1. Instrumentation and control
Masoud Baghelani
Ilam Gas Refinery
1/14/2019
Masoud Baghelani

2. Part I: History& Control Systems
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Masoud Baghelani

3. History Water clock: the first industrial control system 1/14/2019
Masoud Baghelani

4. History
The first industrial control system which used mathematical model
James watt control system for steam engine
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Masoud Baghelani

5. History 20th and 21th Century: Frequency and Laplace analysis method
Space State methods
Stochastic Processes control
Adaptive Control
Fuzzy Logic Control
Neural networks
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Masoud Baghelani

6. Control Systems (Structures)
Pneumatic
Analog
Direct Digital Control (DDC)
Distributed Control Systems (DCS)
Field Control Systems (FCS)
1/14/2019
Masoud Baghelani

7. Control Systems (Structures)
Pneumatic
Active components
Compressor
Transmission lines
Air tank
Pneumatic hoses
Open atmosphere (for returning the spent gas to the compressor)
Valves
Passive components
Pneumatic cylinders
1/14/2019
Masoud Baghelani

8. Control Systems (Structures)
Analog
Single loop analog electronics
DDC
Direct Digital Control
1/14/2019
Masoud Baghelani

9. Control Systems (Structures)
A comparison between DDC DCS and FCS
1/14/2019
Masoud Baghelani

10. DCS overcomes these drawbacks
Control Systems (Structures)
DDC (Direct Digital Control)
Specifications
All control functions are executed by an intensive central system.
Data transfer between sensors and actuators is done by I/O cards .
Drawbacks:
DCS overcomes these drawbacks
If the central system fails, we loose all control!
Wiring
1/14/2019
Masoud Baghelani

11. Control Systems (Structures)
DCS (Distributed Control Systems)
Specifications
Control processes are distributed over multiple systems
Instrument Technical Room (ITR)
Redundancy
Drawbacks:
Occupying large areas in ITR.
FCS
1/14/2019
Masoud Baghelani

12. Control Systems (Structures)
FCS (Field Control Systems)
Transferring Control Processes to the site
Using data busses
Decreasing in wiring
Serial data transfer
Bidirectional data communication
Intensive control room is just for monitoring, applying regulation points.
Failure in central room makes no failure in controllers.
1/14/2019
Masoud Baghelani

13. Control Systems (Hardwares)
Controllers:
Mechanical controllers: Pressure regulators& Mechanical timers.
Electromechanical Controllers: Hydraulic jacks controllers
Relays & Contactors
Electronic Diode controllers
Digital Controllers
Analog Controllers: (Air industry applications)
Microprocessors and Microcontrollers
1/14/2019
Masoud Baghelani

14. Control Systems (Hardwares)
Controllers:
8. Single or multi loop PID controllers
Computer Controllers
PLC Controllers
DCS Controllers
FCS Controllers
1/14/2019
Masoud Baghelani

15. Control Systems Advantages of modern industrial automation
Increasing the quality of products
Increasing the speed of production
Faster and more precise control
Decreasing the trashes
Increasing the efficiency of industrial units
Ability to operational management in ERP level
Precise tuning capability
Using industrial standards for adapting the controller and software's
Decreasing in wiring
Simplicity extending control software's and hardware's
Decreasing in troubleshooting time
More safety for human resources
More safety for machines
The ability to analyze the processes.
1/14/2019
Masoud Baghelani

16. Control Systems Advantages of PLC over relays& contactors
Lower installation costs
Lower installation time
Small sizes
Simple repair and maintenance
Simple for extension
High reliable
Changing the program is possible even online
Remote controllable
Ability to add peripherals such as printers and etc.
The ability to work with user friendly HMI systems
1/14/2019
Masoud Baghelani

17. Control Systems Advantages of DCS
Decreasing the peripheries and wiring cost
Decreasing the repairing cost
Simplicity in troubleshooting because of self-diagnostic system
The ability to work in power-off conditions because of its back up battery
Decreasing the number of operators because of its simplicity
Fast and precious operation
Optimization of products and process due to advancement and its flexibility
Data storing capability
Simplicity and the ability to extension and changing the design without interrupt
Management information system with simple availability for manager
Redundancy
1/14/2019
Masoud Baghelani

18. Control Systems Importance of monitoring
Monitoring the instantaneous condition of each machine
Monitoring and recording important parameters
Monitoring and recording different alarms in diagnostics times
Monitoring the locations of diagnostics and their time
Monitoring the production processes using proper graphical devices
The ability to change some process control
The tuning ability
1/14/2019
Masoud Baghelani

19. Control Systems Parts of control systems Measurement tools Controllers
Actuators
output
input
Process + -
Controller
Actuator
Measurement tools
1/14/2019
Masoud Baghelani

20. Control Systems Specifications of instrumentation systems Range
Accuracy
Repeatability
Sensitivity
Performance
Response
1/14/2019
Masoud Baghelani

21. Control Systems Calibration What is calibration?
Calibration in ISO 10012
Why calibration?
Calibration time
Calibration location
In situ calibration:
Advantages:
Minimize the stresses due to displacement
Simpler and cheaper
Reliability
Time saving
Drawbacks:
Local conditions can affect the reference systems
Size of reference systems can cause difficulties
More cost
1/14/2019
Masoud Baghelani

22. Control Systems Calibration procedure Calibration flowchart
Calibration for correcting and detecting
Calibration for detecting
Calibration for correcting
No calibration
Calibration flowchart
1/14/2019
Masoud Baghelani

23. Thank you for your attention
1/14/2019
Masoud Baghelani