Instrumentation and Process Control

(ChE- 425)
Credit Hours: 3+1

Instructor: Dr. Muhammad Nadeem Amin

 Sensors
 A Sensor as an input device which provides an output (signal) with respect to a
specific physical quantity (input).
 The term “input device” in the definition of a Sensor means that it is part of a bigger
system which provides input to a main control system (like a Processor or a
Microcontroller).
 Another unique definition of a Sensor is as follows: It is a device that converts
signals from one energy domain to electrical domain. The definition of the Sensor
can be understood if we take an example in to consideration.
 Classification of Sensors

There are several classifications of sensors made by different authors and experts. Some are
very simple and some are very complex. The following classification of sensors may already
be used by an expert in the subject but this is a very simple classification of sensors.
 In the first classification of the sensors, they are divided in to Active and Passive. Active
Sensors are those which require an external excitation signal or a power signal.
 Passive Sensors, on the other hand, do not require any external power signal and directly
generates output response.
 The other type of classification is based on the means of detection used in the sensor. Some
of the means of detection are Electric, Biological, Chemical, Radioactive etc.
 The next classification is based on conversion phenomenon i.e. the input and the output.
Some of the common conversion phenomena are Photoelectric, Thermoelectric,
Electrochemical, Electromagnetic, Thermooptic, etc.
 The final classification of the sensors are Analog and Digital Sensors. Analog Sensors
produce an analog output i.e. a continuous output signal with respect to the quantity being
measured.
 Digital Sensors, in contrast to Analog Sensors, work with discrete or digital data. The data
in digital sensors, which is used for conversion and transmission, is digital in nature. 
 Different Types of Sensors
Different types of sensors that are commonly used in various applications. All these sensors
are used for measuring one of the physical properties like Temperature, Resistance,
Capacitance, Conduction, Heat Transfer etc.

 Temperature Sensor
 Proximity Sensor
 Accelerometer
 IR Sensor (Infrared Sensor)
 Pressure Sensor
 Light Sensor
 Ultrasonic Sensor
 Smoke, Gas and Alcohol Sensor
 Touch Sensor
 Color Sensor
 Humidity Sensor
 Tilt Sensor
 Common Sensors
Some sensors are common which are as follows,

 Transmitters
 Controllers
 Actuators
 Recorders
 Switches
 Transmitters

 A transmitter is a device that converts the signal produced by a sensor into a

standardization instrumentation signal such a 3-15 PSI air pressure, 4-20 mA DC
electric current, Filedbus digital signal etc.

 The indicating or controlling device is often located in a centralized control room.

 The transmitter often combines a sensor and the transmitter in a signal piece.

 The sensor measures the process variable and generate a proportional signal.

 The transmitter amplifies and conditions the sensor signal for onward transmission
to the receiving or controlling device.
 Transmitters

 The transmitters are broadly divided into two broad groups.

(a) Electronic Transmitter

(b) Pneumatic Transmitter

 Electronic transmitters can either be analog or digital/smart .

Transmitters according to the types of signals they produce namely.

(a) pneumatic Transmitters

(b) Analong Transmitters

(c) Digital Transmitters

 Transmitters

Pneumatic Transmitters

 These transmitters output a pneumatic signal corresponding to the process variable.

 The pneumatic signal that is commonly used in industrial plants today is the 3 to 15 psig
corresponds to the lower range (LRV) and 15 psig corresponds to the upper range value.

 It is still commonly used today especially on remote locations where electric power is not
readily available.

 As shown below, a pneumatic pressure transmitter is supplied with air pressure 20 to 30 psig.
Depending on the application.

 Process pressure is applied to the high port of the transmitter. As the process pressure varies, the
transmitter produces an output signal (3 to 15 psig) that is proportional to the process pressure.
 Pneumatic Type pressure Transmitter

Analog Transmitters
Analog transmitters are mostly electronic in nature.
They output an electric signal (current or voltage) whose magnitude represents a
physical measurement or a control quantity.
The transmitter is classified as being analog by virtue of the fact it uses an analog signal
standard to communicate information.
The most common standard for transmitting an analog signal is the 4-20 mA current
signal.
A transmitter sends a small current, proportional to the physical measurement through a
set of wires.
 Analog Transmitter
Digital Transmitters
Digital transmitters produce digital signals that are combines in a variety of ways to enhance

communication with the devices

It enhances diagnostic capabilities of the device and makes control of the devices and

processes relatively easy and smooth.

Digital signals are discrete labels or values that are combined in specific ways to represent

process variables and also carry other important information such as diagnostic information.

Digital transmitters combines the digital signals in a variety of the ways leading to various

communication protocols such as Fieldbus, Hart etc.

 Electronic Transmitters

Electronic transmitters can be grouped according to the number of wires necessary to

provide transmitter power. Accordingly, there 2-wire, 3-wire and 4-wire transmitters.

Use of Transmitters in Process Instrumentation

In the process industries, there are four type common variables of interest.

(a)Pressure

(b)temperature

(c)Flow Level

(d)Level

In addition to these variables, there is also the need to analyse various chemical compositions and components.

(e)Pressure Transmitters

(f)Temperatures Transmitters

(g)Flow Transmitters

(h)Level Transmitters

(i)Analytic Transmitters O2 ( Oxygen), CO (Carbon Monoxide), pH etc.

 Controllers

A controller is an instrument used for controlling a process variable (measurement). Its continuously monitors

the error signal and gives a corrective output to the final control element.

(a)
Measurement Variable

(b)
Desired variable

(c)
Deviation

(d)
Output
(a) Measurement Variable
It is the demand variable measured and controlled.

(b) Desired Value

It is the demand signal (set point) to which the process variable is controlled.
(c ) Deviation
It is the error signal caused by the difference between the measurement and the demand signal.
(d) Output
It is the corrective signal from the controller to the final control element.
 Actuator
An actuator is a component of a machine that is responsible for moving and controlling a

mechanism or system, for example by opening a valve. In simple terms, it is a "mover".

An actuator requires a control signal and a source of energy. The control signal is

relatively low energy and may be electric voltage or current, pneumatic or hydraulic

pressure, or even human power. Its main energy source may be an electric

current, hydraulic fluid  pressure, or pneumatic pressure. When it receives a control signal,

an actuator responds by converting the signal's energy into mechanical motion.

An actuator is the mechanism by which a control system acts upon an environment. The

control system can be simple (a fixed mechanical or electronic system), software-based

(e.g. a printer driver, robot control system), a human, or any other input.
 Main Actuator Basement

The proper actuator is based on following considerations

 The valve application

 The means available to power the actuator
 The speed at which the valve needs to operate
 The amount of force required to operate the valve
 The type of valve to be operated
 The cost versus the benefit for using each type of actuator
Examples of Actuators

 Comb drive
 Digital micromirror device
 Electric motor
 Electroactive polymer
 Hydraulic cylinder
 Piezoelectric actuator
 Pneumatic actuator
 Screw jack
 Servomechanism
 Solenoid
 Stepper motor
 Shape-memory alloy
 Thermal bimorph
 Hydraulic actuators