Instrumentation Systems -Fundamentals and Applications-

Tasuku Senbon, Futoshi Hanabuchi (Eds.)

Instrumentation Systems Fundamentals and Applications

Springer-Verlag Berlin Heidelberg GmbH

Instrumentation Systems-Fundamentals and Applications.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, recording or otherwise, without the prior written permission of the copyright owner.

First published in Japanese in 1987 by Ohmsha, Ltd. Tokyo as 1 Keisou Shisutemu no Kiso to OuyouJ

© 1991 Springer-Verlag Berlin Heidelberg Originally published by Springer-Verlag Berlin Heidelberg New York in 1991

Exclusive worldwide distribution by:

ISBN 978-3-662-12091-0 ISBN 978-3-662-12089-7 (eBook) 10.1007/978-3-662-12089-7 DOI

PREFACE

This book, though small, contains a wealth of technical informa­tion on control engineering and instrumentation engineering for indus­trial quantities, on control-system component elements (sensing, con­version, control, monitoring, and actuation), and on the system-design approaches (system engineering) used in process automation (PA) and factory automation (FA), discussing them based on examples of their applications, and covering everything from basics to applications.

Process automation has a long history, with automation of individ­ual functions having begun as early as the 1920's. The feedback control techniques that constitute its basis grew into an indispensable core technology along with the rapid advance of control theory and control devices from the 1960's onward. Today we are progressing further to­wards system-scale optimal control technology. One of the influences that spurred major innovation along the way was the birth of micropr­ocessor-based digital computer control in the 1970's. This enabled the realization of batch and sequential control together with feedback con­trol in the same processor thus allowing an intimate interlinkage among them all. Technology for communication between multiple pr­ocessors was also introduced, fostering rapid advances in functional sophistication and installation density. Moreover, this did not stop with process automation, but also spread to total factory automation covering entire plants. This included factory automation aimed at dis­crete processes.

This book begins with a discussion of control theory. It moves on to discuss the product hardware and software that implement the theo­ry, and then proceeds to describe instrumentation examples and the system-design approaches (system engineering) suitable for a variety of production processes. Thus, we believe it to be ideally suited for use as a college-level textbook on instrumentation and automation for undergraduate or graduate students, or as a reference book for practic­ing instrument engineers in industry.

Since the subject matter deals with extremely specialized technolo-

Preface v

gy, the responsibility for the authorship has been undertaken by Yok­ogawa Electric experts continually involved in these areas. The Yok­ogawa Electric Training Center has undertaken the task of editing and compiling these writings into a text.

At the same time that we express our gratitude to the authors of the many works used for reference, we would also like to offer our dee­pest thanks to the staff of our publisher, Ohmsha, Ltd., for their hard work and earnest cooperation. We hope that this book will be of assis­tance to our readers in their study of instrumentation and control sys­tems.

September, 1987

vi

Hisashi Tamura, Senior Vice President Director, SBU Administration

Yokogawa Electric Corporation

Preface

ABOUT THE ENGLISH-LANGUAGE EDITION

Since its publication in 1987, the original Japanese-language edi­tion of lnstrumentataion Systems has already gone through several print­ings. This is due to its wide readership among those responsible for instrumentation and control in Japan. There is a significant relation­ship between the expanding number of readers of this book and the continuing rapid growth of Japan's industry and economy, with process automation and factory automation as two of its driving forces.

Today as the barriers between East and West crumble away, we hope that an even wider international dissemination of this book will lend support to the world's movement toward global industrial and eco­nomic development. The authors and editors have felt this to be one of their missions. A necessary condition has been the creation of this Eng­lish-language edition.

This opportunity to carry the English-language version to realiza­tion with the full cooperation of Ohmsha, Ltd. and Springer-Verlag has been a source of great pleasure to the authors and editors. We wish to extend our thanks for the assistance of those who undertook the translation and editorial supervision.

It is the hope of all those involved that this book will be widely read and found useful by members of the instrumentation and control community all over the world.

About the English-Language Edition

Akio Yamamoto, General Manager Y okogawa Electric Training Center

vii

LIST OF CONTRIBUTORS

EDITORS

Tasuku Senbon Futoshi Hanabuchi

AUTHORS (alphabetical order)

Naoki Asakawa Y oshio Fukai Katsuhiro Hikasa Kiyokazu Ishii Tadamichi Kai Isao Katsuoka Hiroshi Kawai Toshio Kimura Takane Kudo Hidesada Kurioka Tetsuro Matsumoto Kiyoshi Matsunaga Teruyoshi Minaki Y oshiaki Murakami Y oshio Nagasaki Shinobu N agase Eizo Oku

EDITORIAL ASSISTANCE

Akio Yamamoto Sumiaki Nishikata

List of Contributors

Kazuo Omori Yoshikatsu Sakai Makoto Sekiya J un Shiozawa Fuso Takamura Shin-ichi Takigishi Akira Tanaka Yukio Tanaka Katsuaki Tokunaga Masahito Tsukamoto Hideo Tsurumaki Masahiko Ushioda Sadahito Watanabe Shigehiko Yamamoto Shigeru Yamamoto Michio Yoshioka Tsuneo Zeniya

!X

CONTENTS

Preface v About the English-Language Edition vii List of Contributors ix

Chapter 1 INDUSTRY AND INSTRUMENTATION 1.1 The Word "Instrumentation" ...................................... 1 1. 2 The Development of Instrumentation ............................... 2 1. 3 Trend toward Total FA .............................................. 4 1. 4 Classification and Use of Instruments .............................. 6 References .................................................................. 9

Chapter 2 PROCESS CONTROL 2 .1 Fundamentals of Feedback Control.. .............................. 11

2 .1.1 Configuration of a control system ............................ 11 2 .I. 2 Characteristics of a control system ........................... 13 2 .I. 3 Feedback control and stability ................................ 19

2 . 2 Process Characteristics .............................................. 23 2. 2 .1 Process degrees of freedom and controlled and

manipulated variables ......................................... 23 2 . 2. 2 Process characteristics ......................................... 25 2. 2. 3 Process models .................................................. 26

2. 3 Control Formats for Various Types of Processes ................ 32 2 . 3 .1 Single loop control systems .................................... 32 2. 3 . 2 Compound loop control system ................................ 39

2. 4 Optimal Adjustment of Control Systems ......................... .45 2. 5 Sequential Control ................................................... 50

2.5.1 Meaning of "sequential control" ............................. 51 2. 5. 2 Types of sequential control.. .................................. 51 2. 5. 3 Sequential control description ................................. 52 2. 5. 4 Devices for sequential control ................................. 57

Practice Questions ........................................................ 58 Answers to Questions .................................................... 59 References ................................................................. 59

Contents xi

Chapter 3 DETECTION AND CONVERSION OF INDUSTRIAL VARIABLES

3 .1 Measurement of Industrial Variables .............................. 62 3 .1.1 Methods of measurement ....................................... 62 3 .1. 2 Accuracy of measurement ..................................... 66

3.2 Measurement of Temperature ...................................... 71 3. 2 .1 Thermoelectric thermometers ................................. 72 3. 2 . 2 Resistance thermometers ....................................... 84 3.2.3 Protective tube .................................................. 91 3. 2. 4 Thermistor thermometers ...................................... 92

3. 3 Measurement of Flow ............................................... 98 3. 3 .1 Differential pressure flowmeters .............................. 99 3. 3. 2 Float-type area flowmeters ................................... 105 3. 3. 3 Volumetric flowmeters ........................................ 110 3. 3. 4 Turbine flowmeters ............................................ 113 3. 3. 5 Magnetic flowmeters .......................................... 117 3. 3. 6 Vortex flowmeters ............................................. 125 3. 3. 7 Ultrasonic flowmeters ......................................... 130

3. 4 Measurement of Pressure .......................................... 135 3 .4 .1 Pressure transmitters .......................................... 136 3. 4. 2 Types of pressure detectors .................................. 138

3. 5 Measurement of Liquid Level ..................................... 141 3.5.1 Float liquid-level meters ...................................... 141 3. 5. 2 Pressure differential liquid-level meters .................... 141 3.5.3 Displacer liquid-level detectors .............................. 144 3. 5. 4 Purge-type liquid-level meters ............................... 145 3.5.5 Ultrasonic liquid-level meters ................................ 146 3.5.6 Capacitance liquid-level meters .............................. 147

3. 6 Measurement of Displacement and Angle ........................ 148 3. 6.1 Resistance potentiometer methods ........................... 148 3. 6. 2 Electromagnetic induction methods .......................... 148 3. 6. 3 Magnetic balance method ..................................... 152 3. 6. 4 Magnetic strain method ....................................... 153

3. 7 Measurement of Rotation .......................................... 153 3. 7 .1 Measurement using tachometer generators ................. 153 3. 7. 2 Pulse output sensors ........................................... 155 3. 7. 3 Digital counting tachometers ................................. 156

3. 8 Measurement of Composition ..................................... 158 3. 8.1 Gas chromatography .......................................... 158 3. 8. 2 Infrared analyzers ............................................. 163 3. 8. 3 Oxygen analyzers .............................................. 166 3. 8. 4 pH meters and ORP meters .................................. 169

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3. 8. 5 Moisture/humidity meters .................................... 172 3.8.6 Turbidity meters ............................................... 174 3. 8. 7 Conductivity meters ........................................... 176 3. 8. 8 Other composition measuring devices ....................... 179

3. 9 B/M Systems ........................................................ 188 3. 9.1 Basis weight sensor (B sensor) ............................... 189 3. 9. 2 Moisture sensors (M sensors) ................................. 191 3. 9. 3 Calipers (paper thickness gauges) ............................ 192 3. 9. 4 Moisture sensor for thick paper .............................. 193 3. 9. 5 Color sensors ................................................... 194 3. 9. 6 Ash sensors ..................................................... 195

3.10 Signal Converters ................................................. 195 3.10 .1 The purpose of signal converters ........................... 195 3.10. 2 Thermocouple signal converters ............................ 197 3.10. 3 Resistance signal converters ................................ 199 3.10. 4 Two-wire signal transmission .............................. 200 3.10. 5 Pulse signal converters ...................................... 201 3.10. 6 Computer input equipment. .................................. 202

Practice Questions ....................................................... 205 Answers to Questions ................................................... 205 References ................................................................ 205

Chapter 4 RECORDERS AND CONTROLLERS 4 .1 Recorders ............................................................ 209

4 .1.1 Types of recorders ............................................ 209 4 .1. 2 Recorder functions ............................................. 210 4 .1. 3 Pen recorders .................................................. 212 4 .1. 4 Multipoint recorders ........................................... 218

4. 2 Controllers ........................................................... 222 4. 2 .1 Pneuma tic and electronic controllers ........................ 222 4. 2. 2 Analog electronic controllers ................................. 223 4. 2. 3 Digital controllers ............................................. 226 4. 2. 4 Programmable controllers .................................... 231 4. 2. 5 Batch controllers and blending controllers ................. 235

4. 3 Computing Stations and Set Stations ............................. 241 4. 3.1 Alarm set stations ............................................. 241 4. 3. 2 Programmable computing units .............................. 242 4. 3. 3 Manual set stations and manual operating stations ....... 243

References ................................................................ 245

Chapter 5 SYSTEM CONTROL EQUIPMENT 5.1 Overview of System Control Equipment ......................... 248

5 .1.1 Development .................................................... 248

Contents xiii

5 .1. 2 Configuration of a total FA system ......................... 252 5. 2 Distributed Control System ........................................ 256

5. 2 .1 Concept of the distributed control system ................... 256 5. 2. 2 Configuration of the distributed control system and

its functions ................................................... 259 5. 2. 3 Feedback control .............................................. 267 5. 2. 4 Sequential control ............................................. 271 5.2.5 Man-machine interface ....................................... 276 5. 2. 6 Communication with other systems .......................... 284 5. 2. 7 Engineering ..................................................... 285

5. 3 Production Line Control System .................................. 291 5. 3 .1 Summary of production line control systems ............... 291 5. 3. 2 Types of production line control systems ................... 292 5. 3. 3 FA computer systems ......................................... 295 5. 3. 4 FA computer system hardware ............................... 298 5. 3. 5 FA computer software ........................................ 303

5.4 Computer System Equipment for Production Management .... 306 5. 4.1 Computer components and configuration ................... 306 5. 4. 2 Software for production management computer systems .. 316

5. 5 Data Communication and Equipment ............................. 325 5. 5 .1 Data communication and standards ......................... 325 5. 5. 2 Methods of data communications ............................ 327 5.5.3 The IEEE-488 instrument bus ................................ 329 5. 5. 4 The RS-232 C interface and modems ........................ 331 5. 5. 5 Local area networks .......................................... 334 5. 5. 6 Optical communications ....................................... 335

5. 6 Basic Components of Digital Control.. ........................... 336 5. 6 .1 Microprocessors ................................................ 336 5. 6. 2 Memory elements and storage equipment ................... 343 5. 6. 3 Display elements and devices ................................. 346 5.6.4 Analog/digital conversion .................................... 351 5. 6. 5 Optical communication elements ............................. 353

References ................................................................ 354

Chapter 6 FINAL CONTROL ELEMENTS 6.1 Types of Control Valves ........................................... 355

6 .1.1 Pneumatic control valves ..................................... 355 6 .1. 2 Electrical control valves ...................................... 355 6 .1. 3 Hydraulic control valves ...................................... 356 6 .1. 4 Self-powered control valves .................................. 356

6. 2 Choice of Control Valves .......................................... 356 6. 2 .1 Various conditions affecting choice .......................... 356 6.2.2 Sizing ........................................................... 360

xiv Contents

6 0 2 0 3 Flow characteristics ........................................... 361 6 0 2 0 4 Rangeability .................................................... 363 60205 Materials ....................................................... 364

6 0 3 Control Valve Bodies .............................................. 367 6 0 3 01 Characteristics of various types of valves .................. 367 60302 Rating ........................................................... 373 6 0 3 0 3 Connection to piping .......................................... 37 4

6 0 4 Control Valve Actuators ........................................... 37 4 6 0 4.1 Conditions under which an actuator should be installed .. 37 4 6. 4. 2 Power sources .................................................. 37 4 6. 4. 3 Types of actuators and their characteristics ............... 376

6. 5 Positioners and Accessories ....................................... 384 6. 5.1 Positioner functions ........................................... 384 6. 5. 2 Pneumatic pressure positioners .............................. 384 6. 50 3 Current-to-pneumatic positioners ............................ 384 6 0 50 4 Current-to-current positioners ............................... 386 6 0 5. 5 Accessories ..................................................... 386

6 0 6 Self-powered Valves ............................................... 388 6. 6 01 Pressure-regulating valves ................................... 388 6 0 6. 2 Temperature control valves .................................. 389 6. 6. 3 Flow control valves ........................................... 389 6. 6. 4 Float valves .................................................... 389

Practice Questions ....................................................... 390 Answers to Questions ................................................... 390 References ................................................................ 390

Chapter 7 SYSTEM ENGINEERING 7 .1 System Engineering Basics ........................................ 392

7 01.1 Plant construction overview .................................. 392 7 0102 System design considerations ................................. 395

7. 2 Instrumentation System Design ................................... 399 702.1 Job planning .................................................... 399 7 0 2 0 2 System specifications .......................................... 403 7 0 2. 3 Device and function specifications ........................... 407 7.2.4 Instrumentation work specifications ......................... 430 7 0 2 0 5 Related work ................................................... 434 7. 2. 6 Instrumentation drive system design ........................ 436 7. 2 0 7 Other system functions (safety, failsafe and

redundancy measures) ........................................ 444 7 0 3 Control Room and Man-Machine Interface ...................... 453

7. 3 .1 Human engineering and control panel design .............. 453 7 0 3 0 2 Control room engineering ..................................... 457

7. 4 Instrumentation Work and Startup ............................... 460

Contents XV

7. 4. 1 Overview ........................................................ 460 7. 4. 2 Instrumentation work planning .............................. 460 7. 4. 3 Instrumentation work design ................................. 463 7. 4. 4 Startup execution .............................................. 467 7. 4. 5 Startup operations ............................................. 469

7. 5 Quality Assurance .................................................. 470 7. 5 .1 Engineering quality ............................................ 4 70 7. 5. 2 Design review (DR) ............................................ 4 71

References ................................................................ 482

Chapter 8 ADVANCED CONTROL 8 .1 Control Theory Considerations Control ......................... 483 8. 2 Feedforward Control ............................................... 486

8.2.1 Feedforward control in a heat exchanger ................... 486 8. 2. 2 Combining feedforward control and feedback control ..... 488 8. 2. 3 Determination of feedforward elements ..................... 489 8. 2.4 Feedforward control application examples ................. 490

8.3 Control of Dead-Time Processes ................................ .492 8. 3.1 Dead-time processes ........................................... 492 8. 3. 2 Smith controllers .............................................. 494 8. 3. 3 Sampling PI controller ........................................ 500

8. 4 Non-interacting Control ........................................... 502 8. 4.1 Interaction between process variables ....................... 502 8. 4. 2 Influence exerted by mutual interaction ..................... 504 8. 4. 3 Expressing the degree of interaction ........................ 504 8.4.4 Controlled variable and manipulated variable

combination ................................................... 508 8. 4. 5 Non-interacting control ....................................... 509 8. 4. 6 An example of non-interacting control ..................... 511

8. 5 Self-tuning Controller .............................................. 511 8.5.1 Overview ........................................................ 511 8. 5. 2 Gain-scheduling control. ...................................... 514 8. 5. 3 Self-tuning controller (STC) .................................. 515 8. 5. 4 STC based on the expert method ............................ 517 8. 5. 5 STC application considerations .............................. 521

8. 6 Optimal Control. .................................................... 521 8. 6.1 The meaning of "state" ..................................... 521 8. 6. 2 Integral optimal regulator .................................... 522

8. 7 Kalman Filter ....................................................... 524 8. 7 .1 Kalman filter formula ......................................... 524 8. 7. 2 Application to the parameter estimation problem ......... 525

8.8 Other Forms of Advanced Contro1.. .............................. 527 References ................................................................ 527

xvi Contents

Chapter 9 CONTROL OF PROCESS UNITS (Application I ) 9. 1 Overview ............................................................ 529 9. 2 Control of Fluid Transport Processes ............................ 530

9. 2 .1 Pump control ................................................... 530 9. 2. 2 Compressor control ............................................ 533

9. 3 Control of Heat Transfer Processes .............................. 540 9. 3.1 Control of heat exchangers ................................... 540 9. 3. 2 Heating furnace control. ...................................... 546

9. 4 Control of Distillation Processes .................................. 550 9. 4 .1 Binary-component distillation column control ............. 550 9. 4. 2 Multi-component distillation column control.. ............. 566

9. 5 Control of Reaction Processes .................................... 573 9. 5.1 Control of a stirred-tank polymerization reactor .......... 573 9.5.2 Control of a gas-phase solid-catalytic reactor ............. 580

9. 6 Other Process Control. ............................................. 590 9. 6 .1 Control of refrigeration equipment .......................... 590 9. 6. 2 Evaporator control ............................................ 592 9. 6. 3 Drying process control ........................................ 595

Practice Questions ....................................................... 600 Answers to Questions ................................................... 601 References ................................................................ 602

Chapter 10 INSTRUMENTATION TO MANUFACTURING INDUSTRIES (Application IT)

10 .1 Instrumentation Application in the Petroleum Industry ....... 604 10 .1.1 The petroleum industry and instrumentation .............. 604 10 .1. 2 Topping unit instrumentation ............................... 606 10 .1. 3 Off-site instrumentation ..................................... 614

10.2 Instrumentation Applications in the Iron- and Steel-Industry .................................................... 621

10.2 .1 Overview of instrumentation in the iron·-and steelmaking process ......................................... 621

10.2. 2 Blast furnace instrumentation ............................... 624 10.2. 3 Continuous casting equipment instrumentation ............ 635 10.2. 4 Instrumentation for an electrolytic galvanizing line ...... 642

10.3 Instrumentation Applications in the Power Industry .......... 648 10.3 .1 Overview ...................................................... 648 10. 3. 2 Thermal power plants ....................................... 648 10.3. 3 Boiler control ................................................. 649 10.3. 4 Turbine control ............................................... 663 10.3. 5 Power plant system control ................................. 667 10.3. 6 Nuclear power plant overview .............................. 669

Contents xvii

10.3. 7 Pressurized water reactor control system ................. 675 10.4 Instrumentation Applications in the Food Processing

Industry ............................................................ 687 10.4 .1 Overview ...................................................... 687 10.4. 2 Whiskey distillery instrumentation ......................... 689 10.4. 3 Sugar refinery instrumentation ............................. 693

10.5 Instrumentation Applications in the Paper Manufacturing Industry ........................................................... 706

10.5 .1 Overview of an integrated paper mill. ..................... 706 10.5. 2 Pulp plant instrumentation .................................. 709 10.5. 3 Instrumentation applied to the papermaking process ..... 719

10.6 Waterworks Instrumentation Applications ..................... 726 10.6.1 Overview of waterworks facilities .......................... 726 10.6. 2 Water treatment-related detectors ......................... 727 10.6. 3 Filtration equipment instrumentation ...................... 731 10.6. 4 Chemical injection equipment instrumentation ............ 732 10.6. 5 Instrumentation for water-supply and

distribution facilities ........................................ 737 10.6. 6 An integrated control system for large-scale,

wide-area waterworks facilities ........................... 738 10.6. 7 Water distribution information management system ..... 739 10.6. 8 Wastewater system overview ............................... 7 45 10.6. 9 Overview of activated-sludge processes ................... 7 45 10.6.10 Wastewater treatment instrumentation ................... 7 4 7 10.6.11 Sludge treatment instrumentation ......................... 7 49

10.7 Instrumentation Application in the Automobile Industry ..... 751 10.7 .1 Overview of automobile industry instrumentation ........ 751 10.7. 2 Production management at a painting factory ............ 752 10.7. 3 Storage control ............................................... 755

10.8 Product Control in Batch Processing ........................... 759 10.8.1 Batch process recipe management .......................... 760 10.8. 2 Batch process control ........................................ 763 10.8. 3 Recipe management and operation methods ............... 769

References ................................................................ 773

APPENDIXES App.1 Reference Thermoelectromotive Force Tables ............... 778 App.2 Reference Resistance Value of Pt 100 ......................... 782 App.3 Tables of Laplace Transform .................................. 784

Index ...................................................................... 785

xviii Contents