EM14-1 Instrumentation & Control Systems
Contents
1. 23 and P amp ID 5 24 25 c Q 25 e ais eS ERN E E 25 mes 26 27 Instrument Lines 28 General Instruments 29 An Example of Instrument Symbols in a P amp ID 30 1 9 Loop CATO NNI T 30 Process POS ROTE T T Um 33 POS HOTS CONAN SVC 33 Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a EQUIPMENT MODULE E2. Creation Revision Date Element Reference Agrium 2015 08 301 Review Date i lt a gt Site Functional Area Functional Group Subject Area Document Type Document Sub Type Document Category Document Manual Std Operation Equipment Module EM14 1 uL UEM EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS EM14 1 Instrumentation amp Control Systems Equipment Module Agrium Wholesale Element Owner Document Owner Caretaker Printed Choose an item Choose an item Choose an item 30 08 2015 8 12 AM Page 1of 43 If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS TABLE OF CONTENTS Definitions Generic Instrumentation cssesesee RI IRR Rem RtmRmRtRttrRtmemetettttretemerirr erem eririai aei 4 Purpose of this 5 E cunn CUI E unm 6 ci MT T ee 7 Hazards IO E OO 7 IVI ANON T 7 7 Instrumentation and Control Basics ccecececececececececececcecccceceacucacaca
3. EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS INGERSOU AANO INTELLIS VS Figure 21 A typical vendor control panel e primary scrubber feed tank grizzly controls Figure 22 Grizzly screen deck operator control panel Vendor controls are built specifically for their application and tend to have unique user interfaces and operating features In some cases they provide communications interfaces that allow limited information and control via VPO s distributed control system System Redundancy To ensure that important functions continue to operate in the event of a failure in the PCS the following portions of the system are redundant Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a si ME EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYsTEMS e Process control network communications including cabling and electronics e Most DCS process controllers e Cabinet power supplies The following portions of the system are not redundant e Communications between the PLCs and the PCS network e Most PLC process controllers Uninterruptible Power Supply UPS Figure 23 Uninterruptible Power Supply A UPS protects sensitive electronic equipment from the most common power problems including power failures power sags power surges br
4. etc Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS e The type of equipment element E transmitter T valve V alarm Tips and Techniques i Pid A controller C etc It s helpful to learn these numbering conventions You will see them on the HMI displays Whether the loop includes an indication 1 So flow loop may have all of the following Aflow element e g FE 2533 e Aflow transmitter e g FT 2533 flow controller with indicator e g FIT 2533 e Aflow control valve e g FV 2533 Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a si ME EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYsTEMS The following table from 100J7747 provides a list of standard instrument identification letters FIRST LETTER SUCCEEDING LETTERS READOUT PASSE OR OUTPUT FUNCTION NOTE 2 MEASURED OR IHITITATED VARIABLE AMALYSIS MOTE 3 ALARM B BURHER FLAME C CONDUCTMITY CONTROL CLOSED DENSITY OR SPECIFI
5. BEEN Controller LIC 1217 block Jet PN AA AAD T a WERE Output to other display Valves Process Eng Oveisysi Pump running Figure 24 An HMI process display Green dots on the process display indicate that the equipment pump in this example is running operating correctly If a piece of equipment fails to operate correctly a Failure to Operate icon appears Typically the pump in this example icon changes colour to yellow The HMI also provides several other types of displays including faceplate displays real time trend displays and alarm displays Each provides a way of accessing status indications and controls necessary to run the process Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a i E EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Automatic versus Manual Operation The PCS provides a means of automating many of the plant operations Tips and Techniques which provide many benefits for operators and the company Some of As the size and complexity esea of a process system grows it becoming increasingly important that controls are automated Once the initial tuning and optimization is complete and confidence in the system grows automation becomes the operator s
6. VPO is reagent mixing control loops Reagents added to the flotation circuit must be added at a rate based on the mill feed rate The wild feed flow measurement shown in the following diagram would be the mill feed rate The controlled feed flow measurement shown would be the reagent flow rate The reagent flow rate would be adjusted to track the mill feed based on a preset ratio Note Typically the PCS allows the operator to adjust the ratio on the HMI within a preset range of values Wild Feed FT la ad a FT Controlled Feed Mixed Flow gt lt Figure 6 Ratio Control Feedforward Control Feedforward control is a technique that detects disturbances in a control system before they have a chance to affect the output of the process Usually feedforward is combined with feedback control The following Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYsTEMS diagram shows a heat exchanger a typical application for feedforward control Feedfonward Controller Feedback Controller Heat Exchanger Tips and Techniques Advanced control techniques can appear complicated at first but they do work Be patient you didn t learn Process Flow
7. av moa err H A811 TWG NO d TED FT Cod Figure 8 A typical P amp ID Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a i E EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Who uses P amp IDs Process diagrams are used by many technical personnel in one way or Tips and Techniques another Process engineers use process flow diagrams and symbols PFDs and P amp IDs look during the design process to map the flow of the process and equipment complicated This can be S intimidating at first Break used in it Control and automation engineers use PFDs during the the diagram down into process of designing instrumentation and control systems They produce pieces Look for symbols he P amp ID bol you can identify numbers the P amp IDs using standard instrumentation and measurement symbols to you recognize and labels label instrument loop diagrams Maintenance personnel use PFDs and you are familiar with Then work from there Keep this P amp IDs in planning and executing preventative and reactive maintenance document handy for activities including planning or verifying lockout procedures Technical writers use PFDs an
8. best friend e Simplifies the duties of the operator e Increases production time e Optimizes production rate and efficiency e Simplifies startup and shutdown operations e Improves safety There are two main types of automation used at VPO e Automatic sequencing when starting up and shutting down equipment and systems e Automatic process control using multiple and cascaded control loops Automatic Sequencing Automatic sequencing of startup and shutdown is accomplished primarily by PLCs The size complexity and interdependence of the mill processes requires that putting equipment into service must be timed and staged For example belts must be started before feeders which in turn must be started before other upstream equipment Theses sequences cannot be effectively or safely accomplished in manual by operators Shutting down systems may be even more critical since shutting down the wrong equipment first or too quickly could result in build ups overflows and even damage to equipment The operator s role is to understand these operations ensure the equipment is ready and able to start or stop and work with Central Control and other operators in monitoring the plant during startups and shutdowns Automatic Process Control An experienced and knowledgeable area operator understands the equipment and processes in his her area However even the best Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controll
9. bin level controller will increase its output which increases the setpoint of the control loop that controls the ore feeder This will ensure that the ore feeder operates at a rate that can keep the fine ore bin level constant Master Level qu Eck EIE OU EE ring Controller Controller f LEVE ak WIC 8079 Setpoint Output c3813AB setpoint Weight Level Measurement Measurement 3 Belt Scale Ore 70712 Feeder Fine Ore _ storage Bin 02704 14701 Figure 5 Example of cascade control at VPO Note For information on an example of cascade control used in the mill see PM10 4 Crushing Circuit process module Operation and Control section Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Ratio Control A ratio controller accepts two different instrumentation signals and provides an output based on an operator set ratio between the two For example in a mixing system where two different materials must be mixed in a fixed ratio the flow rates of both feeds can be measured and one controlled to ensure it flows at the correct rate to achieve the mix ratio One example of ratio control as it is used at
10. built into the system to detect if the light did not turn on and take some action to correct the problem This is an open loop system Control Signal Input Controller Process Output Open Loop System Control Input Controller pu Signal Process Output Measuring Element Closed Loop System Figure 2 Open and closed loop control system diagrams In closed loop control systems the results are monitored and corrections Tips and Techniques are made based on feedback A furnace thermostat is an example When Most control loops in the plant are closed loop and the air temperature around the thermostat drops below its setpoint the should be operated in thermostat sends a signal to the furnace to start The thermostat Automatic to ensure the ee stants continues to monitor the temperature and when it rises above the setpoint operation Ultimately plus a deadband value a signal is sent to the furnace to turn off A operation in Automatic mode will make the operator s activities easier Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing closed loop system is also called a feedback control system e Revision Date Revision Number Element Reference um 2015 08 30 00 n a EQUIPMENT MODULE 14 1 INSTRUMENTATION amp CONTROL SYSTEMS Closed loop control systems can
11. controller increases its output ramps by a set amount per unit time As the output changes the process changes causing the measurement to change this in turn causes the error to become smaller Eventually the difference becomes zero which is the goal of the controller Note Integral is expressed in terms of number of seconds per Repeat or Repeats per second depending on the equipment manufacturer A Reset is defined as the amount the controller output will change in a second for a given error PV SP with a given Gain setting Derivative Derivative control responds to how quickly the measurement PV is changing If the rate of change is large the controller makes a larger change to the output This brings the PV back to setpoint more quickly ensuring that quick measurement changes do not affect the process significantly Derivative control is typically used in temperature control systems where an external event e g introduction of wet feed into a dryer will change the temperature quickly When a fast change is detected the control causes a large amount of heat to be added quickly to bring the temperature back into line before it changes too much Note Derivative or Rate is expressed in terms of time usually seconds but sometimes in minutes Tuning Most analog control systems employ proportional and integral control Tips and Techniques some also implement derivative For best results a controller must be sometime
12. document contains e Learning outcomes for this module Safety related information e Instrumentation and control basics e Instrumentation standards symbols and drawings e Process control systems e Troubleshooting e Appendices with additional related information Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a i E EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Learning Objectives On completion of this learning module you will be able to e List and describe the key hazards and risks associated with working on or around the equipment described in this module e dentify steps necessary to mitigate risks when working on or around this equipment e Describe safety systems that are part of the equipment e List the parts of a control loop and describe their functions e Describe various control actions in simple terms e Describe the two key instrumentation drawings used at VPO e Recognize and explain the use of standard instrumentation symbols in drawings e List and describe the basic functional parts of process control system e Describe operating considerations of instrumentation equipment and systems e Describe basic control system troubleshooting techniques for operators Printed 2015 08 30 8 12 AM If printe
13. 0 8 12 AM Page 29 of 43 If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS An Example of Instrument Symbols in a P amp ID Electrical Signal Pressure Equipment serviced by 4 20mA Transmitter instrumentation Local Temperature alarm Pressure alarms d fe High Low Differential High High ndication m Interlock N epa 61845 V PaL l PDAH Ball Valve 1 Y oA Kor Te on ane Ce eat Level and Temperature Hydraulic Signal f PSV switches Pressure Safety Valve gt 6695 i a SE cuoc Ky o 61845M1 tru 1 KA PE A 6695 um 61845Mz TYPE A High Low Low Low Piping Level alarms HYD POWER PACK Figure 16 Examples of symbols on a P amp ID Instrument Loop Identification Instrument loops are identified on drawings using a standardized set and format of letters and numbers Each loop is identified by a unique loop number Each piece of equipment in the loop is identified separately but all include the loop number E g Pl 2047 and PIT 2047 are two parts of the same loop The type of instrument loop is identified using two to four letters that indicate e The type of loop flow F pressure P level L temperature T
14. 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a i E EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Definitions Generic Instrumentation Term Description DeviceNet DeviceNet is a network system used in the automation industry to interconnect control devices for data exchange HART Protocol The HART Communications Protocol Highway Addressable Remote Transducer Protocol is a digital industrial automation protocol Its most notable advantage is that it can communicate over legacy 4 to 20 mA analog instrumentation wiring sharing the pair of wires used by the older system Due to the huge installed base of 4 to 20 mA systems throughout the world the HART Protocol is one of the most popular industrial protocols In 1986 it was made an open protocol All terms found at http www engineering dictionary org Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a i E EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Purpose of this Document The EM14 1 Instrumentation amp Control Systems learning module is a key resource created to help operations personnel learn about the systems used to control the process used at Vanscoy Potash Operations This
15. 5 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing Revision Date Revision Number Element Reference 2015 08 30 00 n a Measured Parameter Units of Measure Sl Pressure kiloPascal kPa Speed Velocity metre per second m s Sound Pressure Level decibels A scale weighted dBA Temperature degree Celsius C Turbidity Nephelometric Turbidity Units NTU Viscosity Pascal second Pa s 1 mPa s 1cP Voltage alternating amp direct Volts VAC VDC Vibration Inches per second in sec or cycles sec cps Standard Signals and Ranges Information regarding control signals power and air are included in this section Controlled Parameter Measure Local pneumatic control 20 100 kPa g Plant air supply pressure 550 760 kPa g Instrument air supply pressure 40 C dew point 590 760 kPa g DCS Distributed Control System analog electronic input output signals isolated 4 20 mA DC c w HART Protocol UPS Uninterruptable 120 VAC 60 Hz PLC Programmable Logic Controller control voltage for motor starters and related 120 VAC 60 Hz controls PLC Programmable Logic Controller discrete electric input signals isolated 120 VAC 60 Hz PLC Programmable Logic Controller discrete electric output signals dry contact 120 VAC 60 Hz Solenoid valve control 120 VAC 60 Hz Printed 2015 08 30 8 12 AM If printed this b
16. ALL VALVE DIAPHRAGM VALVE peq GLOBE VALVE DIAPHRAGM VALVE N CHECK VALVE A DIAPHRAGM VALVE PLUG VALVE ROTARY VALVE DK NEEDLE VALVE 3 PINCH VALVE Of BUTTERFLY VALVE VALVE cate a S WAY VALVE SLIDE ROD GATE OR pk HAND WHEEL OPERATED 4 WAY VALVE j WEDGE VALVE ANGLE VALVE S Pp 4 SAMPLE VALVE L DOLE VALVE JL DART VALVE TECH TAYLOR VALVE Figure 13 Valve symbols legend drawing 100J7745 Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Instrument Lines INSTRUMENT LINES ELECTRICAL SIGNAL JA hh PNEUMATIC SIGNAL CH CAPILLARY SIGNAL C O Us SOFTWARE LINK L rLE L t L L HYDRAULIC SIGNAL ELECTRO MAGNETIC SONIC OPTICAL OR NUCLEAR SIGNAL INST SUPPLY OR CONNECTION TO PROCESS uu RADAR SIGNAL NOT GUIDED Figure 14 Instrument lines legend on drawing 100J7747 Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Ele
17. C GRAVITY AF FERENTIAL E UE E M F PRIMARY ELEMEHT FLOW RATE i RATIO FRACTION G GAUGING DIMENSIONAL _ _ HAND MANUALLY INITIATED HIGH o INDICATE J Power SCAN K TIME CONTROL STATION eee LEVEL LOW OR LIGHT PILOT MOISTURE OR HUMILITY MIDDLE OR INTERMEDIATE MOTOR USER S CHOICE USER S CHOICE DPERATION ORIFICE OR RESTRSCTION OPEN PRESSURE OR VACUUM POINT OR TEST CONNECTICH TORQUE INTEGRATE OR TOTALIZE RADSOACTIITY OR RESTRICTION RECORD OR PRINT SPEED OR FREQUENT SAFETY OR SWITCH TEMPERATURE TRANSMITTER u MULTIFUNCTION Y ON m VALVE DAMPER OR pickle W pmm FORCE WELL X mmm UNCLASSIFIED Y EVENT STATE OR RELAY COMPUTE OR MISC SOLENOID DRIVE ACTUATE OR UNCLASSIFIED Z POSTON OR STATUS ELEMEHT Figure 17 Instrument identification number Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a si ME EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Process Control System PCS Most plant processes are monitored and controlled by the process control system PCS The PCS is made up of the distributed control system DCS local programmable logic controllers PLC and workstations that display the human mac
18. I can a O E ORT screens Process displays include graphics of bins you refer to a screen are you conveyors compressors valves etc and status indications on off talking about a computer mode trips flow temperature etc monitor Is the information shown on a computer monitor Operators control equipment by clicking graphic representations of the Could the person you are l talking to think you are referring equipment on the screen Typically this opens an overlay a smaller a piece of production window sometimes called a popup with buttons value boxes and other equipment that sort different sized product Use the words process display and overlay when referring to information on the HMI graphics used to control the equipment Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing Revision Date Revision Number Element Reference 2015 08 30 00 n a Document ae EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Fl FoxView CTLWP1 CTLWP1 Cp4 Scrubbers aA EE fig Disp ri a Help 2 733 07 2301 17 13 Unable to resolve aias 2013 072 Overlay 174732 See Control Block Pressure Indicator Piping Lines other displays Level Indicating
19. M14 1 INSTRUMENTATION amp CONTROL SYSTEMS FOOT Logie m 33 POR 34 Main Control Room EH amp S Building 35 Tanini ROOM SaO NONE g5 E OE A E E E T ET IM MEM E E EA i 35 PCS Architecture and aO Sessor coca tes E eaten tat IR ta Dur NAI NITOREM nan A 36 f iololgizoivie goo iei 36 DROO O m 37 Uninterrupiibie Power SUDDIV EE 38 PCS AVI OMe 39 Human Machine ET P HH 39 versus Manual ODOFallOl e EE E E uad 41 TEE TS LS LEN 41 Automatic Process uu 41 ege nic NER Tm 42 POC dE Cc 43 eco E 43 acces M RM 43 Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for
20. Overall Plant Control System Communications Block Diagram Technical 000 E SP 001 Electrical and Instrumentation opecification Requirements for Mechanical Equipment opecification Vendor Doc 334562 EPC P81 Black Box LBI100A HD ST 24 amp 48 7100 0486 LBH2001A H SC Product Data Sheet Vendor Doc 334562 EPC P81 Stratix 8000 and 8300 Ethernet Managed 48 100 0229 Switches Hardware User Manual Vendor Doc 334562 EPC C80 Pelco Digital Sentry Network Video 00 0000 0006 Recorder Vendor Doc 334562 EPC C80 Pelco KBD300USBKIT Installation 00 0000 0008 Operation Revision History Date Revision Revised by Position 2014 01 24 00 Ron Johnson Technical Writer Printed 2015 08 30 8 12 AM Element Reference n a EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Appendix Location Link Search for this document on the ADOM document management system Search for this document on the ADOM document management system Search for this document on the ADOM document management system Search for this document on the ADOM document management system Search for this document on the ADOM document management system Search for this document on the ADOM document management system Notes If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing
21. able assistance to level maintenance personnel 74267 n sensor u level Figure 1 A typical analog control loop The output signal is used to operate a final control element solenoids valves regulators circuit breakers relays indicators variable frequency drive motor or other actuator In response to the output signal the final control element manipulates the process flow temperature pressure etc Often this is the same parameter measured by the sensor or it may be another parameter which affects the parameter measured by the sensor This completes the loop allowing the control system to ensure the process is controlled to the value specified by the setpoint Controllers may be standalone controllers or part of a digital control system Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a i E EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Open and Closed Loop Control There are two common classes of control systems open loop control systems and closed loop control systems In open loop control systems an output is initiated by a change in an input but no attempt is made to monitor the results and adjust accordingly For example when a wall switch is switched on a light should turn on But there is nothing
22. d this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a EQUIPMENT MODULE 14 1 INSTRUMENTATION amp CONTROL SYSTEMS At Vanscoy Potash Operations employee safety is our top priority Every employee must be aware of all pertinent workplace safety procedures and do their part to keep themselves and others safe Hazards and Risks The systems described in this document measure or control some aspect of the process either directly or as part of a larger machine or system This means personnel may come in contact with process hazards when operating adjusting or inspecting the system Note For additional safety information related to working in plant areas refer to the applicable building overview and process modules for the area Risk Mitigation When working on or around this equipment maintain the following safe work practices e Read the manual before working with any of the products described in this document e Always follow standard operating procedures when operating or maintaining this equipment Safety Systems e Grounding to protect against electric shock Failsafe configurations in instruments and equipment that protect personnel in the event of equipment failure e Radiation warning signs for nuclear devices e devices must comply with Hazardous Area Certification Pri
23. d P amp IDs during the creation of procedures checklists your best friend when figuring out what is going and training materials Operators use P amp IDs to understand the on in a plant system processes they operate and to use the procedures best practices they employ to operate their areas effectively Resource Materials for Reading P amp IDs A library of PFDs P amp IDs and other engineering resource materials is available to VPO personnel on the ADOM document management system Included in this library are several documents that provide a key to the symbols and conventions used on PFDs and P amp IDs These documents are listed in the following table and in the Related Documents section at the end of this manual File Name Description Contents 100J7745 P amp ID Symbols Sheet 1 of 5 Piping line symbols Valve symbols Normally closed valve symbols Tips and Techniques Insulation and tracing symbols Get your supervisor to print out a copy of these sheets ON OFF page connector symbols and keep them somewhere Pipe identification symbols that you can find them Valve identification symbols Refer to them when you Pipe material identification symbols need to They will prove DU read P amp IDs Fluid service code symbols Piping components symbols Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revisi
24. e and keyboard keypad suitable for rugged use in an industrial environment PCS Architecture and Communications PLCs and the DCSs communicate by sending and receiving digital information via Ethernet TCP IP communication protocol over network Tips and Techniques cables Backbone communication main communications trunks is via Fibre optic cable is not inal de fib he Related D ond susceptible to electrical single mode fibre optic cable See the Related Document section for noise Process Control System overview and Architecture Block Diagram 334562 0000 48DD 7100 Sub systems are linked to the PCS via Ethernet IP or DeviceNet communication protocols BACnet IP to Ethernet IP protocol converters are used in some cases to interface with fire alarm or building automation systems In select cases Modbus communication protocol is used to interface with vendor equipment control packages Where a control system is not supplied with a vendor package instrument signals are hard wired directly to the plant PCS Vendor Equipment Controls oome turnkey equipment comes from the manufacturer with integrated control systems Examples include e the controls on compressor air systems and air dryers Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing Revision Date Revision Number Element Reference 2015 08 30 00 n a EQUIPMENT MODULE
25. ecomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYsTEMS Instrumentation Standards Symbols and Drawings There are two key types of drawings used to show how the equipment and instrumentation in process plants are connected as systems These are e Process flow diagrams PFD e Piping and instrument diagrams P amp ID PFDs show process equipment and how it is interconnected by piping and other conveyances The simplicity of these diagrams makes them Tips and Techniques E useful in understanding the overall flow of materials through the process Operators who can read plant drawings and relate including how equipment is interconnected them to actual systems in the plant can operate those P amp IDs show similar information to that shown in PFDs but also include systems more effectively information about instrumentation and controls and how they are They can also provide valuable assistance to connected together and to supervisory control systems This makes maintenance personnel P amp IDs more complex but they provide more information A typical process plant requires many diagrams Each captures some area or process in detail Standard symbols are used The organization that sets the standards for symbols identifier
26. ed document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a EQUIPMENT MODULE 14 1 INSTRUMENTATION amp CONTROL SYSTEMS operator cannot detect and respond to process upsets as quickly or effectively as a properly designed and tuned control system The control system is designed to monitor upstream changes to feed rate ore grade and other factors and use that information to optimize reagent and other addition rates later in the process This optimization is accomplished automatically by the PCS which makes the changes on time and according to pre determined formulae Operators Roles Automation requires that area operators Central Control operators and other personnel understand the system and work as a team Process control engineers who design and optimize the control strategies implemented by the PCS are also part of the team Teamwork includes accepting the need for automation and working together to ensure automated systems are implemented and refined until they are accomplishing their purposes Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing Revision Date Revision Number 2015 08 30 00 Agrium Document Title Related Documents Doc Doc Number Doc Name Drawing 000F7101 Instrumentation General VPO
27. everything about operating Disturbance your smart phone the first day you had it Condensate Feedforward Feedback Control Figure 7 Feedforward control In this example the flowrate of the process input to the heat exchanger is monitored as well as the output of the exchanger If the flowrate of the incoming fluid increases significantly it will cause a decrease in return temperature which feedback then has to react to By monitoring the supply flow events that might result in a system upset can be detected and reacted to before they affect the return temperature Instrumentation and Control Codes and Standards The specifications codes and standards that govern the installation operation and maintenance of control systems are defined by a multitude of organizations Since this document primarily focuses on operations oN personnel only a few key organizations will be mentioned here ISA Probably the two key organizations that dictate how control systems are designed built and documented are ISA International Society of Automation e IEEE Institute of Electrical amp Electronic Engineer Canadian organizations that play a part in control systems include e CSA Canadian Standards Association Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing Revision Date Revision Number Element Reference 2015 08 30 00
28. f printing Revision Number Element Reference e Revision Date Agr um 2015 08 30 00 n a EQUIPMENT MODULE 14 1 INSTRUMENTATION amp CONTROL SYSTEMS 6 PBL PSC2GP 172 DOR6 FROM PROCESS BRINE LOWER LOOP PUMPS 61755 756 938 B SL PPE2KS 172 0056 TG RECLEANER PNEUMATIC COLUMN FLOTATION CELL 36703 Figure 11 Inputs and outputs on P amp IDs Piping Line Symbols Piping is shown on P amp IDs using several different styles and weights of lines Additional information about lines is included in text labels adjacent to the line PIPING LINE SYMBOL J PRIMARY PROCESS LIHES SECONDARY PROCESS AND UTILITY LINES TERTIARY PROCESS LINES ALL EXISTING LINES PROCESS LIMK oc VENDOR PACKAGE AND AREA BOUNDARY Figure 12 Piping Line Symbol legend on drawing 100J7745 Note These lines never represent electrical lines Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYsTEMS Valves A variety of symbols are used to depict valves The following table found on drawing 100J7745 shows these symbols VALVES _ gt lt GATE VALVE fplj stop CHECK VALVE B
29. ftware packages and licenses installed Satellite Stations The Compaction control room contains one quadruple screen operator Tips and Techniques workstation for Compactors 4 and 5 The room is environmentally Being able to operate equipment from the HMI is controlled This is a full application workstation AW capable of an important bird controlling selected areas displaying and annunciating alarms and MM viewing the rest of the operating plant areas The workstation has all monitoring operating required operating software packages and licenses installed systems from remote workstations The Deslime Flotation area has one dual screen remote operator workstation located in an environmentally controlled room This station will allow the field operator from either area to control his area of responsibility manipulating operating setpoints and basic control for his Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a EQUIPMENT MODULE 14 1 INSTRUMENTATION amp CONTROL SYSTEMS unit as required This workstation has all required operating software packages and licenses installed Loadout has one single screen operator station for the area It includes a computer system in a hardened enclosure including filters and fans with mous
30. hine interface HMI Figure 18 Block diagram of the PCS Distributed Control System The distributed control system is an industrial network that consists of industrial computers communications media and other devices Field devices sensors transmitters signal converters etc connect into the DCS input output The DCS converts the signals to digital form which is used by the system s industrial computer which runs control software The control software provides the functionality of controllers historians and other devices Programmable Logic Controllers Programmable logic controllers are digital computers used for automation of electromechanical processes They accept discrete and analog signals and control equipment such as fixed speed motors and other electrical loads Typically PLCs perform control functions using programs often in the form of ladder logic Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a si ME EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Tips and Techniques You may never see the actual computers or PLCs that make up the process control system but understanding how they work together will help you operate especially if exceptional situations E g if a piece of equipment fails or if commu
31. l enters the system Once in digital format the data can be displayed stored or manipulated for control purposes A measurement signal in a control system is usually referred to as the process variable or PV The PV is typically sent to a controller which is a device that attempts to maintain consistent control of the process The controller compares the PV with a setpoint SP The setpoint is the value at which the controller will try to maintain the PV When everything is working properly they should be same value The controller uses a control algorithm program that responds to differences errors between the PV and SP and creates an output OP signal Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Pneumatic signal 3 to 15 psi Signal Converter current to pressure aka I P Actuator valve positioner Electric signal ERN 4 to 20 mA current Final Control Element valve nat Controller m level Tips and Techniques Electric signal Operators who can read plant drawings and relate them to actual systems in the plant can operate those systems more effectively 4to20 mA current They can also provide Transmitter valu
32. ment Reference Agr um 2015 08 30 00 n a EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS General Instruments mu GENERAL INSTRUMENTS PROGRAMMABLE LOGIC v CONTROLLER HMI HUMAN hel ig gears Q fet LIGHT OR INDICATING DOCS DISTRIBUTED CONTROL di SYSTEM HMI HUMAN INTERLOCK EFFECTIVE A MACHINE IHTERFACE ONLY IF ALL INP UTS EXIST FUNCTION OR DISPLAY gem come c ETE E een INSTRUMENT REAR PURGE OR FLUSHING PANEL RACK OR CABINET DEVICE MOUNTED _ VARIABLE FREQUENCY ees ps PROCESS CONTROL SYSTEM INSTRUMENT MOUNTED 1 INTERLOCK GROUP NUMBER f REAR OF FIELD PANEL ING HH ACTION p X PROCESS CONTROL SYSTEM ine ANALOG ALARMS bwa TEE px TIME DELAY Figure 15 General Instruments legend on drawing 10077747 The basic form used in representing continuously variable instruments is a circle used for depicting locally mounted instruments Adding a line across the circle indicates it is front panel mounted Variations on this line provide information about alternative panel mounting configurations When the circle is located inside a square it means it is connected to the DCS On off devices are represented by diamond shapes When located inside a square they are connected to a PLC Additional information may be included to indicate functionality such as logical AND OR time delay etc Printed 2015 08 3
33. n a EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Calculate control actions and multiply each by Error add up all 3 subtract PV from SP Controller Output PV Figure 4 PID Control Proportional When a controller implements proportional control it compares the setpoint value with the measurement value and produces an output value proportional to the difference By configuring the controller the magnitude of the output can be set For example if the difference is 10 of the measurement range the controller can be set to change its output 10 20 etc in response The amount the controller s output is set to change is called its proportional band Note Proportional Band is expressed in Gain is expressed as a multiplier PB 100 Gain SO A Proportional Band of 100 is a Gain of 1 A Proportional Band of 5096 is a Gain of 2 etc Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a EQUIPMENT MODULE 14 1 INSTRUMENTATION amp CONTROL SYSTEMS Integral Integral control is used to augment proportional control Integral control action responds by increasing the output ramping at a rate configured into the controller In response to the error difference between the PV and SP the
34. n a EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS e CEC Canadian Electrical Code oignificant international organizations include e EC International Electrotechnical Commission 50 International Organization for Standardization Related provincial organizations include e SEA Saskatchewan Electrical Authority SWCB Saskatchewan Workers Compensation Board e SMR Saskatchewan Mines Regulations Important safety related organizations include e MSHA Mine Safety and Health Administration CFR 30 Subchapter N and Part e 56 57 of the Mine Health and Safety Standards e OH amp S Saskatchewan Occupational Health and Safety OH amp S Act 1993 OH amp S Regulations 1996 e MSC Nuclear Safety Association Measurements Units Agrium s standards indicate that personnel should use metric units in based on the International System of Units 51 for instrumentation and control applications A list of standard units follows Measured Parameter Units of Measure Sl Concentration parts per million ppm Conductance Siemens uS Density kilograms per cubic metre kg m Electrical Current Energy Flow mass Flow volumetric Amperes A milliamps mA Joule J Kilowatt hours KWh tonnes per hour t h kilograms per hour kg h Litres per minute l min Frequency Hertz Hz Level Percentage 90 of full Mass kilograms kg tonne t Power Consumption Watt W kilowatt KW Printed 201
35. nications is lost Figure 19 A PLC panel in a switchroom PLCs are often modular and can be customized to accept the number and types of inputs and outputs needed PLCs are typically located in switchrooms which are located in various plant areas They communicate digitally with the DCS to receive and share data with the larger system In some applications PLCs may be equipped to control analog loops employing PID control E g PLCs at the Reclaim Brine Pumphouse incorporate analog control loops Workstations Workstations are individual computer systems PCs including computer keyboard mouse video monitor etc that are connected to the PCS via a network Workstations run the human machine interface HMI software and display HMI windows that enable operators to monitor and control the process Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a s EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Figure 20 Control Room Workstation Displays Main Control Room EH amp S Building Stations The main control room Central Control contains multiple operator workstations that display the HMI Training Room Stations The Training Room contains one single seat operator training simulator OTS system complete with all operating so
36. nted 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a i E EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Instrumentation and Control Basics Instrumentation is defined as the art and science of measurement and control of process variables within a production or manufacturing area Measurement systems may be as simple as direct reading thermometers or may be as complex as multi variable process analyzers A control system is a device or set of devices that manages commands directs or regulates the behavior of other devices or systems Control systems typically are made up of multiple devices working together to detect communicate indicate and control one or more processes Process control systems typically include sensors transmitters communications media signal interfaces I O controllers or control systems signal converters and actuators final control elements FCE Control systems are typically made up of multiple control loops each monitoring and controlling different parameters Systems may implement open or closed loop control Control algorithms determine how control systems respond to measurement changes Sensors Sensors detect real world physical parameters Real world parameters Tips and Techniques that exist in two po
37. on Number Element Reference um 2015 08 30 00 n a EQUIPMENT MODULE 14 1 INSTRUMENTATION amp CONTROL SYSTEMS 100J7746 P amp ID Symbols Sheet 2 of 5 Miscellaneous specialty equipment symbols Pump symbols Mixer symbols Vessel symbols Driver symbols Blower symbols Compressor symbols Process unit symbols 100J7747 P amp ID Symbols Sheet 3 of 5 Instrument identification General electrical control symbols Miscellaneous instrumentation Instrument identification letters Instrument line symbols Instrument abbreviations General instrument symbols Control valve symbols Primary element flow instrument symbols 1007748 P amp ID Symbols Sheet 4 of 5 Material handling equipment symbols 1007749 P amp ID Symbols Sheet 5 of 5 HVAC symbols HVAC abbreviations Fire suppression abbreviations and symbols Motor control types DCS HMI displayed PLC HMI displayed PFD and P amp ID Conventions PFDs and P amp IDs are drawn to standards that all personnel can understand The drawing typically show flow from left to right top to bottom Equipment process lines and signals instrumentation and other information is show using standard symbols Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a s EQUIPMENT MODULE EM14 1 INSTRUMENTATION am
38. onnel However a basic understanding of instrumentation systems will assist the operator in recognizing problems and working with the instrumentation and other personnel in solving problems Control Loops Discrete signals may be sent to indicators such as panel indicator lights to show the status of some aspect of the process Older analog instrumentation systems many of which still exist used analog signals represented by pneumatic pressure 3 to 15 psi electrical current 4 to 20 mA or less often voltage or signal frequency In a simple system analog signals may be sent to a gauge or meter to indicate a range of values In more complex systems analog signals are sent to a controller which is used to control some aspect of the process Modern instrumentation and control systems typically convert signals from analog to digital data so the information is compatible with computer systems The point in the system where analog to digital A D conversion takes place may vary depending on the vintage and complexity of the system There are also hybrid systems that combine analog and digital signals in the same communications link e g HART protocol Discrete analog and digital signals can be sent to a programmable logic controller PLC digital control system DCS supervisory control and data acquisition SCADA system or other type of computerized controller Any needed signal conditioning or conversion is done as the signa
39. ownouts line noise high voltage spikes frequency variations switching transients and harmonic distortion Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS PCS Environmental Control PCS equipment must be maintained in a clean temperature controlled Tips and Techniques environment to ensure continuous reliable operation This is Computer systems can fail if their environment is too accomplished by dedicated HVAC systems for the PCS equipment hot You can prevent costly Programmable controllers are used to control the blower cooling production losses by maintaining awareness of heating and mixing economizers that are part of this system These are whether HVAC systems are known as HVAC controls The HVAC controller can be configured to working properly control one or two independent control processes at the same time This is managed by BACnet BACnet is a data communication protocol for Building Automation and Control Networks Human Machine Interface Tips and Techniques Each process area has one or more process displays a full screen Using the proper terminology window on the HMI Sometimes these displays are also called pages or when referring to the HM
40. p CONTROL SYSTEMS Footer All drawings are formatted with a footer that contains important information about the diagram Plant Area PROJECT VAULT PROJECT 334562 wir N PROCESS PIPING CHARGE CODE 0100 46DD 7790 SECON AREA 172 CLEANER AND RECLEANER FLOTATION 5 PIPING AND INSTRUMENTATION DIAGRAM RECLEANER FLOTATION FEED 100J7790 10 Drawing number Revision number Drawing name Figure 9 P amp ID drawing footer Equipment List The equipment list located at the top of the P amp ID lists all the equipment on the diagram and includes equipment numbers Typically the equipment name number appears above the location it appears on the drawing 36713 96714 Tip san d Techn i ques SCRUBOER FEED LAUNDER SCRUBBER FEED LAUNDER SCREEN TEED Learn the names of each iita piece of equipment None of us can afford to make a mistake caused by a misunderstanding 14 CPBL P5C2GP 172 0085 Figure 10 Equipment list at top of the P amp ID Connectors On the left and right sides of the P amp ID pointed boxes containing the numbers of other P amp IDs show the inputs and outputs to and from the equipment on the drawing Typically a note describes where the inputs come from and the outputs go to Often additional information about pipe sizes etc is included as well Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time o
41. range from simple to complex Simple on off or on off with deadband as described relies on discrete sensors and actuators More complex control systems monitor continuous signals and provide continuous outputs Direct Reverse Acting Control Controllers change their output to the final control element in response to measurement changes PV In some cases the controller output signal must act opposite to the input change For example in a temperature control system if temperature increases the controller may have to decrease the amount of fuel to a burner to bring the temperature back to setpoint In this case when temperature increases fuel flow must decrease This is called reverse acting If the system used a cooling system to control temperature when temperature increases coolant flow must increase This is direct acting On Off Control The thermostat control system previously described is an example of a simple on off feedback controller Initially the temperature is below the setpoint and the heater is on When the temperature PV increases past the temperature setpoint SP a switch opens switching off the heater In this type of on off control to ensure that the thermostat does not cycle on and off frequently deadband often also called hysteresis is incorporated into the controller As the temperature decreases it must go past the setpoint It only turns on the heater when it reaches the turn on point The range of value
42. s and terminology is the International Society of Automation ISA Note The International Society of Automation ISA is a non profit technical society for engineers technicians businesspeople educators and students who work study or are interested in industrial automation and pursuits related to it such as instrumentation It was originally known as the Instrument Society of America ISA and the society s scope now includes many technical and engineering disciplines Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a Si ME EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS An Example of a P amp ID 61703 gt Wel HDI 4 i i 8 i 2 mW 4 g Sa o i Saree n sit j g ht e 228 1 i SEE 1 5 9 0 2 0 0 0 9 9 0 50 2 c 52 2 3 o s 9 9 9 0 0 9 60 0 0 E BP EHE p Hoe jb Bae g5 i rt 8 ur 8 69 i 45 8 p 0 0 0 2 2 0 9 0 70 70 0 9 2 9 u0 i i 9 3 B cu bo i HoiEWS E i D D 3 Fi B gt 171 050
43. s between the turn on and turn off points is called the deadband The width of deadband may be adjustable or programmable This is a relatively crude level of control and is often not adequate for industrial control systems Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a EQUIPMENT MODULE 14 1 INSTRUMENTATION amp CONTROL SYSTEMS Temp Output turns off Set point Hysteresis Output turns on Time Figure 3 On Off Control PID Control A PID controller calculates an error value as the difference between a measured process variable and a desired setpoint The controller Tips and Techniques attempts to minimize the error by adjusting the process control outputs PID control only functions when a system is set to The PID controller algorithm involves three separate parameters and is Automatic mode accordingly sometimes called three term control These are e Proportional P also often expressed in terms of Gain e Integral 1 also known as Reset e Derivative D also known as Rate Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference Agr um 2015 08 30 00
44. s tuning a control Toning sth Padiuetad th t of h t loop can take time and uned Tuning is the process of adjusting the amount of each parameter experimentation Don t give to get optimal results from the process it is on Many factors can affect up too soon and revert to 2 Tm loop tuning is typically done by process engineer and Manual once completed is not changed by the operator Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference Agr um 2015 08 30 00 n a EQUIPMENT MODULE 14 1 INSTRUMENTATION amp CONTROL SYSTEMS Cascade Control In some situations the desired setpoint of a loop may need to change in response to other plant parameters For example when the plant is processing ore at a specific rate tonnage some other systems may have to operate at a rate based on the tonnage If the tonnage is increased the other systems must increase proportionately If plant feed rate is controlled by one loop the output of that loop can be used as the setpoint for one or more other control loops As tonnage increases the setpoint to the other loops increase In the following example the plant feed rate is controlled by the feeder on the bottom of the fine ore bin not shown As feed out of the bin increases the level in the bin will start to decrease The
45. ssible states on off are called discretes A typical Most sensors are not l l accessible to the operator example is a switch opening and closing Parameters that vary However you can monitor continuously through a range such as flow temperature level distance the physical condition of the sensor housings angle pressure etc are called analog or continuous parameters Analog transmitters and cabling sensors typically produce low level output signals electrical or pneumatic and report any damage or deterioration Also if the indications produced by sensors appear incorrect in most industrial applications that vary over a known range of values Typically analog sensors are connected to transmitters A transmitter is a or erratic report this to your device that takes a small signal conditions it amplifies it standardizes its supervisor Central Control range and sends it along to the next segment of the control system as a and or maintenance standard signal Printed 2015 08 30 8 12 AM If printed this becomes a copy of a controlled document This copy is valid for 24 hours ONLY from the time of printing e Revision Date Revision Number Element Reference um 2015 08 30 00 n a i E EQUIPMENT MODULE EM14 1 INSTRUMENTATION amp CONTROL SYSTEMS Signals Tips and Techniques Calibration maintenance and repair of instrumentation systems is the responsibility of the instrument maintenance pers
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