INSTRUMENTATION

FOR
P&ID’s
Learning Objectives
Be Able to Interpret Controls Symbology
Know what the physical manifestation of the
symbology is
Know the parts of a ‘control loop’
Know what a Control Valve looks like and
how it works
Be able to look at a control scheme and
understand how it works
Be able to design some basic control schemes
Instrumentation Cookbook
Instrumentation
Why Are We Doing This For this Project
ChemEcon – Includes Controls in ‘factors’
ChemEcon – To Size The Pumps We Need
To Include “Inline” Instrumentation
pressure drop

FE PI
 Instrumentation Cookbook
Control Loop
A Simple Feedback Control Loop

Set Point Often not shown

Measured Manipulated
Variable (temp, Controller Variable
pressure, flow...)

FE FIT FIC
FV
 Controllers Readout Devices Switches and Alarm Devices Transmitters
Self
Actuated
Initiating or First Control
Measured Variable Letter Recording Indicating blind Valves Recording Indicating High Low Comb Recording Indicating Blind
Analysis A ARC AIC AC AR AI ASH ASL ASHL ART AIT AT
Burner, Combustion B BRC BIC BC BR BI BSH BSL BSHL BRT BIT BT

Instrumentation Naming
Users Choice C
Users Choice D
Voltage E ERC EIC EC ER EI ESH ESL ESHL ERT EIT ET
Flow Rate F FRC FIC FC FCV FICV FR FI FSH FSL FSHL FRT FIT FT
Flow Quantity FQ FQRC FQIC FQR FQI FQSH FQSL FQIT FQT
Flow Ratio FF FFRC FFIC FFC FFR FFI FFSH FFSL
Users Choice
Hand Instrument Society Of America (ISA)
Current (Electrical)
G
H
I IRC
HIC
IIC
HC HR
IR
HI
II ISH ISL
HS
ISHL
HRT
IRT
HIT
IIT
HT
IT
Power J JRC JIC JR JI JSH JSL JSHL JRT JIT JT
Time K KRC KIC KC KCV KR KI KSH KSL KSHL KRT KIT KT
Level L LRC LIC LC LCV LR LI LSH LSL LSHL LRT LIT LT
Users Choice M

Solenoids,
Relays, Viewing
Initiating or First Computing Primary Well Of Device, Safety Final
Measured Variable Letter Devices Element Test Point Probe Glass Device Element
Analysis A AY AE AP AW AV
Burner, Combustion B BY BE BW BG BV
Users Choice C
Users Choice D
Voltage E EY EE EZ
Flow Rate F FY FE FP FG FV
Flow Quantity FQ FQY FQE FQV
Flow Ratio FF FE FFV
Users Choice G
Hand H HY HV
Current (Electrical) I IY IE IZ
Power J JY JE JV
Time K KY KE KV

ISA Typical Letter Combinations.xls

Instrumentation Cookbook
P&ID’s - Symbology
Equipment Symbology
Instrumentation Symbology

See the document “P&ID Symbols and

Photos.DOC”
 Instrumentation Cookbook
P&ID’s - Symbology
Located in DCS
LIC (process control
computer)

Software Signal

Physically
LT located
‘in field’
Physical wire
“hardwired”
 Instrumentation Cookbook
The “Control Valve” Elec Signal
To valve
(4-20 mA
DC signal)
Actuator -
driven by
Compressed
Air

Valve
 Instrumentation Cookbook
The “Control Valve”
Control Valve Sizing
CV vs % Opening Characteristic

Spec_Gravity
CV Volumetric_Flow
Pressure_Differential

gal Pressure
Volumetric_Flow
min Drop

Pressure_Differential psi
Flow Rate
Instrumentation Cookbook
The “Control Valve”
CV vs % Opening Characteristic Cv

% open
Instrumentation Cookbook
Typical Controls
Level
Flow
Pressure
Temperature
Composition
Instrumentation Cookbook
Level Control
Purpose
Prevent the tank from overfilling / running
dry

LT
LIC

LV
 Instrumentation Cookbook
Level Control
Purpose
Hold a liquid “Seal”

LT
LIC

No Gas!
LV
 Instrumentation Cookbook
Level Control
Purpose
Prevent pump from running dry and thus
being destroyed
RO
LT
LIC

LV
Note: - valve always on disch to prevent flashing on pump suction
- pump may also require a minimum flow bypass
Control Systems
Aside - Speed
Measured Variable can be slow to measure
(i.e. the composition using an analyser) or,
fast (i.e. pressure)
The Manipulated Variable can be slow too
i.e. adjusting the hot water tap in your
shower
The level in a tank can take hours to
change (slow)
Control Systems
Aside - Speed
Slow Things Fast Things
Say > few seconds Less than a second
Reducing Pressure Measure Pressure
by Opening a valve Measure Flow (Diff
on a large gas filled Press)
tank Measure Temp (?)
Measure Composition
(analysers)
Change Level In
Large Tank
But…. It’s all RELATIVE !!
Instrumentation Cookbook
Flow Control
Purpose: Ensure steady material flow rate
Smooth feed to columns
Set Production rate
Fast to Measure
Flow Changes usually require a control valve
to change it’s position which can take
seconds.
Vapour systems have a ‘capacitance’ that
need to be overcome before the flow changes
are experienced everywhere in the system
 Instrumentation Cookbook
Flow Control
FT
FIC

FE FIC
M
FT
I
FV SIC
FE
Variable Speed Drive

Mount FE upstream in vapour systems to minimize pressure/density

effects
Instrumentation Cookbook
- Ratio Flow Control
SP
FIC

FT FRIC SP Set one flow

rate
FV Other flow is
FE proportionally
FIC
SP
controlled to
FT first flow
Ensure correct
mixture / recipes
FV
FE
Instrumentation Cookbook
Pressure Control
Similar to Level (control of material inventory)
Very fast for incompressible fluids
Hard to say for compressible fluids, depends
on system volume but probably slow
 Instrumentation Cookbook
Pressure Control
Control Upstream | Control Downstream

PIC PIC
PT PT

PV PV

Need to downstream (header or

Need to control vessel pressure
process) pressure
Instrumentation Cookbook
Pressure Control
Condensable Gas

PIC
PV
PT

Need to control vessel pressure

Fast or slow?
Instrumentation Cookbook
Pressure Control
Liquid Pressure Control

PIC
PT

PV

Control pump discharge pressure - not very useful

 Instrumentation Cookbook
Pressure Control
Liquid Pressure Control

PIC FIC

PT

FT
PV

Control pump discharge pressure - ensure FV

constant feed pressure to FV FE
Instrumentation Cookbook
Temperature Control
Normally control the ‘flow’ of one fluid to
change the temperature of another
In Reality it’s an LMTD change that affects
the exchanger duty
Q = U A Tln
 Instrumentation Cookbook
Temperature Control
Liquid / Liquid - control on cooling media

C/w
 Instrumentation Cookbook
Temperature Control
Liquid / Liquid - control on process

C/w
Instrumentation Cookbook
Temperature Control
Steam Pressure Control

T Increase Stm
Pressure
Instrumentation Cookbook
Temperature Control
Condensate Level Control

Reduce flooded
Area
Instrumentation Cookbook
Cascade Control
Example - Driving to Montreal
You’re driving / steering the car
Someone else is telling you which roads to
drive on and when to turn
 Instrumentation Cookbook
Cascade Control
One Control Loop Determines Setpoint of a
Second Loop
FT

-Using the
FE FIC
M SP flow through
High Speed
the pump to
P I
control the
rotational
Low Speed
SIC SP speed of the
Variable Speed Drive pump
Flow
Instrumentation Cookbook
Cascade Control
PIC FIC

FT

FE FV
PT

Common Around Distillation

Columns Where There Are
Slow Loops
Instrumentation Cookbook
Controller Interaction
Many Controllers Interact but some
configurations Interfere with each other
I.e.
the control of reflux flow interacts with the
column bottom level control
but two flow controllers on the same pipe
will interfere with each other (they duel for
control of the flow)
 Instrumentation Cookbook
Controller Interaction
Duelling Control ?

LT
LIC

FIC
FT LV
FE
 Instrumentation Cookbook
Controller Interaction
Duelling Control ?

LIC

LT FIC
FT
FE

LV
 Instrumentation Cookbook
Controller Interaction
Duelling Control ?

SP= 75 psig SP= 35 psig

PIC PIC
PT PT
100 psig
Compressed
Air PV PV

User 2 User 2
User 1 User 1
User 3 User 3
P&ID Cookbook
-By Equipment
P&ID Cookbook
- Pumps
PRV PI PI

HS
I M
HS
Pump - Min Flow Bypass
RO

PI
LT PI LIC

LV

HS
I M
HS
 Reflux Tanks Vent to Safe Locn
Set@ PI
From Condenser From Pump

LAHL
TI HLL = 4’-6”
NLL = 3’-6” LIT LIC TO
LLL = 2’-0” LV
LSLL
LLLL = 2’-0”

LALL
I Pump
S/D

To Pump
Compressors - Centrifugal
For our purposes treat controls as a black box
But... Provide an input control signal (cascade)
Remember cooling water req’d (lube system...)

CWS CWR

Control
SIC
From ?
M
By Vendor
By Owner
Requirements for Column Control
Feed rate control
Level control for reboiler and condensate
receiver
Column pressure control
Two controllers, corresponding to the two
degrees of freedom, to deal with the
specifications in PRO/II
This is a very complex topic and can only be
dealt with superficially in this course
 Columns
Composition control
Level control
Pressure control

Provide a
control scheme
Treat the
to ensure
top and bottom
Feed rate is
independently
constant or is Level control of each other
slowly
changing

Composition
control
 Columns - Put level control on bottoms outflow
when
outflow rate > 10 x boil up rate
Bottoms Put level control on Steam control
boilup rate > 10 x outflow rate
otherwise either scheme okay

FIC

HHLL FT
5 bar
Stm
HLL
LIT NLL
LLL
LLLL Low
T P Cond
TE
LAHL
LIC TIC
TE XIC Columns - Overhead
PT PIC

CWS

FV
CWR
Set@ PI PV
FIC
RO
FT
LAHL
TI HLL = 4’-6”
LIT LIC
NLL = 3’-6”
LLL = 2’-0” PI
LSLL
LLLL = 2’-0”
PI

LALL
I Pump
S/D LV

HS
I M
HS
Instrumentation Cookbook
Column Control
How to Choose the Stream that will control
Level in the reflux tank

Column Overhead Control - Scheme 1

when the draw rate is 10 x > reflux rate
Manipulate Distillate draw rate to control Reflux
level
Manipulate reflux rate to control Column
Composition
Instrumentation Cookbook
Column Control
Column Overhead Control - Scheme 2
when the reflux rate is 10 x > draw rate
Manipulate Distillate draw rate to Manipulate
Column Composition
Manipulate reflux rate to control control Reflux
Drum level
 Instrumentation Cookbook
Tanks - Storage
PRV
LAHH Temperature
Control
LSHH
I May Be
Required
-does material
LY LSHH
freeze / boil?
TI
s LI LSLL

LAHL

LIT

LV
I M
Workshop
Add the composition control to the Solvent
Column overhead
Hint: use the pressure and temperature
Workshop
Draw a P&ID, including Control Scheme for
column top
Explain how it works
15,420 kg/hr, 113 °C

33,316 kg/hr, 113 °C

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