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Automation Module
Engineering Foundation Course 2011
Contributors to the CourseSteven Laycock: Technology Leader for Process Control and Automation in Unilever Europe since 2003 and the Global Engineering Excellence Team. Joined Unilever (Leeds) in 1996, after working for an independent systems integrator.
Stuart Dow: Systems Development Manager with Haden Freeman Ltd. (engineering design and consultancy company). 13 years as engineer & manager working on projects in a variety of industry sectors.
Karam Rehani: Head of Instrumentation & Controls in Unilever India & AAMET since 1994. Joined Unilever (HLL) in 1981 & has worked at various locations manufacturing soaps, detergents, personal products & chemicals. Before joining Unilever, worked for 9 Yrs with Leading fertiliser co’s in India.
Endress + Hauser : Live Product Demo
Rockwell Automation : Live Product Demo
Siemens : Totally Integrated Automation Concept (Presentation Content)
Adhi Winata K : Instrumentation, Control, Automation & Electrical Manager in Unilever Indonesia. Joined Unilever in 2006. Before joining Unilever, worked with telecommunication company.
Objective
What are we going to cover today
3 key areas
- Understanding of the use of control systems
- Key knowledge necessary to manage an automation project
- Reasons to choose from the control options available
Agenda
Section 1:Introduction to ControlBuilding blocks – Measurement & Action
Example Equipment (Endress & Hauser)
Section 2: Building Blocks – Evaluation & Logic
Pack Line Case Study : OMAC (Rockwell)
Section 3:Automation Projects & Industry Standards
Process Plant Case Study : Implementation of ISA S88 & ISA S95 (Rockwell)
Section 4: Multiple Choice Questionnaire
Agenda
Section 1:Introduction to ControlBuilding blocks – Measurement & Action
Example Equipment (Endress & Hauser)
Section 2: Building Blocks – Evaluation & Logic
Pack Line Case Study : OMAC (Rockwell)
Section 3:Automation Projects & Industry Standards
Process Plant Case Study : Implementation of ISA S88 & ISA S95 (Rockwell)
Section 4: Multiple Choice Questionnaire
Reasons for Automation
Marketing: A marketing push may require increased production, re-branding,
re-packaging or new formulations for example, or a requirement to search for new growth or markets
Commercial: Higher output, lower utility costs, better yield, less labour
Quality : Better quality, fewer
rejects
It is to realize highest productivity enhancements by intelligently connecting quality, speed, and cost and finding the optimal balance
between all three
Challenge for Automation
Automation CharacteristicsSoftware for Controller and HMI programming :• STEP 7 (Siemens)• RSLogix 5000 (Allen-Bradley)
IT Security in the network :• Restricted Access• Firewall• Encoding• VPN Network
Safety for humans & machines :• Safety Interlock• Alarm Management• Safety Integrated Solutions (SIS)
Standard data transparency across all automation levels :• Communication Protocol• Logger / Historian• Report
Diagnostic functionalities that enable fast detection and correction of errors :• Maintenance Station• Engineering Station
Industrial capability equipment with highest robustness :• Industrial Type Hardware
The Automation Pyramid
Automation System Components
ERP Enterprise Resource Planning SystemBasic functions of the business. Production Planning, Material Management
MES Manufacturing Execution SystemMeasure and control critical production activities. Equipment tracking, product genealogy, scheduling, KPI monitoring
SCADA “Supervisory Control & Data Acquisition” SystemInterface to monitor & control the manufacturing plantHMI, Data Logger / Historian, Batch Management
Control LevelMonitor & control the manufacturing plantPLC - “Programmable Logic Controller”, PC Based Controller, Single / Multiple Loop PID (Proportional, Integral, Derivative) Controller
Field Level Final executor of the manufacturing plant Sensors, Actuators, I/O Module, Hardware
Response time and hierarchical level
PlanningLevel
ExecutionLevel
ControlLevel
SupervisoryLevel
ms seconds hours days weeks month years
ERP(Enterprise Resource
Planning)
DCS
MES(Manufacturing
Execution System)
PLC(Programmable Logic Controller)
(Distributed Control System)
(Supervisory Control and Data Acquisition)
SCADA
Automation System Components
Automation System ComponentsLayer Function Application Example Product Example
ERPCovers all basic functions of the business
• Production Planning SAP
• Orders Oracle
• Finance
• Material Management
MES
Measure and control critical production activities
• Equipment tracking SIMATIC IT
• Product genealogy FactoryTalk Integrator
• Scheduling InSQL
• KPI monitoring
• Workflow
SCADA
Interface to monitor & control the manufacturing plant
• Operator Station WinCC, FT View, InTouch
• Engineering Station
• Batch Control SIMATIC Batch, FTBatch, InBatch
• Logger
ControlMonitor & control the manufacturing plant
• PLC SIMATIC S7-400, ControlLogix
• PID Controller SIPART, Eurotherm T640
• PC Based Controller ACCOSS (Invensys Integrator)
• Motion Controller, CNC SIMOTION, SINUMERIK
FieldFinal executor of the manufacturing plant
• I/O Module SIMATIC ET200 M, Flex I/O
• Field Instruments E+H, Emerson, SITRANS
• Actuator Motor, Valve
Production Order Management
Detailed Production Scheduling
Product Specification Management
Production Operations Recording
Material Management
Production Planning
HMI ServerBatch Server
Data Logger Server
HMI ClientBatch Client
Event Logger
Automation System ComponentsApplication Example : Siemens Totally Integrated Automation
Automation System ComponentsReal Plant Example : Skin Care Processing Plant Cikarang
Basics
Monitor Evaluate Action
How Do We Control?
Information
Basics
We monitor the temperature.
Is it too cold or too hot?
If so we adjust the tap to correct.
Wait for a bit (system dynamics)
If temperature OK then have shower
Else if temperature not OK adjust again(but with benefit of knowing impact of last adjustment)
Go to ‘Wait for a bit’ and repeat.
An Everyday Example
BasicsControl Loop
Instrumentation
Engineering Foundation Course 2011
Agenda
Section 1:Introduction to ControlBuilding blocks – Measurement & Action
Example Equipment (Endress & Hauser)
Section 2: Building Blocks – Evaluation & Logic (Process & Packing Line)
Pack Line Case Study : OMAC (Rockwell)
Section 3:Automation Projects & Industry Standards
Process Plant Case Study : Implementation of ISA S88 & ISA S95 (Rockwell)
Section 4: Multiple Choice Questionnaire
Building Blocks:Measurement & Action
I. Monitoring & measurement1. Process Instrumentation
• Flow Measurement• Level Measurement• Temperature Measurement• Pressure Measurement• Analytical Measurement
2. Packing Line Sensors
II. Action1. Process Instrumentation2. Packing Line Actuators
III. Hardware Selection : Which to Pick
Building Blocks:Measurement & Action
I. Monitoring & measurement1. Process Instrumentation
• Flow Measurement• Level Measurement• Temperature Measurement• Pressure Measurement• Analytical Measurement
2. Packing Line Sensors
II. Action1. Process Instrumentation2. Packing Line Actuators
III. Hardware Selection : Which to Pick
Measure the velocity flowrateExample :
Magnetic Turbine Ultrasonics
Flow Measurement1. Velocity
2. Inferential
3. Mass
Determine flow by measuring some other physical property such as differential pressure, area meter, impact force, etc and then correlate it to flowExample :
Differential Pressure (DP) : Orifice, Pitot Tube, Venturi Area Meter : Rotameter Impact Force : Target
Measure the mass flowrateExample :
Coriolis Mass Flowmeter Thermal Mass
Flow Measurement
1. Velocity Flow : Magnetic Flowmeter
• A magnetic field at right angles to the flow stream is generated• Two opposing electrodes measure the voltage produced by the fluid moving
Flow Measurement1. Velocity Flow : Magnetic Flowmeter
Video Time !!!
Flow Measurement
1. Capable of handling extremely low flow2. Having very low pressure drop (no obstruction), minimize pumping cost3. Suitable for most acids, bases, waters, and aquaeous solutions, because
the lining materials are corrosion resistant4. Widely used for slurry services5. Can be used as bidirectional meters
Limitations :
1. Work only with conductive fluids (can not measure pure substances, hydrocarbons, and gases)
2. Electrical installation care is essential (Proper Grounding)3. Flow measurement inaccuracy due to fluids with magnetic properties
(Liquid Sodium and its solutions)
Advantages :
1. Velocity Flow : Magnetic Flowmeter
Flow Measurement
1. Velocity Flow : Turbine/Paddlewheel
A rotor (like a propeller) is supported by bearings to allow free rotation in the fluid flow.
As the blades spin in the moving flow a pickup device counts the passing rotor blades and generates a frequency.
As this frequency is proportional to the rate of flow and we know how much quantity each pulse represents we can calculate the volumetric flow.
Flow Measurement
1. One of the most accurate flow meter (use for trading)2. Having a fast response3. Not sensitive to changes in fluid density (though at very low specific
gravities, rangeability may be affected)
Limitations
1. Not recommended for measuring steam2. Sensitive to dirt3. Can not be used for highly viscous fluids or for fluids with varying
viscosity4. Potential for being damaged by over-speeding (esp. during
commissioning or start up)
Advantages
1. Velocity Flow : Turbine/Paddlewheel
Flow Measurement
2. Inferential Flow : dP Orifice Plate
Orifice plate : a flat piece of metal with a hole bored in it.
A dP (differential pressure) is created across the plate.
D d
p+p-
)(2
1
2
pp
A
A
ACQ
pipe
orifice
orificed
Flow Measurement
2. Inferential Flow : dP Orifice Plate
An instrument that can measure dP is connected by pipework (called impulse lines) to a tapping point on either side of the plate.
The square root of the dP measured is proportional to the flow. (Normally accounted for in the electronics of the measuring instrument)
Flow Measurement2. Inferential Flow : dP Orifice Plate
Video Time !!!
Flow Measurement
Elbow Taps
2. Inferential Flow : dP VariousPitot Tube Venturi Tube
Flow Nozzle
Flow Measurement
2. Inferential Flow – dP VariousType Advantages Limitation
Orifice
Wide range of applications Low accuracy
Simplest & cheapest among dp types (except big size) High irrecoverable pressure loss
Sturdy
Pitot Tube
Applicable for measurement of large flows Low accuracy
Can be used to obtain the velocity profiles Depend much on velocity profiles in one point
Very Low pressure loss
Venturi Tube
Low Pressure Loss More expensive than orifice
Resistant to abrasion Installation is more difficult
Can be used to measure dirty fluids & slurry
Elbow TapsLow cost solution for large pipe Inaccurate measurement
Very Low Pressure Loss Requiring high flow velocities & short radius elbow
Venturi NozzleLess expensive than venturi tube Higher Pressure Loss than venturi tube
Resistant to abrasion Installation is more difficult
Flow Measurement3. Mass Flow : Coriolis Effect
Tube(s) are forced to oscillate at their natural frequencies perpendicular to the flow direction.
The resulting Coriolis forces induce a twist movement in the tubes which is measured and is related to the mass flow.
Flow Measurement3. Mass Flow : Coriolis Effect
Video Time !!!
Flow Measurement3. Mass Flow : Coriolis Effect
Two most common types are the
1. Used mainly for multiphase fluids and for fluids that can coat or clog since the straight type can be easily cleaned
2. Having a low pressure loss3. Reduces the probability of air
and gas entrapment4. Must be perfectly aligned with
the pipe
1. Having a wider operating range, measures low flow more accurately
2. Available in larger sizes3. Tends to be lower in cost4. Having a higher operating
temperature range 5. More sensitive to plant
vibrations
Straight Tube Curved Tube
Flow Measurement
Advantages :
• Directly measures mass flow with high accuracy
• High rangeability
• Directly measure density
• Highly independent of the flow profile and fluid properties (specific gravity and viscosity)
• Can be used for many different applications, including corrosive fluids
Limitations :
• High Price
• Can not be used for liquids with any significant gas content
• Not available for large pipelines
• Not suitable for low pressure gases
3. Mass Flow : Coriolis Effect
Flow MeasurementOther Methods
Thermal Mass Flowmeter
Vortex Shedding
Ultrasonic
Target
Weir & Flume
Variable Area / Rotameter
Flow MeasurementFlowmeter Comparison Table
Flow MeasurementFlowmeter Comparison Table (cont’d)
Building Blocks:Measurement & Action
I. Monitoring & measurement1. Process Instrumentation
• Flow Measurement• Level Measurement• Temperature Measurement• Pressure Measurement• Analytical Measurement
2. Packing Line Sensors
II. Action1. Process Instrumentation2. Packing Line Actuators
III. Hardware Selection : Which to Pick
Level Measurement
Wave : Radar, ultrasonic, Guided Radar (TDR) Nuclear radiation Electrical Properties : Capacitance, Conductance Mechanical Contact : Floats, Tuning fork, Paddle wheel
2. Position (height) of the surface
3. Weight
Load Cells
1. Pressure / Force
Pressure : Differential pressure, Diaphragm, Air bubblers Buoyancy Force : Displacer
Level MeasurementPulse 6 GHz
RadarPressure Guided Wave
Radar TDRFMCWPulse
24 GHz RadarCapacitance Ultrasonic
Level Measurement
1. Pressure Static Head
Pressure/Static Head: (also known as hydrostatic)- Based on the height of the liquid head & the density of the liquid - Accurate level calculation requires known & constant density
Advantages :1. Have a wide range of measurement2. Straightforward calibration
Limitations :1. Affected by changes in liquid density (only
for liquids with fixed SG)2. Susceptible to dirt or scale entering the
tubing
Pressurized Vessel
Atmospheric Vessel
Level Measurement
Wave is transmitted to target, reflected, and total transit time is determined
2. Position of Surface : Wave
Type Wave Source Carrier Medium Wave Speed
RadarElectromagnetic Wave (4-30 GHz)
Not needed (able to propagate in empty / vacuum space)
Speed of Light (300,000 km/s)
UltrasonicMechanical Wave (> 20 kHz)
Needed (air, liquid, solid)Speed of sound (344 m/s)
Free Wave
Radar
Ultrasonic Guided Radar
Free Wave Guided Wave
Level Measurement
Type Advantages Limitation
Ultrasonic
1. Able to measure the level without making physical contact with process material
1. May not be used if vapour space of the material is dusty, or it contains foam, water vapour, or mists
2. Unaffected by changes in the composition, density, moisture content, electrical conductivity, and dielectric constant of the process fluid
2. Not applicable should the material has sound-absorbing surface (fluffy solids)
3. Reliable performance for difficult slurry or sludge-type services
3. Require a consistent temperature, since it is affected the speed of sound
Radar
1. Able to measure the level without making physical contact with process material
1. Not applicable for low-dielectric material that absorb the microwave
2. Unaffected by changes in the composition, density, moisture content of the process fluid
3. Changing vapour and foam has less effect than on ultrasonic type
4. Reliable performance for applications of medium difficulty, such as fuming acids, asphalt, LNG, tars, and other heavy hydrocarbons
Guided Radar
1. Able to measure liquid interface level (with some conditions related with dielectric constant of the material & no emulsion layer)
1. Not applicable for low-dielectric material that absorb the microwave
2. Position of Surface : Wave
Level Measurement
• Measures the changing electrical capacitance• Applicable for both conductive and nonconductive fluids• Provide both continuous and point measurement• The dielectric constant of the fluid must remain constant• Can not measure liquid interface
• Electric current flows through the fluid, container wall and the probe which actuates a relay
• Applicable for conductive fluids only• Provide only point measurement• Can provide differential level control (three-probe-
type)
2. Position of Surface : Electrical PropertiesCapacitive
Conductive
Level Measurement
• A radioactive source radiates through the vessel. The gamma quantum is seen by the radiation detector (such as a Geiger counter) and is transformed into a signal
• Unaffected by temperature, pressure, and corrosion
• Applied where other types of measurement cannot be used
2. Position of Surface : Nuclear Radiation
Level Measurement
• Keeping the probe vibrate in its natural frequency• Relay triggered when process material in the tank reaches
the vibrating elements and damps out the vibration• Applicable for both liquid and solid material
• Small synchronized motor keeps the paddle in motion at very low speed
• When level raised to the paddle, it is stopped
• Applicable for solid material
• Applicable for liquid material
• Applicable for both point and continuous measurement
2. Position of Surface : Mechanical ContactTuning Fork (Vibration)
Rotating Paddle Switch Float
Level Measurement
3. Load Cells
The strain gauge (either foil or semiconductor) measures the stress which is introduced into a metal element, both compression & tension
A bending beam type designuses strain gauges to monitor the stress in the sensing elementwhen subjected to a bending force.
Level Measurement
3. Load Cells TypeType Explanation Picture
Compression (Canister)
Designed to operate in compression only
Load can be applied at one end only, for some types it can be compressed by force at both ends
Shear BeamFixed rigidly at one end with the force being applied to the other end
Bending Beam
It consists of a straight beam attached to a base at one end and loaded at the other. Its shape can be that of a cantilever beam, a binocular design, an S-shaped or a ring design .
Ring TorsionRound and flat bending beam sensors consisting of bonded foil strain gages encapsulated in a housing
HelicalThe operation of a helical load cell is based on that of a spring. A spring balances a load force by its own torsion moment
Level Measurement
3. Load Cells Comparison Table
Level Measurement
Level Sensor Comparison Table
Level Measurement
Level Sensor Comparison Table (cont’d)
Building Blocks:Measurement & Action
I. Monitoring & measurement1. Process Instrumentation
• Flow Measurement• Level Measurement• Temperature Measurement• Pressure Measurement• Analytical Measurement
2. Packing Line Sensors
II. Action1. Process Instrumentation2. Packing Line Actuators
III. Hardware Selection : Which to Pick
Temperature Measurement
Thermocouples
1. Voltage
2. Resistance
3. Radiation Pyrometer (Infra Red)
4. Material Expansion
RTD Thermistor
Optical Ratio / Two-Color Broadband (Total) Radiation
Liquid-in-glass Bimetallic Filled system
Temperature Measurement
1. Thermocouples
A thermocouple consists of two dissimilar metals, joined together at one end. When the junction of the two metals is heated or cooled a voltage is produced that can be correlated back to the temperature.
Temperature MeasurementThermocouples Type
Type
Wire Material Range (in °C)
Scale LinearityAtmosphere Environment
RecommendedFavorable Points Less Favorable Points
Positive Negative Min Max
BPt 70% - Rh 30%
Pt 94% - Rh 6%
0 1860Good at high temps. Poor below 535 °C
Inert or Slow Oxidizing
E Chromel Constantan -184 982 Good Oxidizing Highest mV/°CLarger drift than other base metal couples
J Iron Constantan 0 816Good; nearly linear from 150°C to 425°C
Reducing Most economicalBecomes brittle below 0°C
K Chromel Alumel -184 1260Good; most linear of all TCs
Oxidizing Most LinearMore expensive than T or J
RPt 87% - Rh 13%
Platinum 0 1649Good at high temps. Poor below 535 °C
OxidizingSmall size, fast response
More expensive than K
SPt 90% - Rh 10%
Platinum 0 1760Good at high temps. Poor below 535 °C
OxidizingSmall size, fast response
More expensive than K
T Copper Constantan -184 399Good but crowded at low end
Oxidizing or reducing
Good reststance to corrosion from moisture
Limited temperature
Y Iron Constantan -129 982Good; nearly linear from 150°C to 425°C
Reducing Not Industrial Standard
Temperature Measurement
2. RTD (Resistance Temperature Detector)Measure temperature by correlating the resistance of the RTD element with temperature.
The RTD element is made from a pure material whose resistance at various temperatures has been documented. It has a predictable change in resistance as the temperature changes
• Winding the wire on a glass or ceramic bobbin and sealing with molten glass
• Limited by strain induced at higher temperature
• Threading a wire helix through a ceramic cylinder• Allows the wire coil to expand more freely over temperature • Not suited for extreme vibration
• Depositing a thin film on a ceramic substrate• Small, fast, inexpensive, less stable
Wire-Wound
Coil Elements
Thin Film
RTD element construction type
Temperature Measurement
Metal
Range (in °C) Ice Point
ResistanceCharacteristic
Min Max
Platinum -200 850
Thin Film Type : 100, 1000 Ω
Most Linear
Wire-wound Type : 100, 200, 500 Ω
Widely used
Nickel -196 316
120, 500, 1000 Ω Not linear
Strain-sensitive
Highest Temperature coefficient
Copper -196 120 10, 100 ΩUsed in electrical machinery due to very low reactanceRTD Wiring configuration
RTD Detector Type
• Poor Accuracy• No compensation for resistance of
the connecting wires • Transmitter must be placed very
near with the sensor
• Best accuracy• Another pair of wires to form an
additional loop that cancels out the lead resistance
• Better accuracy than 2-wire• Two leads to the sensor are
on adjoining arms, therefore the lead resistance is cancelled out
2-wire 3-wire 4-wire
Temperature Measurement
Characteristic Thermocouple RTD
Measurement Range Wide Narrow
Response Time Fast Slow
Linearity Less Linear More Linear
Price Cheap Expensive
Accuracy Less Accurate More Accurate
Sensitivity Less sensitive More Sensitive
Repeatability Fair Excellence
Long-Term Stability Fair Good
Self Heating Effect Medium N/A
Point (end) sensitive Fair Excellent
Lead Effect Medium High
Thermocouples Vs RTD
Temperature Measurement
3. Optical
The most basic design consists of a lens to focus the infrared (IR) energy on to a detector, which converts the energy to an electrical signal that can be displayed in units of temperature after being compensated for ambient temperature variation.
Infrared pyrometers allow users to measure temperature in applications where conventional sensors cannot be employed. Specifically, in cases dealing with moving objects ( i.e., rollers, moving machinery, or a conveyor belt),
Temperature Measurement
Temperature Sensor Comparison Table
Building Blocks:Measurement & Action
I. Monitoring & measurement1. Process Instrumentation
• Flow Measurement• Level Measurement• Temperature Measurement• Pressure Measurement• Analytical Measurement
2. Packing Line Sensors
II. Action1. Process Instrumentation2. Packing Line Actuators
III. Hardware Selection : Which to Pick
Pressure Measurement
Bourdon Tubes Diaphragm Bellows
1. Elastic Pressure Chamber (Mechanical)
3. Liquid Level Column
Manometer
Capacitive Strain Gauge (Piezoresistive) Piezoelectric Inductive
2. Electronics
Pressure Measurement1. Mechanical
Bourdon
A bent oval tube.One end of the tube is linked tothe process pressure, and the other end is sealed and linked to the mechanism operating the PointerShapes : C, Spiral, Helical
Converts the increasing process pressure on one side of the disk into a mechanical movement by monitoring the bulging of the disk
One-piece axially expandable and collapsible element.Consists of many folds
Diaphragm
Bellows
Pressure Measurement2. ElectronicsA typical electronics pressure transmitter consists of two parts:
1. Primary elementConverts the pressure into an displacement / torque / mechanical value to be read by the secondary value. It may be diaphragm, bellows, etc
2. Secondary elementThe electronics that output from the primary element to a readable signal. It may be strain gauges, capacitive, piezoelectric, etc
Primary Element
Secondary Element
Pressure Mechanical Electric
- Displacement- Torque
- Resistance- Capacitance- Voltage- Current
Pressure Measurement2. Electronics
The inlet pressure activates a diaphragm that ismounted between two fixed plates. This causes a capacitance change
Piezoresistive materialchanges its resistance when strain is applied
Strain Gauges / Piezoresistive
Capacitive
additional temperature sensor for permanent self monitoring
dPceramic cell
fill fluid
ceramic membrane
capacitor plates C1
C2
process pressure
ceramic body
additional temperature sensor for permanent self monitoring
dPceramic cell
fill fluid
ceramic membrane
capacitor plates C1
C2
process pressure
ceramic body
Pressure Measurement2. Electronics
The inlet pressure activates a diaphragm / bellows that applies strain on a crystal (e.g., quartz). The strained quartz produces an electrical charge that is measured by the electronics
The inlet pressure activates a diaphragm / bellows moves a magnetic core inside the transformer. It creates an imbalance that is measured in the electronics
Inductive
Piezoelectric
Pressure MeasurementPressure Measurement Reference1. Gage pressure
Reference : Atmospheric pressure
2. Absolute pressure Reference : Complete vacuum
3. Differential pressureDifference between two pressure levels
Absolute
DP
Level
Gauge
Absolute Zero Pressure
Atmospheric Pressure
Absolute Pressure(psia, bara)
Vacuum Pressure(-psig, -bar)
Gauge Pressure(psig, bar)
Pressure MeasurementPressure Sensor Comparison Table
Building Blocks:Measurement & Action
I. Monitoring & measurement1. Process Instrumentation
• Flow Measurement• Level Measurement• Temperature Measurement• Pressure Measurement• Analytical Measurement
2. Packing Line Sensors
II. Action1. Process Instrumentation2. Packing Line Actuators
III. Hardware Selection : Which to Pick
Analytical Measurement
pH Conductivity Gas Detector
MC Meter Chlorine Meter Turbidity
Building Blocks:Measurement & Action
I. Monitoring & measurement1. Process Instrumentation
• Flow Measurement• Level Measurement• Temperature Measurement• Pressure Measurement• Analytical Measurement
2. Packing Line Sensors
II. Action1. Process Instrumentation2. Packing Line Actuators
III. Hardware Selection : Which to Pick
MeasurementPosition
Position and distance sensors detect the presence or not of items on the move. This can be used to identify when an item arrives, count how many items have passed or when an item has left.
Position technologies include photoelectric, laser, mechanical switches, proximity switches and pressure sensors.
MeasurementColour
Colour sensors can detect the presence or not of a successful operation. Has the label been printed, has the bottle got the right fluid in it, did the shrink wrap go on successfully
MeasurementMachine Vision
Machine vision is successfully applied to many industrial inspection problems, leading to faster and more accurate quality control. Machine Vision allows the
manufacturing industry toDetect Defects
Calibrate and control the manufacturing processOptimise the use of resources
Building Blocks:Measurement & Action
I. Monitoring & measurement1. Process Instrumentation
• Flow Measurement• Level Measurement• Temperature Measurement• Pressure Measurement• Analytical Measurement
2. Packing Line Sensors
II. Action1. Process Instrumentation2. Packing Line Actuators
III. Hardware Selection : Which to Pick
ActionValves
Switching a pneumatic air supply to a valve or piston cylinder
• Achieving precise control of a process fluid• Usually connected to I/P transducer that convert electrical signal into pressure signal
• Switching feeds on and off or, when used in conjunction with other valves, to select routes through pipework systems• It is usually connected to solenoid valve that switch on/off the air supply
Solenoid Valves
Modulating / Control Valves
Discrete Valves
Action
Motors
Motors allow us to move things around whether it’s a pump moving liquids or a conveyor line moving boxes.
Motor operation (start/stop) is usually controlled in the MCC (Motor Control Center). The control circuit in MCC usually consists of contactors & relays.
Variable Speed Drives (VSD / Inverter) connected to the motor allows the motor speed to be controlled.
Building Blocks:Measurement & Action
I. Monitoring & measurement1. Process Instrumentation
• Flow Measurement• Level Measurement• Temperature Measurement• Pressure Measurement• Analytical Measurement
2. Packing Line Sensors
II. Action1. Process Instrumentation2. Packing Line Actuators
III. Hardware Selection : Which to Pick
Action
Motors
Servo drive motors allow added control functionality (ramp up, ramp down, torque) and faster positioning.
Stepper motors give precise control of movement.
Switching a pneumatic air supply to a valve or piston cylinder
Solenoid Valves
Action
Equipment
Remote device interfaces allow us to control and “talk” with an enormous range of equipment and devices. This can take the form of a simple on/off control or a complex data/control interface.
ActionMechatronics
Building Blocks:Measurement & Action
I. Monitoring & measurement1. Process Instrumentation
• Flow Measurement• Level Measurement• Temperature Measurement• Pressure Measurement• Analytical Measurement
2. Packing Line Sensors
II. Action1. Process Instrumentation2. Packing Line Actuators
III. Hardware Selection : Which to Pick
Which to Pick
Environment & System
What are the the parameters the device will be exposed to and expected to perform in during both routine and exceptional circumstances?
What are the performance criteria: speed, size, pass/fail criteria for the line?
With which chemicals and under what conditions will the device be expected to operate?
What hazards will be present and does this impact on the choice of device?
What’s the commercial impact? Cost v benefit.
Which to PickANSI/ISA 60529
Degrees of ProtectionProvided By Enclosures
IP XX
Protection against solid objects
Protection against water
ATEX DIRECTIVES
Minimise, or completely eliminate, the risk of ignition in explosive areas and to limit the harmful effects in case of an explosion.
Which to Pick
ATEX DIRECTIVES
Which to Pick