
Essentials of Modern Measurements and Final Elements in the Process Industry
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Essentials of Modern Measurements and Final Elements in the Process Industry: A Guide to Design, Configuration, Installation, and Maintenance
Advances in sensor technology and in digital positioner and variable speed drive algorithms, combined with smart features, offer a step change in the performance of modern measurement instruments and final elements. The installed accuracy of many smart instruments has increased by an order of magnitude. There has been a correspondingly dramatic reduction in the drift of transmitters and a similar improvement in the resolution of control valves.
This comprehensive resource aims to increase awareness of the opportunities afforded by modern measurement instruments and final elements, and to show how to get maximum benefit from the revolution in smart technologies. It builds an understanding of the fundamental aspects of measurements, measurement instruments, and final elements for applications in the process industry. The terminology and ideas presented provide a firm foundation for subsequent chapters that focus on what is needed for lowest life-cycle cost and best automation system performance. The last chapter provides a comprehensive exploration of the technology that supports the rapidly expanding opportunities of WirelessHART instrumentation.
No prior plant experience with industrial process instrumentation is required. For students and new employees, the chapters on fundamentals will improve productivity on the job and form a basis for further study. For the seasoned veteran, the book offers insights and serves as a guide through today's myriad automation products and application details. It provides a picture of the state of the art for 95% of the field instrumentation and final elements used, or under consideration, in a modern process plant. The reader is encouraged to seek further information on particular types of measurement instruments and final elements, which is available from manufacturers via the Internet and in instrumentation handbooks and ISA publications.
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Content
- Cover
- Title Page
- Copyright
- Dedication
- Acknowledgment
- Table of Contents
- Preface
- Chapter 1: Field Measurement Fundamentals
- 1-1. Learning Objectives
- 1-2. Introduction and Overview
- Advances in Measurements
- Wireless Opportunities
- Industrial R&D Opportunities
- University R&D Opportunities
- Perspective
- Sensing Elements
- Differential Head Flow Measurement Example
- Transmitters
- HART (Highway Addressable Remote Transducer)
- Fieldbus
- WirelessHART
- Enclosures
- Types of Measurements
- Distributed Control Systems
- 1-3. Process Automation
- Control Systems
- Continuous Processes
- Self-Regulating Processes
- Integrating Response
- Batch Processes
- Fed-batch Processes
- Profile Control
- Real Processes
- Safety Systems
- 1-4. Dynamics
- Measurement Response to a Step Change
- Measurement Response to Ramping Disturbance
- Analyzers
- Disturbances
- 1-5. Accuracy
- Turndown (Rangeability) and Span
- Dramatic Improvements in Modern Measurement Instruments
- Estimation of Total Error
- Uncertainty
- Tolerance
- Resolution
- Sensitivity
- Repeatability
- Hierarchy
- Noise
- Hysteresis and Deadband
- Nonlinearity
- Bias
- Stability
- Reproducibility
- 1-6. Setup (Configuration) and Calibration
- Range and Span
- Historical View
- Smart Instrumentation Capability
- Smart Instrumentation Interface
- Calibration Adjustments
- Calibration Methods
- Online Calibration Examples
- Online Level Calibration
- Relative Accuracy of Inventory Measurements
- Online Temperature Calibration
- Online pH Calibration
- 1-7. Installation
- Process Connections
- Differential Pressure Level Example
- 1-8. Questions
- 1-9. References
- Chapter 2: Temperature Measurement
- 2-1. Learning Objectives
- 2-2. Introduction and Overview
- Comparison of Thermocouples and Resistance Temperature Detectors
- Optical Pyrometers
- Blackbodies
- Emissivity and Emittance
- Sensitivity
- Graybodies
- Non-Graybodies
- Single and Two-color Pyrometers
- Equations for Total and Spectral Radiation
- 2-3. Thermocouples and RTDs
- Sensing Element
- Sensor Sheath
- Resistance Temperature Detectors (RTD)
- IEC 751 standard
- Callendar-Van Dusen Equation
- Thermocouples (TC)
- Thermocouple Types
- Hot Junction Configurations
- Voltage Measurement and the Seebeck Effect
- Cold Junction Compensation
- 2-4. Selection of a Temperature Sensor
- Why Use an RTD Rather Than a TC?
- Why Use a TC Rather Than an RTD?
- 2-5. Specifications
- 2-6. Setup and Calibration
- 2-7. Installation
- Thermowells
- Mounting Methods
- Stem Designs
- Communication
- Field-Mount Transmitters
- Head-Mount Transmitters
- Rail-Mount Transmitters
- Wiring Direct
- Extension Wire
- 2-8. Maintenance
- 2-9. Questions
- 2-10. References
- Chapter 3: Pressure Measurement
- 3-1. Learning Objectives
- 3-2. Introduction and Overview
- Requirements
- Combustion Applications
- Bio-Pharmaceutical Applications
- Pipelines
- Column and Reactor Performance
- Wireless Profiles
- Safety
- 3-3. Principles
- Variable Capacitance
- Piezoresistive
- 3-4. Selection
- 3-5. Specification
- Performance
- Process Operating Range
- Wetted Materials of Construction
- Process Connection Sizes and Types
- 3-6. Setup and Calibration
- 3-7. Installation
- 3-8. Maintenance
- 3-9. Questions
- 3-10. References
- Chapter 4: Flow Measurement
- 4-1. Learning Objectives
- 4-2. Introduction and Overview
- Installed Valve Characteristics
- Cascade Control Opportunity
- Feedforward Control Opportunity
- Ratio Control
- Process Analysis
- Process Modeling
- Mass Flow Measurement
- Thermal Mass Flowmeters
- Other Flow Measurement Devices
- 4-3. Differential Pressure Flowmeters
- DP Principles
- DP Selection
- DP Specification
- DP Considerations
- DP Setup and Calibration
- DP Installation
- DP Maintenance
- DP Flowmeter Troubleshooting Guide
- 4-4. Multivariable Differential Pressure Flowmeters
- Multivariable DP Principles
- Multivariable DP Selection
- Multivariable DP Specification
- Multivariable DP Considerations
- Multivariable DP Setup and Calibration
- Multivariable DP Installation
- Multivariable DP Maintenance
- Multivariable DP Flowmeter Troubleshooting Guide
- 4-5. Vortex Flowmeters
- Vortex Meter Principles
- Vortex Meter Selection
- Vortex Meter Specifications
- Vortex Meter Considerations
- Vortex Meter Setup and Calibration
- Vortex Meter Installation
- Vortex Meter Maintenance
- Vortex Meter Troubleshooting Guide
- 4-6. Magnetic Flowmeters
- Magmeter Principles
- Magmeter Selection
- Magmeter Specification
- Magmeter Considerations
- Magmeter Setup and Calibration
- Magmeter Installation
- Magmeter Maintenance
- 4-7. Coriolis Mass Flowmeters
- Coriolis Meter Principles
- Coriolis Meter Selection
- Coriolis Meter Specification
- Coriolis Meter Considerations
- Coriolis Meter Applications
- Coriolis Meter Setup and Calibration
- Coriolis Meter Installation
- Coriolis Meter Maintenance
- 4-8. Questions
- 4-9. References
- Chapter 5: Level Measurement
- 5-1. Learning Objectives
- 5-2. Introduction and Overview
- Storage Tanks
- Columns
- Crystallizers and Reactors
- Surge Tanks
- Admittance Measurements
- Perspective
- 5-3. Differential Pressure Level
- DP Level Principles
- DP Level Selection
- DP Level Specifications
- DP Level Considerations
- DP Level Setup and Calibration
- DP Level Installation
- DP Level Maintenance
- 5-4. Radar Level
- Radar Level Principles
- Radar Level Selection
- Radar Level Specifications
- Radar Level Considerations
- Radar Level Setup and Calibration
- Radar Level Installation
- Radar Level Maintenance
- Radar Level Troubleshooting Guide
- 5-5. Ultrasonic Level Measurement
- Ultrasonic Level Principles
- Ultrasonic Level Selection
- Ultrasonic Level Specifications
- Ultrasonic Level Considerations
- Ultrasonic Level Setup and Calibration
- Ultrasonic Level Installation
- Ultrasonic Level Maintenance
- Ultrasonic Level Troubleshooting Guide
- 5-6. Questions
- 5-7. References
- Chapter 6: pH Measurement
- 6-1. Learning Objectives
- 6-2. Introduction and Overview
- 6-3. Principles
- Glass Electrode
- Reference Electrode
- Resistances
- 6-4. Selection
- Transmitters
- Advanced Diagnostics
- Wireless
- Electrodes
- Process pH
- Process Temperature
- Process Concentrations
- Process Conductivity
- Non-Aqueous and Mixed Solvents
- Sensor Coating and Cleaning
- 6-5. Specifications
- 6-6. Setup and Calibration
- 6-7. Installation
- 6-8. Maintenance
- Middle Signal Selection
- Measurement Noise
- Diagnostic Information
- Asset Management
- 6-9. Questions
- 6-10. References
- Chapter 7: Final Element Fundamentals
- 7-1. Learning Objectives
- 7-2. Introduction and Overview
- Temperature and Pressure Regulators
- 7-3. Valves, Dampers, and Vanes
- Throttling Versus Piping Valves
- Sliding Stem Valves
- Roller Diaphragm Valves
- Pinch Valves
- Rotary Valves
- Dampers and Vanes
- Special Actuators
- Pneumatic Actuators
- Shaft and Stem Connections
- Solenoid Valves
- Pneumatic Positioners
- Digital Positioners
- Valve Accessories
- Valve Best Practices
- 7-4. Variable Speed Drives
- Static Head
- VFD Pulse Width Modulation
- VFD Cable Problems
- VFD Bearing Problems
- VFD Slip
- VFD Turndown
- VFD Controls
- VFD Justification
- Which Is Faster: a Valve or a VSD?
- VSD Best Practices
- 7-5. Dynamics
- Actuator Response
- VSD Response
- Resolution, Deadband, and Hysteresis
- Limit Cycles
- 7-6. Linearity
- Control Valves
- Inherent Valve Characteristic
- Installed Valve Characteristics
- Variable Speed Drives
- 7-7. Rangeability
- Control Valves
- Variable Speed Drives
- 7-8. Questions
- 7-9. References
- Chapter 8: Control Valves
- 8-1. Learning Objectives
- 8-2. Introduction and Overview
- 8-3. Basic Construction and Operation
- Positioners
- 8-4. Sizing and Selection
- Performance Based Selection
- Valve Selection
- Actuator Selection
- Positioner Selection
- Accessory Selection
- Sizing
- Other Selections
- Required Process Information
- 8-5. Installation
- Valves and Actuators
- Positioners, Controllers, and Accessories
- 8-6. Adjustments
- Valves and Actuators
- Digital Positioners
- 8-7. Maintenance
- Valves and Actuators
- Smart Digital Positioners
- 8-8. Diagnostics
- Performance
- 8-9. Valve and Actuator Capabilities
- General-Purpose, Heavy-Duty Globe Valves
- Compact Globe Valve and Actuator Package
- Lightweight Utility Valves
- Low-Flow Valves
- Sanitary-Service Valves
- High-Pressure Valves for Oilfield Applications
- Segmented High-Capacity Ball Rotary Valves
- High-Range Rotary Control Valves
- Throttling Butterfly Valves
- On-Off Butterfly Valves
- Dampers
- Pneumatic Spring-and-Diaphragm Actuators
- Pneumatic Piston Actuators
- 8-10. Questions
- 8-11. References
- Chapter 9: Wireless
- 9-1. Learning Objectives
- 9-2. Introduction and Overview
- Background
- Improved Measurement and Control
- Improved Operations
- Configuration, Installation, and Checkout
- 9-3. Principles
- 9-4. Security and Reliability
- Joining the Network
- Securing Communications
- Sessions
- Reliability
- 9-5. Communication Rules
- Network Routing
- Network Scheduling
- Priority
- Optimizing Communication Resources
- Monitor and Control over a Wireless Sensor Network
- Example - Scheduling Monitoring and Control for a Bioreactor Process
- Network Management and Host Request
- Example - Bioreactor Process Measurements
- Scheduling Example - Single Hop
- Scheduling Example - Multiple Hop
- Scheduling Example - Incorporating Control Devices
- 9-6. Process Control
- The Standard PID Algorithm
- Input Communication Lost
- Output Communication Lost
- Both Input and Output Communication Lost
- The Enhanced PID Algorithm
- Experiments and Results
- Reliable Communications
- Unreliable Communications
- Unreliable Input
- Unreliable Output
- 9-7. Installation of a Wireless Network
- Devices
- Gateways
- Integration with Control Systems
- 9-8. Questions
- 9-9. References
- Appendix A: Answers to Chapter Questions
- Appendix B: Top Ten Things to Consider Before Selecting Your VFD
- Appendix C: Effect of Sample Time on Process Control
- Index
- EULA
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