1. Introduction to Marine Automation

8/12/2019 1. Introduction to Marine Automation

1/46

ISAThe Instrumentation, Systems, and Automation Society

Automation

Introduction to Marine Automation


2/46


Learning Objectives

Define what is meant by Instrumentation

Define: Process control Measurement Accuracy Repeatability Resolution Hysteresis Sensitivity Precision Reproducibility


3/46


Learning Objectives

Explain the three (3) variables involve in process control Manipulative variable Disturbance Controlled variable

Describe simple process control loops using a blockdiagram

Explain the difference between open and closed loop

State the essential requirement for automatic operationof machinery


4/46


5/46


Short History of Instrumentation and

Control

3 BCfloat valve on a water clock is the first control devicerecorded being used

1750-1850Scottish Engineer James Watt devised the flyball

governor for steam engine was the 1

st

significant controlinvention

1850-1900 - Siemens invented first dynamo machine. BrownInstrument Co., Honeywell and Fisher governor companies wereestablished

1900-1920Ervin Bailey invents Bailey Boiler Meter,pneumatically operated instruments are made available and On-off controllers are widely used in the process industry


6/46



Control (Continued)

1920-1940

Bailey Controls introduces the 1stmulti-pointer guage and installs1strecording instrument on a marine boiler.

Leeds & Northrup introduces the 1stconductivity recorder andpioneered the development of glass pH electrodes.

Foxboro begins marketing the 1stproportional plus resetrecorder/controller. Instrumentation grows with over 600companies selling instruments.

Taylor Instrument Co. markets its Model 56R the 1stadjustableproportional controller.

Leeds & Northrup introduces the first conductivity gas analyzer


7/46



Control (Continued)

1940-1960 Coleman B. Moore fouds Moore Products. G.B.

Hoadley receives a patent or LVDT.

Lead sulphide infrared detectors are develop by Gudden inGermany.

Taylor Instruments develops the Fulscope 100 which has threerespnse sensitivity, automatic reset and a pre-act (PID).

John Ziegler and Nathaniel Nichols of Taylor Instruments developthe Ziegler-Nichols method of basic controller tuning.

The ISA was born.

First all-electronic instrument was manufactured by Foxboronamed Dynalog.


8/46



Control (Continued)

1940-1960

Miniature pneumatic controls were develop.

Computers were use in instrumentation and controls.

Electro-magnetic and ultrasonic flowmeters weredevelop.

Capacitance pressure sensors was develop andBeckmen Instruments markets the 1stgas

chromatograph. The 1sttransistorized temperature controller was

develop by Honeywell.


9/46



Control (Continued)

1960-Present

Solid state electronics experience tremendous growth whilepneumatic controllers lose their dominance in the market.

Computers are used more often for industrial applications. The vibrating viscocity meter is develop by Tough, McCormick

and Dask.

Bailey install 1stautomated boiler control system aboard the S.S.

Wiliam G Mather and the S.S. CapeBreton Miner. Fuzzy logic was termed and applied. Micro-miniaturization

started a revolution in the manufacturing industry.


10/46



Control (Continued)

1960-Present

Chance Pilkington release 1stfiber optic and HP introducesLEDs.

Honeywell begins development of DCS.

Maturation of computer technology dramatically advances thefield of instrumentation and control.

Masoneilan revolutionizes control valves with the invention of theCamflex the 1stgeneral rotary stem valve.

First in-situ oxygen sensor was introduced by WestinghouseElectric.


11/46



Control (Continued)

1960-Present

Honeywell and Yokogawa introduced the 1stindustrial applicationof distribution digital electronics in process control.

Texas Instruments markets the 1stPLC with true processcapabilities.

Applications of microprocessors, telemetry, ultrasonics andmodeling techniques lead to major advances in biomedical

instrumentation.

Leeds & Northrrup develops the 1stself-tuning automaticcontroller and fiber-optic data highway.


12/46



Control (Continued)

1960 to Present

Honeywell introduces the St 3000 Smart transmitters.

USDATA introduces FactoryLink the 1stPC-based

application enabler software product for SCADA. FieldBus becomes the talk of the town.

SAAB tank Control pioneers a new non-contact radarmethod measurement for levels of liquid in LPG and

LNG tanks. ISO 900X certification for Instrumentation

Manufacturers


13/46


14/46


Properties of Matter

Physical Propertiesthe qualities of substances usuallyidentified to our senses of sight, sound, smell, touch andtaste Color Smell Insolubility

Chemical Propertiesdefined as how a substance

reacts during chemical change Oxidation (rust) Reduction Corrosion


15/46


Matter

Elementsa substance that cannot be broken downinto simpler chemical form

Atomthe smallest possible quantity of an element

Moleculesare the smallest quantity of a materialmade up of multiple atoms/elements that still retains theproperties of that substance

Molecules can be broken down chemically in toelemental atoms that have completely differentcharacteristics from the original molecule


16/46


Matter

No matter what form , all molecules within a substance are inconstant motion

The higher the level of energy the higher the motion

The amount of space that a substance occupies is called volume

Solids have a definite shape and definite volume

Liquids have a definite volume but do not have a definite shape

Gasses do not have a definite volume and do not have a definite

shape. Its volume and shape is defined by its container Fluids is a liquid or a gas substance that can flow


17/46


Energy

Energy is define as the capacity to do work

Potential energy is energy due to position

Kinetic energy is energy of motion

Kinetic energy of a process fluid can be determined bymeasuring its flow rate

Internal energy comes from the motion of molecules

within the material Internal energy will flow from a warmer body to a cooler

body until equilibrium is reached


18/46


19/46


Measurement

Regardless of its use, every measurement musthave a number and a unit or label to have ameaning

Measurement are made by comparingsomething to a scale

Industry around the world uses either English,Metric or International System of units (SI).


20/46


efinitions Instrumentat iona collection of instruments

or their applications for the purpose ofobservation, measurement or control (ISA)

Measurementis the extraction of signalsfrom physical and chemical systems orprocesses which represents parameters orvariables


21/46


efinitions Process

a natural progressively continuing operation ordevelopment marked by a series of gradualchanges that succeeds one another in a relativelyfixed way and leads towards a particular result or

end (Webster) consist of an assembly of equipment and material

that relates to some manufacturing operation orsequence (ISA)

Process Contro l is a technique of balancing supply and demand

over a period of time at a pre-determined level ofoperation called set point


22/46


efinitions Accuracy

conformity of an indicated value to an acceptedstandard value or true value

Repeatabi l i ty the closeness of agreement among a number ofconsecutive measurements of the output for the

same value of input under identical operatingconditions

Resolut ion the smallest interval between two adjacent

discrete details which can be distinguished onfrom the other


23/46


efinitions Hysteresis

the maximum difference obtained as an output forthe same input between the upscale anddownscale output values during a full rangetransverse in each direction

Sensi t iv i ty the ratio of change in output to the change in

input magnitudes


24/46

ISA

The Instrumentation, Systems, and Automation Society

efinitions Precis ion

the closeness of agreement between test results

Reproducib i l i ty the ability of a system of elements to maintain its

output/input precision over a relatively long periodof time


25/46

ISA


Examples of a Process:

1. Mixing of fluids.

2. Heating or cooling of substances.

3. Pumping out of water.

4. Canning food.

5. Deriving gasoline from crude.6. Many more..


26/46

ISA


Difference between a

Systemand a Process:Often in the past, the term process wasapplied to a plant, that is, to the process

itself as well as all of the piping, valves,and equipment need to manufacture aproduct. In order to use the term

accurately, process should describe whatis occurring within a system.


27/46


28/46

ISA


Process Variable

Instrumentation systems are a group ofinstruments or their application for thepurpose of observation, monitoring, or

control The system has the necessary

measurement and control components to

maintain the process within the properlimits. In most cases, process parametersare referred to as Process Variables.


29/46

ISA


Process Variable

A variable is a property of a substance that may change

The devices used to measure and control process variables are calledprocess instruments

A measuring instrument may: Determine if a particular process variable exist in a material Determine value for that material

A control instrument may: Cause a variable to be maintained at a set value or within set limits

Cause a change in the process that changes the value of thevariable in a known way Cause another mechanism such as a valve to control process

variable


30/46

ISA


Process Variable

A variable is a property of a substance that may change

The devices used to measure and control process variables are calledprocess instruments

A measuring instrument may:

Determine if a particular process variable exist in a material Determine value for that material

A control instrument may: Cause a variable to be maintained at a set value or within set limits Cause a change in the process that changes the value of the

variable in a known way Cause another mechanism such as a valve to control process

variable


31/46

ISA


Typical Process iagram

MANIPULATIVE

VARIABLE

CONTROLLED

VARIABLEPROCESS

DISTURBANCE


32/46

ISA


Simple Process Control Loop

CONTROLLER

CONTROL ELEMENT

MEASUIREMENT

PROCESS

DISTURBANCES

INPUT

SET-POINT

OUTPUT

Dist rbances


33/46

ISA


PROCESSinput output

Disturbances

FCE

PrimaryMeasuring

Element

Secondary

Element

Feedback(control loop)

Correction

Comparison

Measurement

The figure shows the relationship of the 4 Basic Functions of an

Automatic Control System and its 3 Control Elements

Computation


34/46

ISA


Elements of a Control Loop


35/46

ISA


Elements of a Control Loop

Measurementconversion of the process variable in toan analog or digital signal that can be use by the controlsystem

Evaluationmeasurement value is examined, comparedwith a desired value or set-point, and the amount ofcorrective action needed to maintain proper control isdetermined

Controlis the device in the control loop that exerts directinfluence on the process or the manufacturing sequence


36/46

ISA


1. SELF REGULATING

HOT H2O

COLD H2O

STM HEATER


37/46

ISA


2. MANUAL CONTROL W/ INDICATING

INSTRUMENT

HOT H2O

COLD H2O

STM HEATER


38/46

ISA


3.AUTOMATIC CONTROL

HOT H2O

COLD H2O

STM HEATER


39/46

ISA


Pneumatic Control Systems

Less expensive initially in spite of tubing and air supplycost

No heat generation and safe in explosive atmosphere

Less susceptible to power supply variation but do havetime lag

Direct applications, without transducers to large finalpower actuators

Simple system design Short commissioning and set-up period

Higher maintenance cost


40/46

ISA


Pneumatic Control Systems


41/46

ISA


Hydraulic Control Systems

Similar to the advantages of pneumatic controlsystems

More appropriate for high pressure, power or work

requirements

Generally more restricted in application

Requires hydraulic oil compared to pneumaticswhich uses air which is free

Recovery-storage system is required for notallowing fluid to escape


42/46

ISA


Hydraulic Control Systems


43/46

ISA


Electro-Technical Control System

Small and adaptable with cheap flexible transmissionlines

No moving parts, can however generate heat

Stable, generally accurate and very short time lag Low power consumption, direct application to

computers, but often need final control element ortransducers

Lower maintenance cost Better suited for long distance transmission

Superior dynamic response


44/46


45/46

ISA


Definitions

Digital A term applied to a signal or device that uses binary

digits to represent continuous values or discretestates

Analog A term applied to a physical signal or variable which

remains similar to another variable in so far as theproportional relationship are the same over some

specific range (McGraw-Hill Dictionary) a signal or a device that represents a variable which

may be continuously observed or continuouslyrepresented over a range


46/46

Difference Between Analog and

Digital DeviceAnalog

Takes an infinite numbervalues

More accurate in reproducinga quantity, variable or signal

May be transmitted overgreater distance but subjectto energy loss

Operator error is more likely

Instantaneous representationof measured variable

Digital

Variables are limited todefined states

Less susceptible to noise

May be transmitted over longdistance at greater efficiency

Operator error is less likely

Conversion of signal mayincur error depending onsampling rate

Uses Binary Number system

Documents

1. Introduction to Marine Automation