Automation

Introduction to Marine Automation

ISA–The Instrumentation, Systems, and Automation Society

 Learning Objectives
 Define what is meant by “Instrumentation”
 Define:
 Process control
 Measurement
 Accuracy
 Repeatability
 Resolution
 Hysteresis
 Sensitivity
 Precision
 Reproducibility

ISA–The Instrumentation, Systems, and Automation Society

 Learning Objectives
 Explain the three (3) variables involve in process control
 Manipulative variable
 Disturbance
 Controlled variable
 Describe simple process control loops using a block
diagram
 Explain the difference between open and closed loop
 State the essential requirement for automatic operation
of machinery

ISA–The Instrumentation, Systems, and Automation Society

 Learning Objectives
 Differentiate pneumatic, hydraulic and electro-technical
control systems
 Differentiate analog and digital device

ISA–The Instrumentation, Systems, and Automation Society

 Short History of Instrumentation and
Control
 3 BC – float valve on a water clock is the first control device
recorded being used
 1750-1850 – Scottish Engineer James Watt devised the “flyball”
governor for steam engine was the 1st significant control
invention
 1850-1900 - Siemens invented first dynamo machine. Brown
Instrument Co., Honeywell and Fisher governor companies’ were
established
 1900-1920 – Ervin Bailey invents Bailey Boiler Meter,
pneumatically operated instruments are made available and On-
off controllers are widely used in the process industry

ISA–The Instrumentation, Systems, and Automation Society

 Short History of Instrumentation and
Control (Continued)
1920-1940
 Bailey Controls introduces the 1st multi-pointer guage and installs
1st recording instrument on a marine boiler.
 Leeds & Northrup introduces the 1st conductivity recorder and
pioneered the development of glass pH electrodes.
 Foxboro begins marketing the 1st proportional plus reset
recorder/controller. Instrumentation grows with over 600
companies selling instruments.
 Taylor Instrument Co. markets its Model 56R the 1st adjustable
proportional controller.
 Leeds & Northrup introduces the first conductivity gas analyzer

ISA–The Instrumentation, Systems, and Automation Society

 Short History of Instrumentation and
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 in
Germany.
 Taylor Instruments develops the Fulscope 100 which has three
respnse sensitivity, automatic reset and a pre-act (PID).
 John Ziegler and Nathaniel Nichols of Taylor Instruments develop
the “Ziegler-Nichols” method of basic controller tuning.
 The ISA was born.
 First all-electronic instrument was manufactured by Foxboro
named Dynalog.
ISA–The Instrumentation, Systems, and Automation Society
 Short History of Instrumentation and
Control (Continued)
1940-1960
 Miniature pneumatic controls were develop.
 Computers were use in instrumentation and controls.
 Electro-magnetic and ultrasonic flowmeters were
develop.
 Capacitance pressure sensors was develop and
Beckmen Instruments markets the 1st gas
chromatograph.
 The 1st transistorized temperature controller was
develop by Honeywell.

ISA–The Instrumentation, Systems, and Automation Society

 Short History of Instrumentation and
Control (Continued)
1960-Present
 Solid state electronics experience tremendous growth while
pneumatic 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 1st automated 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.

ISA–The Instrumentation, Systems, and Automation Society

 Short History of Instrumentation and
Control (Continued)
1960-Present
 Chance Pilkington release 1st fiber optic and HP introduces
LEDs.
 Honeywell begins development of DCS.
 Maturation of computer technology dramatically advances the
field of instrumentation and control.
 Masoneilan revolutionizes control valves with the invention of the
Camflex the 1st general rotary stem valve.
 First in-situ oxygen sensor was introduced by Westinghouse
Electric.

ISA–The Instrumentation, Systems, and Automation Society

 Short History of Instrumentation and
Control (Continued)
1960-Present
 Honeywell and Yokogawa introduced the 1st industrial application
of distribution digital electronics in process control.
 Texas Instruments markets the 1st PLC with true process
capabilities.
 Applications of microprocessors, telemetry, ultrasonics and
modeling techniques lead to major advances in biomedical
instrumentation.
 Leeds & Northrrup develops the 1st self-tuning automatic
controller and fiber-optic data highway.

ISA–The Instrumentation, Systems, and Automation Society

 Short History of Instrumentation and
Control (Continued)
1960 to Present
 Honeywell introduces the St 3000 Smart transmitters.
 USDATA introduces FactoryLink the 1st PC-based
application enabler software product for SCADA.
 FieldBus becomes the talk of the town.
 SAAB tank Control pioneers a new non-contact radar
method measurement for levels of liquid in LPG and
LNG tanks.
 ISO 900X certification for Instrumentation
Manufacturers

ISA–The Instrumentation, Systems, and Automation Society

 Matter
 Is anything that occupies space and has weight
 An important factor determining the form of
matter is its energy level
 Matter exist in one of three physical forms
 Solid

 Liquid

 Gas

ISA–The Instrumentation, Systems, and Automation Society

 Properties of Matter
 Physical Properties – the qualities of substances usually
identified to our senses of sight, sound, smell, touch and
taste
 Color
 Smell
 Insolubility’
 Chemical Properties – defined as how a substance
reacts during chemical change
 Oxidation (rust)
 Reduction
 Corrosion

ISA–The Instrumentation, Systems, and Automation Society

 Matter
 Elements – a substance that cannot be broken down
into simpler chemical form
 Atom – the smallest possible quantity of an element
 Molecules – are the smallest quantity of a material
made up of multiple atoms/elements that still retains the
properties of that substance
 Molecules can be broken down chemically in to
elemental atoms that have completely different
characteristics from the original molecule

ISA–The Instrumentation, Systems, and Automation Society

 Matter
 No matter what form , all molecules within a substance are in
constant 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. It’s volume and shape is defined by its container
 Fluids is a liquid or a gas substance that can flow

ISA–The Instrumentation, Systems, and Automation Society

 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 by
measuring 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

ISA–The Instrumentation, Systems, and Automation Society

 Energy
Heat is transferred in three ways:
 Conduction – Heat flows through a material by
conduction from atom to atom. Materials that do not
conduct heat well are called thermal insulators.
Example is cooking with the use of frying pan

 Convection – heat is transferred by the motion of

thermal current. Example is cooking by hot air furnace or
oven

 Radiation – Heat is transferred via burst of radiation

energy. Example is the sun heats up the inside of a closed
car

ISA–The Instrumentation, Systems, and Automation Society

 Measurement
 Regardless of its use, every measurement must
have a number and a unit or label to have a
meaning
 Measurement are made by comparing
something to a scale
 Industry around the world uses either English,
Metric or International System of units (SI).

ISA–The Instrumentation, Systems, and Automation Society

 Definitions
 Instrumentation – a collection of instruments
or their applications for the purpose of
observation, measurement or control (ISA)

 Measurement – is the extraction of signals

from physical and chemical systems or
processes which represents parameters or
variables

ISA–The Instrumentation, Systems, and Automation Society

 Definitions
 Process
 a natural progressively continuing operation or
development marked by a series of gradual
changes that succeeds one another in a relatively
fixed way and leads towards a particular result or
end (Webster)
 consist of an assembly of equipment and material
that relates to some manufacturing operation or
sequence (ISA)
 Process Control
 is a technique of balancing supply and demand
over a period of time at a pre-determined level of
operation called “set point”

ISA–The Instrumentation, Systems, and Automation Society

 Definitions
 Accuracy
 conformity of an indicated value to an accepted
standard value or true value
 Repeatability
 the closeness of agreement among a number of
consecutive measurements of the output for the
same value of input under identical operating
conditions
 Resolution
 the smallest interval between two adjacent
discrete details which can be distinguished on
from the other

ISA–The Instrumentation, Systems, and Automation Society

 Definitions
 Hysteresis
 the maximum difference obtained as an output for
the same input between the upscale and
downscale output values during a full range
transverse in each direction
 Sensitivity
 the ratio of change in output to the change in
input magnitudes

ISA–The Instrumentation, Systems, and Automation Society

 Definitions
 Precision
 the closeness of agreement between test results
 Reproducibility
 the ability of a system of elements to maintain its
output/input precision over a relatively long period
of time

ISA–The Instrumentation, Systems, and Automation Society

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…..

ISA–The Instrumentation, Systems, and Automation Society

Difference between a
System and a Process:
Often in the past, the term process was
applied to a plant, that is, to the process
itself as well as all of the piping, valves,
and equipment need to manufacture a
product. In order to use the term
accurately, process should describe what
is occurring within a system.

ISA–The Instrumentation, Systems, and Automation Society

 Instrumentation Devices
Direct observation of actions or events
necessary to most processes, is not
possible but the observation or monitoring
of process parameters is a critical aspect of
control. Consequently, processes can be
monitored and controlled through the use of
various Instrumentation Devices.

ISA–The Instrumentation, Systems, and Automation Society

 Process Variable
• Instrumentation systems are a group of
instruments or their application for the
purpose of observation, monitoring, or
control
• The system has the necessary
measurement and control components to
maintain the process within the proper
limits. In most cases, process parameters
are referred to as “Process Variables”.
ISA–The Instrumentation, Systems, and Automation Society
 Process Variable
 A variable is a property of a substance that may change
 The devices used to measure and control process variables are called
process 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

ISA–The Instrumentation, Systems, and Automation Society

 Process Variable
 A variable is a property of a substance that may change
 The devices used to measure and control process variables are called
process 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

ISA–The Instrumentation, Systems, and Automation Society

 Typical Process Diagram

DISTURBANCE

MANIPULATIVE CONTROLLED
VARIABLE
PROCESS VARIABLE

ISA–The Instrumentation, Systems, and Automation Society

 Simple Process Control Loop
SET-POINT
CONTROLLER
DISTURBANCES

INPUT CONTROL ELEMENT PROCESS OUTPUT

MEASUIREMENT

ISA–The Instrumentation, Systems, and Automation Society

 Disturbances

input output
FCE PROCESS
Correction
Measurement

Feedback Primary
Measuring
(control loop) Element

Secondary
Element
Computation Comparison

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

Automatic Control System and its 3 Control Elements
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Elements of a Control Loop

ISA–The Instrumentation, Systems, and Automation Society

 Elements of a Control Loop
Measurement – conversion of the process variable in to
an analog or digital signal that can be use by the control
system
Evaluation – measurement value is examined, compared
with a desired value or set-point, and the amount of
corrective action needed to maintain proper control is
determined
Control – is the device in the control loop that exerts direct
influence on the process or the manufacturing sequence

ISA–The Instrumentation, Systems, and Automation Society

 1. SELF REGULATING

HOT H2O

STM HEATER

COLD H2O

ISA–The Instrumentation, Systems, and Automation Society

 2. MANUAL CONTROL W/ INDICATING
INSTRUMENT

HOT H2O
STM HEATER

COLD H2O

ISA–The Instrumentation, Systems, and Automation Society

3.AUTOMATIC CONTROL

HOT H2O
STM HEATER

COLD H2O

ISA–The Instrumentation, Systems, and Automation Society

 Pneumatic Control Systems
 Less expensive initially in spite of tubing and air supply
cost
 No heat generation and safe in explosive atmosphere
 Less susceptible to power supply variation but do have
time lag
 Direct applications, without transducers to large final
power actuators
 Simple system design
 Short commissioning and set-up period
 Higher maintenance cost
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Pneumatic Control Systems

ISA–The Instrumentation, Systems, and Automation Society

 Hydraulic Control Systems
 Similar to the advantages of pneumatic control
systems
 More appropriate for high pressure, power or work
requirements
 Generally more restricted in application
 Requires hydraulic oil compared to pneumatics
which uses air which is free
 Recovery-storage system is required for not
allowing fluid to escape
ISA–The Instrumentation, Systems, and Automation Society
Hydraulic Control Systems

ISA–The Instrumentation, Systems, and Automation Society

 Electro-Technical Control System
 Small and adaptable with cheap flexible transmission
lines
 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 or
transducers
 Lower maintenance cost
 Better suited for long distance transmission
 Superior dynamic response
ISA–The Instrumentation, Systems, and Automation Society
Electro-Technical Control System

ISA–The Instrumentation, Systems, and Automation Society

 Definitions
 Digital
 A term applied to a signal or device that uses binary
digits to represent continuous values or discrete
states
 Analog
 A term applied to a physical signal or variable which
remains similar to another variable in so far as the
proportional 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 continuously
represented over a range
ISA–The Instrumentation, Systems, and Automation Society
 Difference Between Analog and
Digital Device
Analog
 Takes an infinite number
values
 More accurate in reproducing
a quantity, variable or signal
 May be transmitted over
greater distance but subject
to energy loss
 Operator error is more likely
 Instantaneous representation
of measured variable
ISA–The Instrumentation, Systems, and Automation Society
Digital
 Variables are limited to
defined states
 Less susceptible to noise
 May be transmitted over long
distance at greater efficiency
 Operator error is less likely
 Conversion of signal may
incur error depending on
sampling rate
 Uses Binary Number system