Quick Guide to Measurement & Control--Condensed coverage of process-control/Instruments and measuring instruments

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1. Introduction

What Is Measurement and Control?
Definitions
Overview
Historical Summary
Guide Structure
Sections
Selecting Measurement and Control Devices
Accuracy and Repeatability

2. Identification and Symbols (coming soon)

Identification
Instrument Line Symbols
General Instrument or Function Symbols

3. Analyzers

Overview
- Location
- Tagging
- Implementation
- Safety
- Code Compliance
- Selection
- Documentation
- Sampling Systems
- Enclosures
- Testing and Startup
- Maintenance
- Shipment and Delivery
Comparison Table
- Amperometric
- Capillary Tube
- Catalytic
- Chemiluminescence
- Conductivity
- Electrochemical
- Flame Ionization Detector (FID)
- Fourier Transform Infrared (FTIR)
- Gas Chromatograph
- Infrared Absorption
- Mass Spectrometer
Non-Dispersive Infrared (NDIR)
- Paper Tape
- Paramagnetic
- pH
- Polarographic
- Radiation Absorption
- Rotating Disk Viscometer
- Thermal Conductivity Detector (TCD)
- Ultraviolet
- Vibrating U-tube
- X-Ray Fluorescence Spectroscopy (XRF)
- Zirconia Oxide Cell

4. Flow Measurement

Overview
Classification
Measurement
Accuracy
General Application Notes
Type of Fluid
Velocity Profile
Piping Considerations
Line Size
Measuring Solids
Comparison Table
Differential Pressure: General Information
Differential Pressure: Orifice Plate
Differential Pressure: Segmental Orifice Plate
Differential Pressure: Integral Orifice Plate
Differential Pressure: Venturi Tube
Differential Pressure: Flow Nozzle
Differential Pressure: Elbow
Differential Pressure: Pitot Tube
Magnetic
Mass: Coriolis
Mass: Thermal
Turbine
Positive Displacement
Vortex Shedding
Variable Area (Rotameter)
Ultrasonic: Transit Time, Time of Travel, Time of Fl Ultrasonic: Doppler
Weir and Flume
Target

5. Level Measurement

Overview
Classification
Load Cells
Units of Measurement
Measurement of Solids
Comparison Table
Differential Pressure (or Pressure/Static Head)
Displacement
Float
Sonic/Ultrasonic
Tape (Float and Tape)
Weight and Cable
Gage
Radioactive (Nuclear)
Bubbler (Dip Tube)
Capacitance
Conductivity
Thermal
Radar
Beam Breakers
Vibration
Paddle Wheel
Diaphragm
Resistance Tape
Laser

6. Pressure Measurement

Overview
Units of Measurement
Gages
Transmitters
Filled Systems and Diaphragm Seals
Installation
Comparison Table
Manometer
Bourdon Tube, Diaphragm, and Bellows
Capacitive Transducer
Differential Transformer
Force Balance
Piezoelectric
Potentiometer, Wheatstone Bridge
Strain Gage: General Information
Strain Gage: Unbonded
Strain Gage: Bonded
Strain Gage: Thin Film
Strain Gage: Diffused Semiconductor

7. Temperature Measurement

Overview
Units of Measurement
Classification
Thermowells
Comparison Table
Filled System
Bimetallic
Thermocouple
Resistance Temperature Detector (RTD)
Noncontact Pyrometry

8. Control Loops

Overview
Control Modes
On-Off Control
Modulating Control
Control Types
Feedback
Cascade
Ratio
Feedforward
Controller Tuning
Automatic Tuning
Manual Tuning
Based-on-Experience Tuning

9. Programmable Electronic Systems

Overview
Components
Centralized Control versus Distributed Control
Control Room Instrumentation
Programming Languages
Fieldbus
System Specification
Operator Interface
Special Design Considerations
Network Topologies
Transmission Media
Selecting Vendors
Testing
Justification
Benefits
Implementation
Maintenance

10. Alarm and Trip Systems

Overview
Fail-Safe and Deenergize-to-Trip
Safety Integrity Level
Elements
Design
Documentation
Testing
Commissioning and Pre-startup
Management of Change

11. Control Centers

Overview
Design
Physical Aspects
Security
Fire Protection
Air Conditioning
Electrical/Electronic Considerations
Communication

12. Enclosures

Overview
General Requirements
Documentation
Fabrication
Protection and Rating
Nameplates
Electrical
Pneumatics
Temperature and Humidity Control
Inspection and Testing
Certification
Shipping

13. Control Valves

Overview
Shutoff
Noise
Flashing and Cavitation
Pressure Drop
Installation
The Cv Valve Bodies
Rules of Thumb
Cooling Fins (Radiating Bonnet) and Bonnet Extensions
Bellows Seals and Packing
Comparison Table
Globe
Diaphragm (Saunders)
Ball
Butterfly
Eccentric Rotary Plug
Trim
Actuators

14. Engineering Design and Documentation

Overview
Front-end Engineering
Detailed Engineering
Document Quality
Process and Instrumentation Diagrams (P&IDs)
Control System Definition
Logic Diagrams
Process Data Sheets
Instrument Index
Instrument Specification Sheets
Loop Diagrams
Interlock Diagrams
Manual for Programmable Electronic Systems
PLC Program Documentation

15. Installation

Overview
Code Compliance
Scope of Work
Installation Details
Equipment Identification
Equipment Storage
Work Specifically Excluded
Approved Products
Pre-installation Testing
Execution
Wiring
Tubing
Checkout

16. Maintenance

Overview
Implementation
Types of Maintenance
Personnel
Training
Records
Hazards
General Hazards
Hazardous Locations
Confined Space
Electrical Isolation
Programmable Electronic Systems
Alarm and Trip Systems

17. Calibration

Overview
Procedures
Instrument Classification
Class 1 Instruments
Class 2 Instruments
Class 3 Instruments
Class 4 Instruments
Calibration Sheets

18. Project Implementation and Management

Overview
Process Control
1st phase:
2nd phase:
3rd phase:
Communication
Standard and Code Compliance
Control Strategy
Plant Business Strategy
Implementation of a New Control System
Scheduling and Time Management
Cost Estimate
Document Control
Engineering
Front-End Engineering
Detailed Engineering
Quality
Purchasing Equipment
Vendor Documents
Training
Equipment Installation
Commissioning
Startup
Project Closing

19. Decision-making Tools

Overview
Auditing
The Auditing Function
History, Frequency, and Record of Audits
Auditing of Management
Auditing of Engineering Records
Auditing of Maintenance
Auditing of Process Control Systems
Evaluation of Plant Needs
The Brainstorming Session
The Evaluation of Ideas
Issuance of the Report
Justification
Hurdles in the Justification Process
Cost Justification
Costs - The Bottom Line
Cost Justification
Justification Follow-up
System Evaluation

20. Road to Consulting

Overview
Types of Consulting Services
Types of services
Basic Tools
Marketing
Defining your service
Indentifying your market
Selecting a marketing method
From Proposal to Purchase Order
Inquiry Received
Meeting with the client
Proposal submitted
Purchase order received
Fees
Daily/hourly rate contract + expenses
Fixed-Price Contracts
Performance Contracts
Maintaining client relationships

Section A - Units Conversion Tables

Section B - Corrosion Resistance/Rating Guide

Section C - The Engineering Contractor

Section D - Packaged Equipment

Section E - Typical Scope of Work

Section F - Development of Corporate Standards and Guidelines

Section G - Typical Job Titles and Descriptions

Section H - Sample Audit Protocol

Section I - Sample Audit Report

Dedication:

This guide is dedicated to the pioneers of measurement and control. This technology took its first steps along the Nile Valley about 2600 B.C., when Egyptian engineers began using precise yet simple measuring devices to level the foundation for building the Great Pyramid and employing weirs to measure and distribute irrigation water across the fertile delta. Much more recently, hundreds of dedicated people tinkering in their home and labs, working late at night, and overcoming failures and frustrations, created the powerful computer technology we now rely on.

Without these pioneers, whose first tentative steps thousands of years ago have accelerated into today's full-speed sprint toward on-going advances, the world of measurement and control would not exist and this guide would never have been written. And instead of being an I&C engineer, I would have devoted the past three decades to a profession far less interesting and rewarding.

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INTRO:

This is the third edition of this guide (first was online in 1997!!). We sincerely hope that its success will continue--an indication that it’s well accepted by the public at large.

The guide is directed toward all practitioners in process measurement and control as well as other technical personnel such as project managers, process engineers, and mechanical engineers. I wrote it for specialists in process measurement and control and also to help people with little knowledge of process measurement and control to understand that specialty. Learners can find additional detailed information beyond the level of this guide in specialized publications, and major vendors (whose valuable experience and knowledge is readily available to users).

We developed this guide because we wanted to concentrate the knowledge we learned over the years in a guide format and because we felt there is a need for a condensed source that presents information on measurement and control in a clear and concise form. Its condensed format is ideal for everyday use. To the best of our knowledge, there is no other guide quite like this one. One of the main difficulties we faced in creating this guide was deciding how much detail is required -- a task we hope we accomplished successfully. Several web sites or books provide a great deal more detail but don’t actually provide any more substantial information than this text. Because this is a condensed guide, learners seeking more information should refer to vendor publications and detailed textbooks.

It may be helpful to describe how the learner can use this guide. First, it can be studied by anyone seeking to understand the field of process measurement and control, or it can be used as a reference guide to be consulted whenever information is required on a certain topic. We have used the content of this guide as the basis for teaching courses in these subject areas at a few universities across North America.

We hope that this latest revision will guide you in selecting and implementing process measurement and control devices as well as contribute to improving this field of technology. The revision updates most of the sections of the first and second editions while adding sections on maintenance, calibration, project implementation and management, consulting, and tools for decision making. We have made every effort to ensure that this guide is accurate and clear.