Fundamentals of Industrial Instrumentation and Process Control 2nd Edition by William Dunn, ISBN-13: 978-1260122251

Preface

Acknowledgment

1 Introduction

Chapter Objectives

1.1 Introduction

1.1.1 History

1.2 Process Control

1.3 Definition of the Elements in a Control Loop

1.4 Process Facility Considerations

1.5 Units and Standards

1.6 Instrument Accuracy

Summary

Problems

2 Pressure

Chapter Objectives

2.1 Introduction

2.2 Basic Terms

2.2.1 Density

2.2.2 Impact Pressure

2.3 Pressure Measurements

2.4 Pressure Formulas

2.5 Measuring Instruments

2.5.1 Manometers

2.5.2 Diaphragms, Capsules, and Bellows

2.5.3 Bourdon Tubes

2.5.4 Other Pressure Sensors

2.5.5 Vacuum Instruments

2.6 Application Considerations

2.6.1 Selection

2.6.2 Installation

2.6.3 Calibration

Summary

Problems

3 Level

Chapter Objectives

3.1 Introduction

3.2 Level Formulas

3.3 Level Sensing Devices

3.3.1 Direct Level Sensing

3.3.2 Indirect Level Sensing

3.4 Application Considerations

Summary

Problems

4 Flow

Chapter Objectives

4.1 Introduction

4.2 Basic Terms

4.3 Flow Formulas

4.3.1 Continuity Equation

4.3.2 Bernoulli Equation

4.3.3 Flow Losses

4.4 Flow Measurement Instruments

4.4.1 Flow Rate

4.4.2 Total Flow

4.4.3 Mass Flow

4.4.4 Dry Particulate Flow Rate

4.4.5 Open Channel Flow

4.5 Application Considerations

4.5.1 Selection

4.5.2 Installation

4.5.3 Calibration

Summary

Problems

5 Temperature and Heat

Chapter Objectives

5.1 Introduction

5.2 Basic Terms

5.2.1 Temperature Definitions

5.2.2 Heat Definitions

5.2.3 Thermal Expansion Definitions

5.3 Temperature and Heat Formulas

5.3.1 Temperature

5.3.2 Heat Transfer

5.3.3 Thermal Expansion

5.4 Temperature Measuring Devices

5.4.1 Thermometers

5.4.2 Pressure-Spring Thermometers

5.4.3 Resistance Temperature Devices

5.4.4 Thermistors

5.4.5 Thermocouples

5.4.6 Semiconductors

5.5 Application Considerations

5.5.1 Selection

5.5.2 Range and Accuracy

5.5.3 Thermal Time Constant

5.5.4 Installation

5.5.5 Calibration

5.5.6 Protection

Summary

Problems

6 Humidity, Density, Viscosity, and pH

Chapter Objectives

6.1 Introduction

6.2 Humidity

6.2.1 Humidity Definitions

6.2.2 Humidity Measuring Devices

6.3 Density and Specific Gravity

6.3.1 Basic Terms

6.3.2 Density Measuring Devices

6.3.3 Density Application Considerations

6.4 Viscosity

6.4.1 Basic Terms

6.4.2 Viscosity Measuring Instruments

6.5 pH Measurements

6.5.1 Basic Terms

6.5.2 pH Measuring Devices

6.5.3 pH Application Considerations

Summary

Problems

7 Position, Motion, and Force

Chapter Objectives

7.1 Introduction

7.2 Position and Motion Sensing

7.2.1 Basic Position Definitions

7.2.2 ON/OFF Position Sensing

7.2.3 Motion and Distance Sensing

7.2.4 Rotation Sensing

7.2.5 Position Application Consideration

7.3 Force, Torque, and Load Cells

7.3.1 Basic Definitions of Force and Torque

7.3.2 Force and Torque Measuring Devices

7.3.3 Force and Torque Application Considerations

Summary

Problems

8 Safety and Alarm

Chapter Objectives

8.1 Introduction

8.2 Safety Hazards

8.2.1 Personnel Hazards

8.2.2 Environmental Hazards

8.2.3 Control Equipment Hazards

8.2.4 Process Equipment Hazards

8.3 Safety Sensors

8.3.1 Smoke and Fire Sensors

8.3.2 Heat Sensors

8.3.3 Gas Sensors

8.3.4 Artificial Senses Chemical Sensors

8.3.5 Radiation Detectors

8.4 Process Equipment Safety

8.4.1 Alarm and Trip Systems

8.4.2 Safety Instrumented Systems

8.4.3 Power Loss Fail Safe

8.4.4 Safety Instrumented System Example

8.5 Safety and Protection

8.5.1 Personnel Protection

8.5.2 Environmental Protection

8.5.3 Equipment Protection

Summary

Problems

9 Electrical Instruments and Conditioning

Chapter Objectives

9.1 Introduction

9.2 Instrument Parameters

9.2.1 Basic Terms

9.3 Transducers

9.3.1 Definitions

9.3.2 Visual Display Considerations

9.3.3 Mechanical Motion to Electrical Transducers

9.4 Operational Amplifiers

9.4.1 Voltage Amplifiers

9.4.2 Current Amplifiers

9.4.3 Differential Amplifiers

9.4.4 Converters

9.4.5 Buffer Amplifiers

9.4.6 Nonlinear Amplifiers

9.4.7 Instrument Amplifier

9.5 Signal Conditioning

9.5.1 Offset Zero

9.5.2 Span Adjustment

9.5.3 Linearization in Analog Circuits

9.5.4 Linearization in Digital Circuits

9.5.5 Temperature Correction

9.6 Bridge Circuits

9.6.1 DC Bridges

9.6.2 Current-Balanced Bridge

9.6.3 Strain Gauge Sensors

9.6.4 AC Bridges

9.6.5 Capacitive Sensors

9.6.6 Resistance Sensors

9.6.7 Magnetic Sensors

Summary

Problems

10 Regulators, Valves, and Actuators

Chapter Objectives

10.1 Introduction

10.2 Pressure Controllers

10.2.1 Regulators

10.2.2 Safety Valves

10.2.3 Level Regulators

10.3 Flow Control Actuators

10.3.1 Globe Valve

10.3.2 Flow Control

10.3.3 Butterfly Valve

10.3.4 Other Valve Types

10.3.5 Valve Characteristics

10.3.6 Valve Fail Safe

10.4 Actuators

10.4.1 Operation

10.4.2 Control Valves

10.5 Electronic Devices

10.6 Application Considerations

10.6.1 Valves

Summary

Problems

11 Process Control

Chapter Objectives

11.1 Introduction

11.2 Basic Terms

11.3 Control Modes

11.3.1 ON/OFF Action

11.3.2 Differential Action

11.3.3 Proportional Action

11.3.4 Derivative Action

11.3.5 Integral Action

11.3.6 PID Action

11.4 Implementation of Control Loops

11.4.1 ON/OFF Action Pneumatic Controller

11.4.2 ON/OFF Action Electrical Controller

11.4.3 PID Action Pneumatic Controller

11.4.4 PID Action Control Circuits

11.4.5 PID Electronic Controller

11.5 Digital Controllers

Summary

Problems

12 Documentation and Symbol Standards

Chapter Objectives

12.1 Introduction

12.2 System Documentation

12.2.1 Manuals

12.2.2 Alarm and Trip System Documentation

12.2.3 Safety Documentation

12.2.4 PLC Documentation

12.2.5 Circuit Diagrams

12.2.6 Bussing Information

12.3 Pipe and Identification Diagrams

12.3.1 Standardization

12.3.2 Interconnections

12.3.3 Instrument Symbols

12.3.4 Instrument Identification

12.4 Functional Symbols

12.4.1 Actuators

12.4.2 Primary Elements

12.4.3 Regulators

12.4.4 Math Functions

12.5 P and ID Drawings

Summary

Problems

13 Signal Transmission

Chapter Objectives

13.1 Introduction

13.2 Pneumatic Transmission

13.3 Analog Transmission

13.3.1 Noise Considerations

13.3.2 Voltage Signals

13.3.3 Current Signals

13.3.4 Signal Conversion

13.3.5 Thermocouples

13.3.6 Resistance Temperature Devices

13.4 Digital Transmission

13.4.1 Transmission Standards

13.4.2 Smart Sensors

13.4.3 Foundation Fieldbus and Profibus

13.5 Digital Signal Converters

13.5.1 Analog-to-Digital Conversion

13.5.2 Digital-to-Analog Conversion

13.6 Telemetry

13.6.1 Width Modulation

13.6.2 Frequency Shift Modulation

Summary

Problems

14 Logic Gates

Chapter Objectives

14.1 Introduction

14.2 Digital Numbers

14.2.1 Converting Binary Numbers to Decimal Numbers

14.2.2 Converting from Decimal to Binary

14.3 Digital Logic Gates

14.3.1 Buffer Gate

14.3.2 AND Gate

14.3.3 OR Gate

14.3.4 NOT Gate

14.3.5 Signal Inversion

14.3.6 XOR Gates

14.3.7 Logic Symbols

14.4 Boolean Algebra

14.5 Functional Building Blocks

Summary

Problems

15 Programmable Logic Controllers

Chapter Objectives

15.1 Introduction

15.2 Programmable Controller

15.3 Controller Operation

15.4 Input and Output Modules

15.4.1 Discrete Input Modules

15.4.2 Analog Input Modules

15.4.3 Special Function Input Modules

15.4.4 Discrete Output Modules

15.4.5 Analog Output Modules

15.4.6 Smart Input and Output Modules

15.5 Ladder Diagrams

15.5.1 Input and Output Symbols

15.5.2 Ladder Layout

15.5.3 Ladder Gate Equivalent

15.5.4 Ladder Applications

Summary

Problems

16 Motor Control

Chapter Objectives

16.1 Introduction

16.2 Motor Classification

16.3 Motor Operation

16.3.1 DC Motors

16.3.2 AC Motors

16.3.3 Single-Phase Motor

16.3.4 Three-Phase Motors

16.3.5 Universal Motors

16.3.6 Stepping Motors

16.3.7 Servomotors and Synchro Motors

16.4 Motor Ratings

16.4.1 Electrical Ratings

16.4.2 Control Equipment Ratings

16.4.3 Enclosure Standards

16.5 Motor Control Applications

16.5.1 Two- and Three-Wire Starting

16.5.2 Startup Control

16.5.3 Wound Rotor Motor

16.5.4 Speed Control

16.5.5 DC Motor

16.5.6 Actuator Control

16.5.7 Stepper Motor

16.6 Motor Protection

Summary

Problems

A Units

B Thermocouple Tables

C References and Information Resources

D Abbreviations

Glossary

Answers to Odd-Numbered Questions

Index