Install instrumentation & control devices

Information Sheet 3-2: Personal Protective Equipment

 Temperature Scales Conversion:

 Principle of Heat Transfer:
The effectiveness and sensitivity of any temperature sensor or transducer is due on the
principle of heat transfer. There are three (3) basic ways how heat transfers:
conduction, convection, and radiation.

1. Mechanical Temp. Sensors/Transducer
 Liquid-in-glass thermometers
 Filled-System thermometers
 Bimetallic thermometers

3. Electrical Temp. Sensors/Transducer
 Thermo-voltaic Elements (Thermocouple)
 Thermo-resistive Elements
 Temperature Sensitive Materials
 Pyrometers

Note: Refer to Module 1-1 power-point regarding the details of Mechanical Temp. Sensors /
Transducer and Electrical Temp. Sensors / Transducer.

F. FLOW MEASUREMENT:

Code No. Install (ICD) Date: Developed Date: Revised Page #
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Information Sheet 3-2: Personal Protective Equipment

I. INTRODUCTION:
 Flow is actually the amount of fluid that passed a given point. Flow Rate is the
amount of fluid that passed a given point at any given instant, while Total
Flow is the amount of fluid that passed a given point during a specific period
of time.
 Units of Flow:
Volume-based – Examples of volume-based metric units are cc/s, mm3/s, m3/hr,
cc/min, etc. English units include gal/s, gal/min (gpm), ft3/s, ft3/min (cfm), ft3/day,
etc.
Mass-based – Examples of mass-based metric units are g/s, kg/s, kg/min,
kg/hr, etc. English units include oz/s, lb/hr (pph), tons/hr (tph), etc.

II. OPEN CHANNEL FLOW SENSOR/TRANSDUCER
This type of flow measurement is applicable in irrigation systems, dams, water
treatment facilities, desalination plants, etc. It basic principle is forcing the fluid
to pass a specific design of barrier and measuring the rise of its level in an
adjacent still-well, the higher the level at the still-well, the higher also the flow-
rate.
 WEIR
 FLUME

III. ENCLOSED PIPE FLOW SENSOR/TRANSDUCER
 HEAD FLOWMETER
 POSITIVE DISPLACEMENT FLOWMETER
 VELOCITY FLOWMETER
 MASS FLOWMETER

Note: Refer to Module 1-1 power-point regarding the details of Open channel Flow Sensors /
Transducer and Enclosed channel Flow Sensors / Transducer.

G. SUMMARY:

In interpreting work instructions regarding the installation of I&C devices, a technician must have
the knowledge of the fundamentals of instrumentation and control technology. These are
contained in this information sheet.

Code No. Install (ICD) Date: Developed Date: Revised Page #
ECL724301 Instrumentation and Control Devices April 27, 2010 12

Worksheet 3-2: Personal Protective Equipment

Learning outcome:
Use the necessary personal protective equipment needed in installing
instrumentation and control devices.

Learning Activity:
Enumerate the necessary personal protective equipment needed in installing
instrumentation and control devices.
Use properly the necessary personal protective equipment needed in installing an
instrumentation and control devices.

CONTENTS:

A. Introduction
B. Definition of terms
C. Pressure measurement
D. Level measurement
E. Temperature measurement
F. Flow measurement
G. Summary

A. INTRODUCTION:

Have you seen the 80s movie, Rocobop? Well, it’s about this cop who was badly shot in one of
police operations, and in order to save him, he was made into cyborg, partly human and partly
machine. This concept is the principle behind any industrial automation system, where man
and machine use their best qualities for a common cause to improve the manufacturing,
maintenance, etc., and ultimately the existence of all living creatures.

Industrial automation has many allied technologies and one of them is Instrumentation and
control (I&C). One of the main tasks of an I&C technician is to install instrumentation and
control devices. And, its most important sub-task is to interpret work instructions related to
installation of I&C devices.

This information sheet contains the fundamentals of instrumentation and control technology
which are essential in the interpretation of work instructions.

Code No. Install (ICD) Date: Developed Date: Revised Page #
ECL724301 Instrumentation and Control Devices April 27, 2010 1

Worksheet 3-2: Personal Protective Equipment

B. DEFINITION OF TERMS

1. Industrial Automation is a step beyond mechanization. Whereas mechanization provided
human operators with machinery to assist them with the muscular requirements of work,
industrial automation greatly reduces the need for human sensory and mental
requirements as well. Industrial automation has two main categories, machine automation
and process automation.

2. Mechatronics is the synergistic combination of mechanical, electronics/electrical, and
computer software engineering to automate a mechanize control system. It can be referred
to as machine automation.

3. Machine Automation are applicable for semiconductor manufacturing, building automation,
construction machineries, transportation controls (land, sea, air, space)
product packaging machineries, mining equipment controls, etc.

4. Instrumentation is collection of instruments or their application for the purpose of
observation, measurement or control. It can be referred to as process automation.

5. Process Automation is applicable for food processing, biomedical processes petrochemical
refinery, water treatment, pollution control, power generation, etc.

6. Observation is the output of the 5 senses of man. It is expressed in terms of qualitative
characteristics of a physical object or variable. In process automation, observation is derived
from the output of sensors. Figure – 1 below compares man’s senses to machine’s primary
elements.

7. Measurement is the output of man using a tool to determine qualitative and quantitative
characteristics of a physical object/variable. In process automation, measurement is the
output sensors connected to a transducer, indicator, and recorder. From Figure -1, we can
say that measurement is the product of senses and brain (primary and intermediate
elements).

8. Control is the output when man operates using his senses to observe an object or variable,
then use his intellect to give meaning and decide on a course of action, and finally use his
motor faculties to execute his course of action. In Figure – 1, it happens when the machine
elements operates to detect, process, react, and correct changes in control loop variables.

Note: Instrumentation and control is often defined separately because there are some
systems that do not involve observation and control, only observation and measurement.

Code No. Install (ICD) Date: Developed Date: Revised Page #
ECL724301 Instrumentation and Control Devices April 27, 2010 2

Worksheet 3-2: Personal Protective Equipment

AUTOMATIC CONTROL CONCEPT

MAN MACHINE

I. SENSES I. PRIMARY ELEMENT
• Eyes • Photocells
• Ears • Microphone
• Nose • Smoke Detectors
• Skin / Touch • Thermometers
• Tongue • Analytical Sensors

II. BRAIN II. INTERMEDIATE
• Intellect ELEMENT
• Will • Indicators
• Recorders
III. MOTOR FACULTIES • Controllers
• Hands
• Feet III. FINAL ELEMENT
• Body • Motors
Figure 1 – 1 • Cylinders

9. CONTROL SYSTEMS / LOOPS:

 Figure 1 – 2 and Figure 1 – 3 shows a typical heat exchanger control loops.

 The close loop has feedback. The intervention of the operator is less because it’s fully
automatic.

 The open loop has no feedback coming from the sensor and transmitter. Any changes
in controlled variable rely on the operator. This can be referred to as semi – automatic.

Figure 1 – 2: Close Loop Figure 1 – 3: Open Loop

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Worksheet 3-2: Personal Protective Equipment

10. CONTROL LOOP VARIABLES:

 Independent variables (IV) answer the question "What do I change?" In Figure 1 – 2,
the flow of the steam is the IV.

 Dependent variables (DV) answer the question "What do I observe?" In Figure 1 – 2,
the temperature of the water going out of the heat exchanger is the DV.

 Controlled variables (CV) answer the question "What do I keep the same?" In Figure 1
– 2, the temperature of the water inside the heat exchanger is the CV.

 Extraneous variables (EV) answer the question "What uninteresting variables might
mediate the effect of the Independent Variable on the Dependent Variable?" In Figure 1
– 3, the disturbances (energy loss and gain) in and out of the heat exchanger is the
EV.

11. PROCESS VARIABLES:

 Process variables are the objects of process automation (instrumentation and control).
 There are 4 Basic Process Variables; Pressure, Level, Temperature, and Flow.
 Other process variables such as density, force or weight, etc. can be derived from the

basic process variables.

12. ELEMENTS OF PROCESS CONTROL:

 Primary Elements senses or detects the control loop variables. In Figure 1 – 2, the
primary elements are the transducers - sensors and transmitter.

 Intermediate Elements receive signals from primary elements and provide
corresponding output signal either through indication/record or control action. In Figure 1
– 2, the intermediate elements are controller, recorder, and enunciator.

 Final Elements receive signals from a controller and execute corrective action to
manipulated variable. In Figure 1 – 2, the final element is the control valve.

Note:
With the current innovations in automation engineering and technology, instrumentation and
control devices manufacturers combine the functionalities of the different elements of process
control, for instance:

 Some instrumentation and control devices have primary, intermediate, and final
elements in 1 unit.

 Some instrumentation and control devices have primary and intermediate elements, and
some instrumentation and control devices have intermediate and final elements.

13. TRANSDUCER:
 A transducer is a device, electrical, electronic, electro-mechanical, electromagnetic,
photonic, or photovoltaic, that converts one type of energy or physical attribute to
another for various purposes including measurement or information transfer.

Code No. Install (ICD) Date: Developed Date: Revised Page #
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Worksheet 3-2: Personal Protective Equipment

14. SENSORS:
 A sensor is a device that measures a physical quantity and converts it into a signal
which can be read by an observer or by an instrument.
 Types of sensor; self – generating, and passive.
 Characteristics of sensor:
a. A good or ideal sensor is designed to be linear. The output signal of such a sensor is
linearly proportional to the value of the measured property.
b. If the output signal is not zero when the measured property is zero, the sensor has
an offset or bias. This is defined as the output of the sensor at zero input.
c. The sensitivity or gain is then defined as the ratio between output signal and
measured property. If the sensitivity is not constant over the range of the sensor, this
is called nonlinearity.
d. If the output signal slowly changes independent of the measured property, this is
defined as drift.
e. If the sensor has a digital output, the output is essentially an approximation of the
measured property. The approximation error is also called digitization error.

15. TRANSMITTER:
 In industrial process control, a "transmitter" is any device which converts measurements
from a sensor into a signal to be received, usually sent via wires, by some display or
control device located a distance away.

C. PRESSURE MEASUREMENT:

I. INTRODUCTION
 WHAT IS PRESSURE?
 ATMOSPHERIC PRESSURE
 HYDROSTATIC PRESSURE
 MODES OF PRESSURE

II. PRESSURE SENSORS/TRANSDUCERS
 BOURDON TUBE
 SPRING AND PISTON
 BELLOWS AND CAPSULES
 DIAPHRAGM

III. ELECTRICAL PRESSURE TRANSDUCERS
 PIEZO-RESISTIVE STRAIN GAUGE
 CAPACITIVE
 ELECTROMAGNETIC
 OPTICAL

Code No. Install (ICD) Date: Developed Date: Revised Page #
ECL724301 Instrumentation and Control Devices April 27, 2010 5

Worksheet 3-2: Personal Protective Equipment

I. INTRODUCTION
Pressure is defined as a force per unit area, or is the force exerted by an object on a
certain area. Pressure results from molecules exerting a force by impacting over a
defined area. The relationship is given by:

Pressure (P) = Force (F)
Area (A)

Atmospheric pressure is the amount of pressure that a column of air exerts on a body
due to the influence of gravity.

Vacuum is a volume of space that is essentially empty of matter, such that its gaseous
pressure is much less than atmospheric pressure. Vacuum pressure is pressure lower
than atmospheric pressure.
Hydrostatic pressure is the amount of pressure that a column of liquid exerts on a body
due to the influence of gravity.

Pressure (P) =Specific Gravity (S.G.) * Height (H)

The objects of pressure measurements are gas, liquid, and steam.
Modes of pressure measurement:

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Code No.
ECL724301

Worksheet 3-2: Personal Protective Equipment

II. MECHANICAL PRESSURE SENSOR/TRANSDUCER

Bellows

Bourdon Piston

III. ELECTRICAL PRESSURE TRANSDUCER

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ECL724301 Instrumentation and Control Devices April 27, 2010 7

Worksheet 3-2: Personal Protective Equipment

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Worksheet 3-2: Personal Protective Equipment

D. LEVEL MEASUREMENT:

I. Level Transducer Selection Checklist

Key questions to ask before selecting a level measurement transducer:
 Are you measuring a liquid or solid?
 What are the application's temperature and pressure ranges?
 Is point level or continuous measurement required?
 What level measurement range do you need?
 Is the measured material electrically conductive?
 Will the material coat or build up on surfaces?
 Does turbulence, foam, or vapor occur at the surface of the liquid?
 Will you need contact or non-contact level measurement?
 What kind of output do you need–analog, relay, digital display, etc.?

II. Types of Level Transducer

Level measurement transducers fall into two main types:
 Point level measurement type is used to mark a single discrete liquid height–a

preset level condition. Generally, this type of sensor functions as a high alarm,
signaling an overfill condition, or as a marker for a low alarm condition.
 Continuous level measurement type is more sophisticated and can provide level
monitoring of an entire system. They measure fluid level within a range, rather than
at a one point, producing an analog output that directly correlates to the level in the
vessel.

III. Level Transducers
1. Point and continuous level detection for solids
1.1 Vibrating point
1.2 Rotating paddle
1.3 Admittance-type
2. Point level detection of liquids
2.1 Magnetic and mechanical float
2.2 Pneumatic
2.3 Conductive
3. Both for Point Level Detection and Continuous Monitoring of Solids and Liquids
3.1 Capacitance
3.2 Optical interface
3.3 Ultrasonic
3.4 Microwave

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Worksheet 3-2: Personal Protective Equipment
4. Continuous level measurement of liquids
4.1 Magneto-restrictive
4.2 Resistive chain
4.3 Hydrostatic pressure
4.4 Air bubbler
4.5 Gamma ray

Note: Refer to Module 1-1 power-point regarding the details of Level Transducers.

E. TEMPERATURE MEASUREMENT:

1. INTRODUCTION:
 Temperature is the degree of hotness or coldness of a body measured on a
definite scale.
 Temperature Scales:

Code No. Install (ICD) Date: Developed Date: Revised Page #
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Worksheet 3-2: Personal Protective Equipment

 Temperature Scales Conversion:

 Principle of Heat Transfer:
The effectiveness and sensitivity of any temperature sensor or transducer is due on the
principle of heat transfer. There are three (3) basic ways how heat transfers:
conduction, convection, and radiation.

1. Mechanical Temp. Sensors/Transducer
 Liquid-in-glass thermometers
 Filled-System thermometers
 Bimetallic thermometers

3. Electrical Temp. Sensors/Transducer
 Thermo-voltaic Elements (Thermocouple)
 Thermo-resistive Elements
 Temperature Sensitive Materials
 Pyrometers

Note: Refer to Module 1-1 power-point regarding the details of Mechanical Temp. Sensors /
Transducer and Electrical Temp. Sensors / Transducer.

F. FLOW MEASUREMENT:

Code No. Install (ICD) Date: Developed Date: Revised Page #
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Worksheet 3-2: Personal Protective Equipment

I. INTRODUCTION:
 Flow is actually the amount of fluid that passed a given point. Flow Rate is the
amount of fluid that passed a given point at any given instant, while Total
Flow is the amount of fluid that passed a given point during a specific period
of time.
 Units of Flow:
Volume-based – Examples of volume-based metric units are cc/s, mm3/s, m3/hr,
cc/min, etc. English units include gal/s, gal/min (gpm), ft3/s, ft3/min (cfm), ft3/day,
etc.
Mass-based – Examples of mass-based metric units are g/s, kg/s, kg/min,
kg/hr, etc. English units include oz/s, lb/hr (pph), tons/hr (tph), etc.

II. OPEN CHANNEL FLOW SENSOR/TRANSDUCER
This type of flow measurement is applicable in irrigation systems, dams, water
treatment facilities, desalination plants, etc. It basic principle is forcing the fluid
to pass a specific design of barrier and measuring the rise of its level in an
adjacent still-well, the higher the level at the still-well, the higher also the flow-
rate.
 WEIR
 FLUME

III. ENCLOSED PIPE FLOW SENSOR/TRANSDUCER
 HEAD FLOWMETER
 POSITIVE DISPLACEMENT FLOWMETER
 VELOCITY FLOWMETER
 MASS FLOWMETER

Note: Refer to Module 1-1 power-point regarding the details of Open channel Flow Sensors /
Transducer and Enclosed channel Flow Sensors / Transducer.

G. SUMMARY:

In interpreting work instructions regarding the installation of I&C devices, a technician must have
the knowledge of the fundamentals of instrumentation and control technology. These are
contained in this information sheet.

Code No. Install (ICD) Date: Developed Date: Revised Page #
ECL724301 Instrumentation and Control Devices April 27, 2010 12

Information Sheet 3-3: Occupational Health and Safety Policies and Procedures

Learning outcome:
Comply with Occupational Health and Safety policies and procedures in installing
instrumentation and control devices.

Learning Activity:
Define and explain the occupational health and safety policies and procedures in
installing instrumentation and control devices.

CONTENTS:

A. Introduction
B. Definition of terms
C. Pressure measurement
D. Level measurement
E. Temperature measurement
F. Flow measurement
G. Summary

A. INTRODUCTION:

Have you seen the 80s movie, Rocobop? Well, it’s about this cop who was badly shot in one of
police operations, and in order to save him, he was made into cyborg, partly human and partly
machine. This concept is the principle behind any industrial automation system, where man
and machine use their best qualities for a common cause to improve the manufacturing,
maintenance, etc., and ultimately the existence of all living creatures.

Industrial automation has many allied technologies and one of them is Instrumentation and
control (I&C). One of the main tasks of an I&C technician is to install instrumentation and
control devices. And, its most important sub-task is to interpret work instructions related to
installation of I&C devices.

This information sheet contains the fundamentals of instrumentation and control technology
which are essential in the interpretation of work instructions.

Code No. Install (ICD) Date: Developed Date: Revised Page #
ECL724301 Instrumentation and Control Devices April 27, 2010 1

Information Sheet 3-3: Occupational Health and Safety Policies and Procedures

B. DEFINITION OF TERMS

1. Industrial Automation is a step beyond mechanization. Whereas mechanization provided
human operators with machinery to assist them with the muscular requirements of work,
industrial automation greatly reduces the need for human sensory and mental
requirements as well. Industrial automation has two main categories, machine automation
and process automation.

2. Mechatronics is the synergistic combination of mechanical, electronics/electrical, and
computer software engineering to automate a mechanize control system. It can be referred
to as machine automation.

3. Machine Automation are applicable for semiconductor manufacturing, building automation,
construction machineries, transportation controls (land, sea, air, space)
product packaging machineries, mining equipment controls, etc.

4. Instrumentation is collection of instruments or their application for the purpose of
observation, measurement or control. It can be referred to as process automation.

5. Process Automation is applicable for food processing, biomedical processes petrochemical
refinery, water treatment, pollution control, power generation, etc.

6. Observation is the output of the 5 senses of man. It is expressed in terms of qualitative
characteristics of a physical object or variable. In process automation, observation is derived
from the output of sensors. Figure – 1 below compares man’s senses to machine’s primary
elements.

7. Measurement is the output of man using a tool to determine qualitative and quantitative
characteristics of a physical object/variable. In process automation, measurement is the
output sensors connected to a transducer, indicator, and recorder. From Figure -1, we can
say that measurement is the product of senses and brain (primary and intermediate
elements).

8. Control is the output when man operates using his senses to observe an object or variable,
then use his intellect to give meaning and decide on a course of action, and finally use his
motor faculties to execute his course of action. In Figure – 1, it happens when the machine
elements operates to detect, process, react, and correct changes in control loop variables.

Note: Instrumentation and control is often defined separately because there are some
systems that do not involve observation and control, only observation and measurement.

Code No. Install (ICD) Date: Developed Date: Revised Page #
ECL724301 Instrumentation and Control Devices April 27, 2010 2

Information Sheet 3-3: Occupational Health and Safety Policies and Procedures

AUTOMATIC CONTROL CONCEPT

MAN MACHINE

I. SENSES I. PRIMARY ELEMENT
• Eyes • Photocells
• Ears • Microphone
• Nose • Smoke Detectors
• Skin / Touch • Thermometers
• Tongue • Analytical Sensors

II. BRAIN II. INTERMEDIATE
• Intellect ELEMENT
• Will • Indicators
• Recorders
III. MOTOR FACULTIES • Controllers
• Hands
• Feet III. FINAL ELEMENT
• Body • Motors
Figure 1 – 1 • Cylinders

9. CONTROL SYSTEMS / LOOPS:

 Figure 1 – 2 and Figure 1 – 3 shows a typical heat exchanger control loops.

 The close loop has feedback. The intervention of the operator is less because it’s fully
automatic.

 The open loop has no feedback coming from the sensor and transmitter. Any changes
in controlled variable rely on the operator. This can be referred to as semi – automatic.

Figure 1 – 2: Close Loop Figure 1 – 3: Open Loop

Code No. Install (ICD) Date: Developed Date: Revised Page #
ECL724301 Instrumentation and Control Devices April 27, 2010 3

Information Sheet 3-3: Occupational Health and Safety Policies and Procedures

10. CONTROL LOOP VARIABLES:

 Independent variables (IV) answer the question "What do I change?" In Figure 1 – 2,
the flow of the steam is the IV.

 Dependent variables (DV) answer the question "What do I observe?" In Figure 1 – 2,
the temperature of the water going out of the heat exchanger is the DV.

 Controlled variables (CV) answer the question "What do I keep the same?" In Figure 1
– 2, the temperature of the water inside the heat exchanger is the CV.

 Extraneous variables (EV) answer the question "What uninteresting variables might
mediate the effect of the Independent Variable on the Dependent Variable?" In Figure 1
– 3, the disturbances (energy loss and gain) in and out of the heat exchanger is the
EV.

11. PROCESS VARIABLES:

 Process variables are the objects of process automation (instrumentation and control).
 There are 4 Basic Process Variables; Pressure, Level, Temperature, and Flow.
 Other process variables such as density, force or weight, etc. can be derived from the

basic process variables.

12. ELEMENTS OF PROCESS CONTROL:

 Primary Elements senses or detects the control loop variables. In Figure 1 – 2, the
primary elements are the transducers - sensors and transmitter.

 Intermediate Elements receive signals from primary elements and provide
corresponding output signal either through indication/record or control action. In Figure 1
– 2, the intermediate elements are controller, recorder, and enunciator.

 Final Elements receive signals from a controller and execute corrective action to
manipulated variable. In Figure 1 – 2, the final element is the control valve.

Note:
With the current innovations in automation engineering and technology, instrumentation and
control devices manufacturers combine the functionalities of the different elements of process
control, for instance:

 Some instrumentation and control devices have primary, intermediate, and final
elements in 1 unit.

 Some instrumentation and control devices have primary and intermediate elements, and
some instrumentation and control devices have intermediate and final elements.

13. TRANSDUCER:
 A transducer is a device, electrical, electronic, electro-mechanical, electromagnetic,
photonic, or photovoltaic, that converts one type of energy or physical attribute to
another for various purposes including measurement or information transfer.

Code No. Install (ICD) Date: Developed Date: Revised Page #
ECL724301 Instrumentation and Control Devices April 27, 2010 4

Information Sheet 3-3: Occupational Health and Safety Policies and Procedures

14. SENSORS:
 A sensor is a device that measures a physical quantity and converts it into a signal
which can be read by an observer or by an instrument.
 Types of sensor; self – generating, and passive.
 Characteristics of sensor:
a. A good or ideal sensor is designed to be linear. The output signal of such a sensor is
linearly proportional to the value of the measured property.
b. If the output signal is not zero when the measured property is zero, the sensor has
an offset or bias. This is defined as the output of the sensor at zero input.
c. The sensitivity or gain is then defined as the ratio between output signal and
measured property. If the sensitivity is not constant over the range of the sensor, this
is called nonlinearity.
d. If the output signal slowly changes independent of the measured property, this is
defined as drift.
e. If the sensor has a digital output, the output is essentially an approximation of the
measured property. The approximation error is also called digitization error.

15. TRANSMITTER:
 In industrial process control, a "transmitter" is any device which converts measurements
from a sensor into a signal to be received, usually sent via wires, by some display or
control device located a distance away.

C. PRESSURE MEASUREMENT:

I. INTRODUCTION
 WHAT IS PRESSURE?
 ATMOSPHERIC PRESSURE
 HYDROSTATIC PRESSURE
 MODES OF PRESSURE

II. PRESSURE SENSORS/TRANSDUCERS
 BOURDON TUBE
 SPRING AND PISTON
 BELLOWS AND CAPSULES
 DIAPHRAGM

III. ELECTRICAL PRESSURE TRANSDUCERS
 PIEZO-RESISTIVE STRAIN GAUGE
 CAPACITIVE
 ELECTROMAGNETIC
 OPTICAL

Code No. Install (ICD) Date: Developed Date: Revised Page #
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Information Sheet 3-3: Occupational Health and Safety Policies and Procedures

I. INTRODUCTION
Pressure is defined as a force per unit area, or is the force exerted by an object on a
certain area. Pressure results from molecules exerting a force by impacting over a
defined area. The relationship is given by:

Pressure (P) = Force (F)
Area (A)

Atmospheric pressure is the amount of pressure that a column of air exerts on a body
due to the influence of gravity.

Vacuum is a volume of space that is essentially empty of matter, such that its gaseous
pressure is much less than atmospheric pressure. Vacuum pressure is pressure lower
than atmospheric pressure.
Hydrostatic pressure is the amount of pressure that a column of liquid exerts on a body
due to the influence of gravity.

Pressure (P) =Specific Gravity (S.G.) * Height (H)

The objects of pressure measurements are gas, liquid, and steam.
Modes of pressure measurement:

\ Install (ICD) Date: Developed Date: Revised Page #
Instrumentation and Control Devices April 27, 2010 6
Code No.
ECL724301

Information Sheet 3-3: Occupational Health and Safety Policies and Procedures

II. MECHANICAL PRESSURE SENSOR/TRANSDUCER

Bellows

Bourdon Piston

III. ELECTRICAL PRESSURE TRANSDUCER

Code No. Install (ICD) Date: Developed Date: Revised Page #
ECL724301 Instrumentation and Control Devices April 27, 2010 7

Information Sheet 3-3: Occupational Health and Safety Policies and Procedures

Code No. Install (ICD) Date: Developed Date: Revised Page #
ECL724301 Instrumentation and Control Devices April 27, 2010 8

Information Sheet 3-3: Occupational Health and Safety Policies and Procedures

D. LEVEL MEASUREMENT:

I. Level Transducer Selection Checklist

Key questions to ask before selecting a level measurement transducer:
 Are you measuring a liquid or solid?
 What are the application's temperature and pressure ranges?
 Is point level or continuous measurement required?
 What level measurement range do you need?
 Is the measured material electrically conductive?
 Will the material coat or build up on surfaces?
 Does turbulence, foam, or vapor occur at the surface of the liquid?
 Will you need contact or non-contact level measurement?
 What kind of output do you need–analog, relay, digital display, etc.?

II. Types of Level Transducer

Level measurement transducers fall into two main types:
 Point level measurement type is used to mark a single discrete liquid height–a

preset level condition. Generally, this type of sensor functions as a high alarm,
signaling an overfill condition, or as a marker for a low alarm condition.
 Continuous level measurement type is more sophisticated and can provide level
monitoring of an entire system. They measure fluid level within a range, rather than
at a one point, producing an analog output that directly correlates to the level in the
vessel.

III. Level Transducers
1. Point and continuous level detection for solids
1.1 Vibrating point
1.2 Rotating paddle
1.3 Admittance-type
2. Point level detection of liquids
2.1 Magnetic and mechanical float
2.2 Pneumatic
2.3 Conductive
3. Both for Point Level Detection and Continuous Monitoring of Solids and Liquids
3.1 Capacitance
3.2 Optical interface
3.3 Ultrasonic
3.4 Microwave

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Information Sheet 3-3: Occupational Health and Safety Policies and Procedures
4. Continuous level measurement of liquids
4.1 Magneto-restrictive
4.2 Resistive chain
4.3 Hydrostatic pressure
4.4 Air bubbler
4.5 Gamma ray

Note: Refer to Module 1-1 power-point regarding the details of Level Transducers.

E. TEMPERATURE MEASUREMENT:

1. INTRODUCTION:
 Temperature is the degree of hotness or coldness of a body measured on a
definite scale.
 Temperature Scales:

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 Temperature Scales Conversion:

 Principle of Heat Transfer:
The effectiveness and sensitivity of any temperature sensor or transducer is due on the
principle of heat transfer. There are three (3) basic ways how heat transfers:
conduction, convection, and radiation.

1. Mechanical Temp. Sensors/Transducer
 Liquid-in-glass thermometers
 Filled-System thermometers
 Bimetallic thermometers

3. Electrical Temp. Sensors/Transducer
 Thermo-voltaic Elements (Thermocouple)
 Thermo-resistive Elements
 Temperature Sensitive Materials
 Pyrometers

Note: Refer to Module 1-1 power-point regarding the details of Mechanical Temp. Sensors /
Transducer and Electrical Temp. Sensors / Transducer.

F. FLOW MEASUREMENT:

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Information Sheet 3-3: Occupational Health and Safety Policies and Procedures

I. INTRODUCTION:
 Flow is actually the amount of fluid that passed a given point. Flow Rate is the
amount of fluid that passed a given point at any given instant, while Total
Flow is the amount of fluid that passed a given point during a specific period
of time.
 Units of Flow:
Volume-based – Examples of volume-based metric units are cc/s, mm3/s, m3/hr,
cc/min, etc. English units include gal/s, gal/min (gpm), ft3/s, ft3/min (cfm), ft3/day,
etc.
Mass-based – Examples of mass-based metric units are g/s, kg/s, kg/min,
kg/hr, etc. English units include oz/s, lb/hr (pph), tons/hr (tph), etc.

II. OPEN CHANNEL FLOW SENSOR/TRANSDUCER
This type of flow measurement is applicable in irrigation systems, dams, water
treatment facilities, desalination plants, etc. It basic principle is forcing the fluid
to pass a specific design of barrier and measuring the rise of its level in an
adjacent still-well, the higher the level at the still-well, the higher also the flow-
rate.
 WEIR
 FLUME

III. ENCLOSED PIPE FLOW SENSOR/TRANSDUCER
 HEAD FLOWMETER
 POSITIVE DISPLACEMENT FLOWMETER
 VELOCITY FLOWMETER
 MASS FLOWMETER

Note: Refer to Module 1-1 power-point regarding the details of Open channel Flow Sensors /
Transducer and Enclosed channel Flow Sensors / Transducer.

G. SUMMARY:

In interpreting work instructions regarding the installation of I&C devices, a technician must have
the knowledge of the fundamentals of instrumentation and control technology. These are
contained in this information sheet.

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Worksheet 3-3: Occupational Health and Safety Policies and Procedures

Learning outcome:
Comply with Occupational Health and Safety policies and procedures in installing
instrumentation and control devices.

Learning Activity:
Define and explain the occupational health and safety policies and procedures in
installing instrumentation and control devices.

CONTENTS:

A. Introduction
B. Definition of terms
C. Pressure measurement
D. Level measurement
E. Temperature measurement
F. Flow measurement
G. Summary

A. INTRODUCTION:

Have you seen the 80s movie, Rocobop? Well, it’s about this cop who was badly shot in one of
police operations, and in order to save him, he was made into cyborg, partly human and partly
machine. This concept is the principle behind any industrial automation system, where man
and machine use their best qualities for a common cause to improve the manufacturing,
maintenance, etc., and ultimately the existence of all living creatures.

Industrial automation has many allied technologies and one of them is Instrumentation and
control (I&C). One of the main tasks of an I&C technician is to install instrumentation and
control devices. And, its most important sub-task is to interpret work instructions related to
installation of I&C devices.

This information sheet contains the fundamentals of instrumentation and control technology
which are essential in the interpretation of work instructions.

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Worksheet 3-3: Occupational Health and Safety Policies and Procedures

B. DEFINITION OF TERMS

1. Industrial Automation is a step beyond mechanization. Whereas mechanization provided
human operators with machinery to assist them with the muscular requirements of work,
industrial automation greatly reduces the need for human sensory and mental
requirements as well. Industrial automation has two main categories, machine automation
and process automation.

2. Mechatronics is the synergistic combination of mechanical, electronics/electrical, and
computer software engineering to automate a mechanize control system. It can be referred
to as machine automation.

3. Machine Automation are applicable for semiconductor manufacturing, building automation,
construction machineries, transportation controls (land, sea, air, space)
product packaging machineries, mining equipment controls, etc.

4. Instrumentation is collection of instruments or their application for the purpose of
observation, measurement or control. It can be referred to as process automation.

5. Process Automation is applicable for food processing, biomedical processes petrochemical
refinery, water treatment, pollution control, power generation, etc.

6. Observation is the output of the 5 senses of man. It is expressed in terms of qualitative
characteristics of a physical object or variable. In process automation, observation is derived
from the output of sensors. Figure – 1 below compares man’s senses to machine’s primary
elements.

7. Measurement is the output of man using a tool to determine qualitative and quantitative
characteristics of a physical object/variable. In process automation, measurement is the
output sensors connected to a transducer, indicator, and recorder. From Figure -1, we can
say that measurement is the product of senses and brain (primary and intermediate
elements).

8. Control is the output when man operates using his senses to observe an object or variable,
then use his intellect to give meaning and decide on a course of action, and finally use his
motor faculties to execute his course of action. In Figure – 1, it happens when the machine
elements operates to detect, process, react, and correct changes in control loop variables.

Note: Instrumentation and control is often defined separately because there are some
systems that do not involve observation and control, only observation and measurement.

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AUTOMATIC CONTROL CONCEPT

MAN MACHINE

I. SENSES I. PRIMARY ELEMENT
• Eyes • Photocells
• Ears • Microphone
• Nose • Smoke Detectors
• Skin / Touch • Thermometers
• Tongue • Analytical Sensors

II. BRAIN II. INTERMEDIATE
• Intellect ELEMENT
• Will • Indicators
• Recorders
III. MOTOR FACULTIES • Controllers
• Hands
• Feet III. FINAL ELEMENT
• Body • Motors
Figure 1 – 1 • Cylinders

9. CONTROL SYSTEMS / LOOPS:

 Figure 1 – 2 and Figure 1 – 3 shows a typical heat exchanger control loops.

 The close loop has feedback. The intervention of the operator is less because it’s fully
automatic.

 The open loop has no feedback coming from the sensor and transmitter. Any changes
in controlled variable rely on the operator. This can be referred to as semi – automatic.

Figure 1 – 2: Close Loop Figure 1 – 3: Open Loop

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10. CONTROL LOOP VARIABLES:

 Independent variables (IV) answer the question "What do I change?" In Figure 1 – 2,
the flow of the steam is the IV.

 Dependent variables (DV) answer the question "What do I observe?" In Figure 1 – 2,
the temperature of the water going out of the heat exchanger is the DV.

 Controlled variables (CV) answer the question "What do I keep the same?" In Figure 1
– 2, the temperature of the water inside the heat exchanger is the CV.

 Extraneous variables (EV) answer the question "What uninteresting variables might
mediate the effect of the Independent Variable on the Dependent Variable?" In Figure 1
– 3, the disturbances (energy loss and gain) in and out of the heat exchanger is the
EV.

11. PROCESS VARIABLES:

 Process variables are the objects of process automation (instrumentation and control).
 There are 4 Basic Process Variables; Pressure, Level, Temperature, and Flow.
 Other process variables such as density, force or weight, etc. can be derived from the

basic process variables.

12. ELEMENTS OF PROCESS CONTROL:

 Primary Elements senses or detects the control loop variables. In Figure 1 – 2, the
primary elements are the transducers - sensors and transmitter.

 Intermediate Elements receive signals from primary elements and provide
corresponding output signal either through indication/record or control action. In Figure 1
– 2, the intermediate elements are controller, recorder, and enunciator.

 Final Elements receive signals from a controller and execute corrective action to
manipulated variable. In Figure 1 – 2, the final element is the control valve.

Note:
With the current innovations in automation engineering and technology, instrumentation and
control devices manufacturers combine the functionalities of the different elements of process
control, for instance:

 Some instrumentation and control devices have primary, intermediate, and final
elements in 1 unit.

 Some instrumentation and control devices have primary and intermediate elements, and
some instrumentation and control devices have intermediate and final elements.

13. TRANSDUCER:
 A transducer is a device, electrical, electronic, electro-mechanical, electromagnetic,
photonic, or photovoltaic, that converts one type of energy or physical attribute to
another for various purposes including measurement or information transfer.

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14. SENSORS:
 A sensor is a device that measures a physical quantity and converts it into a signal
which can be read by an observer or by an instrument.
 Types of sensor; self – generating, and passive.
 Characteristics of sensor:
a. A good or ideal sensor is designed to be linear. The output signal of such a sensor is
linearly proportional to the value of the measured property.
b. If the output signal is not zero when the measured property is zero, the sensor has
an offset or bias. This is defined as the output of the sensor at zero input.
c. The sensitivity or gain is then defined as the ratio between output signal and
measured property. If the sensitivity is not constant over the range of the sensor, this
is called nonlinearity.
d. If the output signal slowly changes independent of the measured property, this is
defined as drift.
e. If the sensor has a digital output, the output is essentially an approximation of the
measured property. The approximation error is also called digitization error.

15. TRANSMITTER:
 In industrial process control, a "transmitter" is any device which converts measurements
from a sensor into a signal to be received, usually sent via wires, by some display or
control device located a distance away.

C. PRESSURE MEASUREMENT:

I. INTRODUCTION
 WHAT IS PRESSURE?
 ATMOSPHERIC PRESSURE
 HYDROSTATIC PRESSURE
 MODES OF PRESSURE

II. PRESSURE SENSORS/TRANSDUCERS
 BOURDON TUBE
 SPRING AND PISTON
 BELLOWS AND CAPSULES
 DIAPHRAGM

III. ELECTRICAL PRESSURE TRANSDUCERS
 PIEZO-RESISTIVE STRAIN GAUGE
 CAPACITIVE
 ELECTROMAGNETIC
 OPTICAL

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I. INTRODUCTION
Pressure is defined as a force per unit area, or is the force exerted by an object on a
certain area. Pressure results from molecules exerting a force by impacting over a
defined area. The relationship is given by:

Pressure (P) = Force (F)
Area (A)

Atmospheric pressure is the amount of pressure that a column of air exerts on a body
due to the influence of gravity.

Vacuum is a volume of space that is essentially empty of matter, such that its gaseous
pressure is much less than atmospheric pressure. Vacuum pressure is pressure lower
than atmospheric pressure.
Hydrostatic pressure is the amount of pressure that a column of liquid exerts on a body
due to the influence of gravity.

Pressure (P) =Specific Gravity (S.G.) * Height (H)

The objects of pressure measurements are gas, liquid, and steam.
Modes of pressure measurement:

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Worksheet 3-3: Occupational Health and Safety Policies and Procedures

II. MECHANICAL PRESSURE SENSOR/TRANSDUCER

Bellows

Bourdon Piston

III. ELECTRICAL PRESSURE TRANSDUCER

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D. LEVEL MEASUREMENT:

I. Level Transducer Selection Checklist

Key questions to ask before selecting a level measurement transducer:
 Are you measuring a liquid or solid?
 What are the application's temperature and pressure ranges?
 Is point level or continuous measurement required?
 What level measurement range do you need?
 Is the measured material electrically conductive?
 Will the material coat or build up on surfaces?
 Does turbulence, foam, or vapor occur at the surface of the liquid?
 Will you need contact or non-contact level measurement?
 What kind of output do you need–analog, relay, digital display, etc.?

II. Types of Level Transducer

Level measurement transducers fall into two main types:
 Point level measurement type is used to mark a single discrete liquid height–a

preset level condition. Generally, this type of sensor functions as a high alarm,
signaling an overfill condition, or as a marker for a low alarm condition.
 Continuous level measurement type is more sophisticated and can provide level
monitoring of an entire system. They measure fluid level within a range, rather than
at a one point, producing an analog output that directly correlates to the level in the
vessel.

III. Level Transducers
1. Point and continuous level detection for solids
1.1 Vibrating point
1.2 Rotating paddle
1.3 Admittance-type
2. Point level detection of liquids
2.1 Magnetic and mechanical float
2.2 Pneumatic
2.3 Conductive
3. Both for Point Level Detection and Continuous Monitoring of Solids and Liquids
3.1 Capacitance
3.2 Optical interface
3.3 Ultrasonic
3.4 Microwave

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Worksheet 3-3: Occupational Health and Safety Policies and Procedures
4. Continuous level measurement of liquids
4.1 Magneto-restrictive
4.2 Resistive chain
4.3 Hydrostatic pressure
4.4 Air bubbler
4.5 Gamma ray

Note: Refer to Module 1-1 power-point regarding the details of Level Transducers.

E. TEMPERATURE MEASUREMENT:

1. INTRODUCTION:
 Temperature is the degree of hotness or coldness of a body measured on a
definite scale.
 Temperature Scales:

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Worksheet 3-3: Occupational Health and Safety Policies and Procedures

 Temperature Scales Conversion:

 Principle of Heat Transfer:
The effectiveness and sensitivity of any temperature sensor or transducer is due on the
principle of heat transfer. There are three (3) basic ways how heat transfers:
conduction, convection, and radiation.

1. Mechanical Temp. Sensors/Transducer
 Liquid-in-glass thermometers
 Filled-System thermometers
 Bimetallic thermometers

3. Electrical Temp. Sensors/Transducer
 Thermo-voltaic Elements (Thermocouple)
 Thermo-resistive Elements
 Temperature Sensitive Materials
 Pyrometers

Note: Refer to Module 1-1 power-point regarding the details of Mechanical Temp. Sensors /
Transducer and Electrical Temp. Sensors / Transducer.

F. FLOW MEASUREMENT:

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Worksheet 3-3: Occupational Health and Safety Policies and Procedures

I. INTRODUCTION:
 Flow is actually the amount of fluid that passed a given point. Flow Rate is the
amount of fluid that passed a given point at any given instant, while Total
Flow is the amount of fluid that passed a given point during a specific period
of time.
 Units of Flow:
Volume-based – Examples of volume-based metric units are cc/s, mm3/s, m3/hr,
cc/min, etc. English units include gal/s, gal/min (gpm), ft3/s, ft3/min (cfm), ft3/day,
etc.
Mass-based – Examples of mass-based metric units are g/s, kg/s, kg/min,
kg/hr, etc. English units include oz/s, lb/hr (pph), tons/hr (tph), etc.

II. OPEN CHANNEL FLOW SENSOR/TRANSDUCER
This type of flow measurement is applicable in irrigation systems, dams, water
treatment facilities, desalination plants, etc. It basic principle is forcing the fluid
to pass a specific design of barrier and measuring the rise of its level in an
adjacent still-well, the higher the level at the still-well, the higher also the flow-
rate.
 WEIR
 FLUME

III. ENCLOSED PIPE FLOW SENSOR/TRANSDUCER
 HEAD FLOWMETER
 POSITIVE DISPLACEMENT FLOWMETER
 VELOCITY FLOWMETER
 MASS FLOWMETER

Note: Refer to Module 1-1 power-point regarding the details of Open channel Flow Sensors /
Transducer and Enclosed channel Flow Sensors / Transducer.

G. SUMMARY:

In interpreting work instructions regarding the installation of I&C devices, a technician must have
the knowledge of the fundamentals of instrumentation and control technology. These are
contained in this information sheet.

Code No. Install (ICD) Date: Developed Date: Revised Page #
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Information Sheet 4 - 1: Techniques in installing I&C devices

Learning outcomes:
Install instrumentation and control device.

Learning Activity:
Interpret work instrumentation and control diagrams.
Prepare the necessary tools, materials, equipment, and ppe.
Install the instrumentation and control devices.

I. Instrumentation Loop Diagram (ILD):

RTD WHT 1 24 VDC
PT100 WHT 2 TT +
RED 3 10 - + ES1
TE WHT - 10
10 4

250Ω

TV L1 NO1 TIC +
10 L2 NO2 10 -

L1 220 VAC
ES2
+ ES 10

L2- 10

L2
L1

II. Piping and Instrumentation Diagram (P&ID)

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Information Sheet 4 - 1: Techniques in installing I&C devices

III. Resources:

List of I&C devices, Equipment, and Materials

Quantity Tag Description

1 unit TE-10 Pt-100 RTD, 4 wires

1 unit TT-10 Smar TT301 Temp. Transmitter

1 unit TIC-10 Autonics Temp. Indicating Controller

1 unit TV-10 SMC 220VAC Solenoid Valve

1 unit ES1-10 24 VDC regulated power supply, 2W

1 unit ES2-10 220 VAC variable AC source, 5W

1 pc. 250Ω, 1W

1 lot AWG 16 Stranded Wires

1 lot Terminal lags

List of Tools & PPEs Wire stripper Safety helmet
Long-nosed pliers Crimping tool Safety shoes
Diagonal cutters Allen wrench Safety harness
Standard screwdrivers Jeweller’s screwdrivers Safety goggles
Phillips screwdrivers Combination wrench Ear plug/Ear muffs
Electrical pliers Gloves Mask/Face shield
Adjustable wrench

IV. Activities:
A. Plan & prepare for the installation of instrumentation and control devices.
1. Identify the needed tools and personal protective equipment (PPE) to do the
installation from the given selection. Put them on the space provided below:

TOOLS:

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Information Sheet 4 - 1: Techniques in installing I&C devices

PPEs:

2. Identify additional resources; tools, materials, equipment, and ppe, not on the
above list but necessary to perform the installation task. Put them in the space
below:

B. Install instrumentation and control devices according to diagram.
Warning: Install ES1-10 and ES2-10 at the last. Make sure your instructor check your

set-up before you apply power.
1. Tap the (TE-10) 4-wire RTD firmly on TT-10 and follow color code. Insert TE -10

inside the thermowell in the process tank.
2. Check (TT-10) Smar TT-301 manual. Make sure to put the needed jumper in its

terminals.
3. Connect (TIC-10) Autonics Temp. Indicating Controller to TT-10 & TV-10.

Code No. Install (ICD) Date: Developed Date: Revised Page #
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Instrumentation and Control Devices April 27, 2010

Operation Sheet 4 - 1: Techniques in installing I&C devices

Learning outcomes:
Install instrumentation and control device.

Learning Activity:
Interpret work instrumentation and control diagrams.
Prepare the necessary tools, materials, equipment, and ppe.
Install the instrumentation and control devices.

I. Instrumentation Loop Diagram (ILD):

RTD WHT 1 24 VDC
PT100 WHT 2 TT +
RED 3 10 - + ES1
TE WHT - 10
10 4

250Ω

TV L1 NO1 TIC +
10 L2 NO2 10 -

L1 220 VAC
ES2
+ ES 10

L2- 10

L2
L1

II. Piping and Instrumentation Diagram (P&ID)

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Operation Sheet 4 - 1: Techniques in installing I&C devices

III. Resources:

List of I&C devices, Equipment, and Materials

Quantity Tag Description

1 unit TE-10 Pt-100 RTD, 4 wires

1 unit TT-10 Smar TT301 Temp. Transmitter

1 unit TIC-10 Autonics Temp. Indicating Controller

1 unit TV-10 SMC 220VAC Solenoid Valve

1 unit ES1-10 24 VDC regulated power supply, 2W

1 unit ES2-10 220 VAC variable AC source, 5W

1 pc. 250Ω, 1W

1 lot AWG 16 Stranded Wires

1 lot Terminal lags

List of Tools & PPEs Wire stripper Safety helmet
Long-nosed pliers Crimping tool Safety shoes
Diagonal cutters Allen wrench Safety harness
Standard screwdrivers Jeweller’s screwdrivers Safety goggles
Phillips screwdrivers Combination wrench Ear plug/Ear muffs
Electrical pliers Gloves Mask/Face shield
Adjustable wrench

IV. Activities:
A. Plan & prepare for the installation of instrumentation and control devices.
1. Identify the needed tools and personal protective equipment (PPE) to do the
installation from the given selection. Put them on the space provided below:

TOOLS:

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Operation Sheet 4 - 1: Techniques in installing I&C devices

PPEs:

2. Identify additional resources; tools, materials, equipment, and ppe, not on the
above list but necessary to perform the installation task. Put them in the space
below:

B. Install instrumentation and control devices according to diagram.
Warning: Install ES1-10 and ES2-10 at the last. Make sure your instructor check your

set-up before you apply power.
1. Tap the (TE-10) 4-wire RTD firmly on TT-10 and follow color code. Insert TE -10

inside the thermowell in the process tank.
2. Check (TT-10) Smar TT-301 manual. Make sure to put the needed jumper in its

terminals.
3. Connect (TIC-10) Autonics Temp. Indicating Controller to TT-10 & TV-10.

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Information Sheet 5.1: Techniques in ICD Installation

Learning outcomes:
5. Install instrumentation and control devices

Learning Activity:
5.1 Techniques in installing of instrumentation & control devices.

Outline:
Introduction
General Requirements
Storage and Protection
Mounting and Accessibility
Piping System
Air Supplies
Pneumatic Signals
Impulse Lines
Cabling
General Requirements
Cable Types
Cable Segregation
Grounding
General requirements

Introduction

Plant safety and continuous effective plant operability are totally dependent upon correct installation
and commissioning of the instrumentation systems. Process plants are increasingly becoming
dependent upon automatic control systems, owing to the advanced control functions and monitoring
facilities that can be provided in order to improve plant efficiency, product throughput, and product
quality.

The instrumentation on a process plant represents a significant capital investment, and the
importance of careful handling on site and the exactitude of the installation cannot be overstressed.
Correct installation is also important in order to ensure long-term reliability and to obtain the best
results from instruments which are capable of higher-order accuracies due to advances in
technology. Quality control of the completed work is also an important function.

General requirements

Installation should be carried out using the best engineering practices by skilled personnel who are
fully acquainted with the safety requirements and regulations governing a plant site. Prior to
commencement of the work for a specific project, installation design details should be made
available which define the scope of work and the extent of material supply and which give detailed
installation information related to location, fixing, piping, and wiring. Such design details should have
already taken account of established installation recommendations and measuring technology
requirements. The details contained in this chapter are intended to give general installation
guidelines.

Storage and protection

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Information Sheet 5.1: Techniques in ICD Installation

When instruments are received on a job site it is of the utmost importance that they are unpacked
with care, examined for superficial damage, and then placed in a secure store which should be free
from dust and suitably heated. In order to minimize handling, large items of equipment, such as
control panels, should be programmed to go directly into their intended location, but temporary anti-
condensation heaters should be installed if the intended air-conditioning systems have not been
commissioned. Throughout construction, instruments and equipment installed in the field should be
fitted with suitable coverings to protect them from mechanical abuse such as paint spraying, etc.
Preferably, after an installation has been fabricated, the instrument should be removed from the site
and returned to the store for safe keeping until ready for precalibration and final loop checking.
Again, when instruments are removed, care should be taken to seal the ends of piping, etc., to
prevent ingress of foreign matter.

Mounting and accessibility

When instruments are mounted in their intended location, either on pipe stands, brackets, or directly
connected to vessels, etc., they should be vertically plumbed and firmly secured. Instrument
mountings should be vibration free and should be located so that they do not obstruct access ways
which may be required for maintenance to other items of equipment. They should also be clear of
obvious hazards such as hot surfaces or drainage points from process equipment. Locations should
also be selected to ensure that the instruments are accessible for observation and maintenance.
Where instruments are mounted at higher elevations, it must be ensured that they are accessible
either by permanent or temporary means. instruments should be located as close as possible to
their process tapping points in order to minimize the length of impulse lines, but consideration should
be paid to the possibility of expansion of piping or vessels which could take place under operating
conditions and which could result in damage if not properly catered for. All brackets and supports
should be adequately protected against corrosion by priming and painting. When installing final
control elements such as control valves, again, the requirement for maintenance is allowed above
and below the valve to facilitate servicing of the valve actuator and the valve internals.

Piping systems

All instrument piping or tubing runs should be routed to meet the following requirements:
1. They should be kept as short as possible;
2. They should not cause any obstruction that would prohibit personnel or traffic access;
3. They should not interfere with the accessibility for maintenance of other items of equipment;
4. They should avoid hot environments or potential fire-risk areas;
5. They should be located with sufficient clearance to permit lagging which may be required on
adjacent pipe work;

The number of joints should be kept to a minimum consistent with good practice; All piping and
tubing should be adequately supported along its entire length from supports attached to firm
steelwork or structures (not handrails).
(Note: Tubing can be regarded as thin-walled seamless pipe that cannot be threaded and which is
joined by compression fittings. as opposed to piping, which can be threaded or welded.)

Air supplies

Air supplies to instruments should be clean, dry, and oil free. Air is normally distributed around a
plant from a high-pressure header (e.g., 6-7 bar g), ideally forming a ring main. This header, usually
of galvanized steel, should be sized to cope with the maximum demand of the instrument air users
being serviced, and an allowance should be made for possible future expansion or modifications to
its duty. Branch headers should be provided to supply individual instruments or groups of
instruments. Again, adequate spare tappings should be allowed to cater for future expansion.
Branch headers should be self draining and have adequate drainage blow- off facilities. On small

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Information Sheet 5.1: Techniques in ICD Installation

headers this may be achieved by the instrument air filter/regulators. Each instrument air user should
have an individual filter regulator. Piping and fittings installed after filter regulators should be non-
ferrous.

Pneumatic signals

Pneumatic transmission signals are normally in the range of 0.2-1.0 barg (3-15psig), and for these
signals copper tubing is most commonly used, preferably with a PYC outer sheath. Other materials
are sometimes used, depending on environmental considerations (e.g., alloy tubing or stainless
steel). Although expensive, stainless steel tubing is the most durable and will withstand the most
arduous service conditions. Plastic tubing should preferably only be used within control panels.
There are several problems to be considered when using plastic tubes on a plant site, as they are
very vulnerable to damage unless adequately protected, they generally cannot be installed at
subzero temperatures, and they can be considerably weakened by exposure to hot surfaces. Also, it
should be remembered that they can be totally lost in the event of a fire. Pneumatic tubing should be
run on a cable tray or similar supporting steelwork for its entire length and securely clipped at regular
intervals. Where a number of pneumatic signals are to be routed to a remote control room they
should be marshaled in a remote junction box and the signals conveyed to the control room via
multitube bundles.

Such junction boxes should be carefully positioned in the plant in order to minimize the lengths of
the individually run tubes. (See Figure 27.1 for typical termination of pneumatic multitubes.)

Impulse lines

These are the lines containing process fluid which run between the instrument impulse connection
and the process tapping point, and are usually made up from piping and pipe fittings or tubing and
compression fittings. Piping materials must be compatible with the process fluid. Generally, tubing is
easier to install and is capable of handling most service conditions provided that the correct fittings
are used for terminating the tubing. Such fittings must be compatible with the tubing being run (i.e.,
of the same material).

Impulse lines should be designed to be as short as possible, and should be installed so that they are
self-draining for liquids and self-venting for vapors or gases. If necessary, vent plugs or valves
should be located at high points in liquid-filled lines and, similarly, drain plugs or valves should be
fitted at low points in gas or vapor-filled lines. In any case, it should be ensured that there are
provisions for isolation and depressurizing of instruments for maintenance purposes. Furthermore,
filling plugs should be provided where lines are to be liquid scaled for chemical protection and, on
services which are prone to plugging, rodding-out connections should be provided close to the
tapping points.

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Information Sheet 5.1: Techniques in ICD Installation
Cabling

General requirements

Instrument cabling is generally run in multicore cables from the control room to the plant area (either
below or above ground) and then from field junction boxes in single pairs to the field measurement
or actuating devices.

For distributed microprocessor systems the inter-connection between the field and the control room
is usually via duplicate data highways from remote located multiplexers or process interface units.
Such duplicate highways would take totally independent routes from each other for plant security
reasons.

Junction boxes must meet the hazardous area requirements applicable to their intended location
and should be carefully positioned in order to minimize the lengths of individually run cables, always
bearing in mind the potential hazards that could be created by fire.

Cable routes should be selected to meet the following requirements:

1. They should be kept as short as possible.
2. They should not cause any obstruction that would prohibit personnel or traffic access.
3. They should not interfere with the accessibility for maintenance of other items of equipment.
4. They should avoid hot environments or potential fire-risk areas.
5. They should avoid areas where spillage is liable to occur or where escaping vapors or gases
could present a hazard.

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Cables should be supported for their whole run length by a cable tray or similar supporting
steelwork.
Cable trays should preferably be installed with their breadth in a vertical plane. The layout of cable
trays on a plant should be carefully selected so that the minimum number of instruments in the
immediate vicinity would be affected in the case of a local fire. Cable joints should be avoided other
than in approved junction boxes or termination points. Cables entering junction boxes from below
ground should be specially protected by fire-resistant ducting or something similar.

There are three types of signal cabling generally under consideration:

1. Instrument power supplies (above 50 V);
2. High-level signals (between 6 and 50 V). This includes digital signals, alarm signals, and high-
level analog signals (e.g., 4-20 mADC).Low-level signals (below 5 V). This generally covers
thermocouple compensating leads and resistance element leads.

Signal wiring should be made up in twisted pairs. Solid conductors are preferable so that there is no
degradation of signal due to broken strands that may occur in stranded conductors. Where stranded
conductors are used, crimped connectors should be fitted. Cable screens should be provided for
instrument signals, particularly low-level analog signals, unless the electronic system being used is
deemed to have sufficient built-in "noise" rejection. Further mechanical protection should be
provided in the form of singlewide armor and PVC outer sheath, especially if the cables are installed
in exposed areas, e.g., on open cable trays. Cables routed below ground in sand-filled .trenches
should also have an overall lead sheath if the area is prone to hydrocarbon or chemical spillage.

Cable segregation

Only signals of the same type should be contained within any one mnlticore cable. In addition,
conductors forming part of intrinsically safe circuits should be contained in a multicore reserved
solely for such circuits.

When installing cables above or below ground they should be separated into groups according to
the signal level and segregated with positive spacing between the cables. As a general rule, low-
level signals should be installed furthest apart from instrument power supply cables with the high-
level signal cables in between. Long parallel
runs of dissimilar signals should be avoided as far as possible, as this is the situation where
interference is most likely to occur.

Cables used for high-integrity systems such as emergency shutdown systems or data highways
should take totally independent routes or should be positively segregated from other cables.
Instrument cables should be run well clear of electrical power cables and should also; as far as
possible, avoid noise-generating equipment such as motors. Cable crossings should always be
made at right angles.

When cables are run in trenches, the routing of such trenches should be clearly marked with
concrete cable markers on both sides of the trench, and the cables should be protected by
earthenware or concrete covers.

Grounding

General requirements

Special attention must be paid to instrument grounding, particularly where field instruments are
connected to a computer or microprocessor type control system. Where cable screens are used,
ground continuity of screens must be maintained throughout the installation with the grounding at

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Information Sheet 5.1: Techniques in ICD Installation

one point only, i.e.. in the control room. At the field end the cable screen should be cut back and
taped so that it is independent from the ground.

Intrinsically safe systems should be grounded through their own ground bar in the control room.
Static grounding of instrument cases, panel frames, etc., should be connected to the electrical
common plant ground. (See Figure 27.2 for a typical grounding system.)

Instrument grounds should be wired to a common bus bar within the control center, and this should
be connected to a remote ground electrode via an independent cable (preferably duplicated for
security and test purposes). The resistance to ground, measured in the control room, should usually
not exceed 1Ω unless otherwise specified by a system manufacturer or by a certifying authority

Reference: Instrumentation Reference Book, 4th Edition, Walt Boyes, pp. 655 – 658.

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