC

CENTRALIZE

DCS

FCS

MANUAL CONTROL

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SELF ACTUATED CONTROL

COMPARISON BETWEEN DCS&FCS

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COMPARISON BETWEEN DCS&FCS

COMPARISON BETWEEN DCS&FCS

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COMPARISON BETWEEN DCS&FCS

CONVENTIONAL CONTROL ROOM

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TODAY CONTROL ROOM

INDUSTRIAL SAFETY

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What a Safety Instrument System really does (prevention)

Trip level

Operatortakes action

Safety System

High Level Alarm

Wild process parameter

PlantShut Down

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Process parameter value

Normal behaviorDCS Control Level

Control Level

Wild process parameter

Risk-ReductionManagement Systems:

• Procedures

• Operating instructions

• Maintenance

instructionsControl Layer

Human Layer

instructions

Safety System SIS:

• HIPS

• ESD/PSD

Mitigation Systems:

• Fire & Gas Systems

Control Layer

Physical Layer

Mitigation Layer

Prevention Layer

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• Blow-down systems

Physical Systems:

• Dikes

• Concrete Fire walls

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DIN V 19250 AK ClassW1 W2 W3

1S1S: Extent of damage

S1-minor injury/damageS2 serio s inj r /death of one person

2

3

4

5

6

7

8

1

2

3

4

5

6

7

1

2

3

4

5

S2

S3

A1

A2A1

G1

G2

G2

G1S2-serious injury/death of one personS3-Death of several personsS4-Catastrophic consequences

A: Frequency of exposureA1-SeldomA2-Quite often to permanent

G: Avoiding of hazardG1-PossibleG2-Almost impossible

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S4 A2

W: Probability of eventW1-HighW2-LowW3-Very low

Primary cause (by phase) of control system failure (based on 34 incidents)

44.1%Specification

14.7%Design & implementation

5 9%

More than 60% of failures "built into safety-related system" beforetaken into service

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14.7%Operation & maintenance

20.6%Changes after commissioning

5.9%Installation &commissioning

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IEC 61508Safety Integrity Levels

Minor

Serious

Severe

Safety Integrity LevelSIL

PFDProbability ofFAILURE on DEMAND

1

2

3

<10-1 - >10-2

<10-2 - >10-3

<10-3 >10-4

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Severe

Catastrophic

3

4

<10-3 - >10-4

<10-4 - >10-5

SIL Levels of different Systems

Low Safety

PFD = 10-1 1 in 10 Y

Included are: Hardware, Systematic & Common Cause failuresAccording to the TR84 calculations

SIL 1

SIL 2

SIL 3

1 in 100 Y

1 in 1,000 Y

1 in 10 000 Y

10-2

10-3

average

2oo3

1oo2D

DSP PLS

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SIL 4

High Safety

10-5

1 in 10,000 Y

13 wks 26 wks 39 wks 52 wks

Logic Solver periodical Proof Test Interval Time

10-4

1 in 100,000 Y

DSP SLS

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TÜV versus IEC (SIL Levels)

Process pipe

Pipe to Pipe

Process pipe

Safe Fail-Safe

Protection logic

Logic solver

OAD

0 cm

0 cm

0 cm

0 cm

0 cm0 cm

Air

Vent.

Safetyvalve

44

Ü

85

Sensors Final elementsAK

(TÜV)SIL(IEC 61508)

* rough estimate only

TÜV versus IEC*88776655

4

44

33

22

11

System Redundancy1oo1 1oo2

Defected failure,safe and un-safe

1oo2 2oo3

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Safety False Trips

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1oo2D: the best of two worlds

2oo2

1oo2

Safe failures

Diagnostic

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Unsafe Failures

Diagnostic

Relative positionL RedundantInherent FailSafe

Fal

se T

rip

Rat

e

SpecialR l

InherentFailSafe

2oo3

FailSafe

1oo2D

2oo3

88

SafetyL H

Relays

PneumaticsH

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PREVENTION AND MITIGATION LAYER

SAFETY INTEGRITY LEVEL

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SYSTEM ARTECHECTURE

HAZARDOUS AREASENVIRONMENTS:IIA PROPANE AND LIKEIIB ETHYLENE AND LIKEIIC HYDROGEN AND LIKE

ABILITY OF GAS IGNITION ON A HOT SURFACE:T1  450’CT2  300’CT3  200’CT4  135’C

PROTECTION TECHNIQUES:“Ex o” Oil Filled“Ex q” Powder Filling“Ex m” Encapsulation4 35

T5  100’CT6  85’C

ZONES:ZONE 0: CONTINUOUS PRESENCEZONE 1: NORMAL OPERATIONZONE 3: SHORT OCCURRENCE

Ex m  Encapsulation“Ex p” Pressurization“Ex e” Increased Safety (Dust/Water)“Ex d” Flameproof“Ex I” Intrinsically safe

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ANY QUESTION

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