IE 401 PROCESS INSTRUMENTATION

Teaching scheme                                                                                            Examination Scheme

 Lectures: 3 hrs/week                                                                                         Mid- Sem Test– 30 marks,

                                                                                                Assignments and Quizzes- 20 marks,

                                                                                                                        End Sem  Exam - 50 marks

Unit 1: Process Characteristics

Types of processes (dead time single & multi capacity, self & non-self regulating, interacting & non-interacting, Linear & non-linear), Process gain, process reaction curve, process time constant & constant step analysis method for finding time constant, dead time, dynamic elements in control loops, PID control of processes, Process simulator.

[07 hrs]

Unit 2: Analysis & properties of some common loops

Flow, pressure level, temperature, composition, pH etc., linear & non-linear controllers, review of PID with limitations (offset, saturation in D, & reset windup) rate before reset, PID variations & tuning , digital controller(position & velocity algorithms, effect of sampling time) hardware structures, features & specification, single loop & multi loop controller & the application programs (PID, Timer, counter, dead time, lead lag, linearise, add-substract-muti-div. of two input signals temp, pressure compensation of gas flow, sq. root, median selector, pattern program, radio set, adaptive gain, feed forward, valve lineariser etc.) non-linear controller-two state, three state, proportional time, dual mode optimal switching.

[07 hrs]

Unit 3: Multi loop & multivariable process control systems

Feedback, Feed Forward control, Cascade Control, Ratio Control, Selective Control, Split-range Control. Interaction & Decoupling, Relative Process Gain Matrices (RPG) & applications, Statistical Process Controls.

[07 hrs]

Unit 4: Control Systems for various processes

Development of control loops, Design aspects and selection criterion for filed instruments and instrumentation scheme for boiler, compressors, pumps, chiller, evaporators, dryer, cooling tower, distillation column, CSTR

[07 hrs]

Unit 5: Development of control loops

Design aspects of Instrumentation for Power, Water and Waste-Water Treatment, Food and Beverages, Pharmaceuticals (Introduction to International Standards S88, S95 and US FDA 21CFR 11), Cement, Automobile and Building Automation.

[07 hrs]

Unit 6: Control valve design

Designing control valve for gas, vapor, and liquid. Effects and remedies of cavitations, flashing condition, noise, control valve linearizer, valve auxiliary parts, flow characteristics of valve control effects of load changes, high pressure & high temperature service, control valves, installed range ability & viscosity correction for control valve. Control valve application & selection, valve sizing by ANSI/ISA-S-75.01 std. valve capacity & testing by ANSI/ISA-S-75.02 std. Control valve seat leakage, Valve noise calculation & reduction method, Smart valve package. Intelligent-smart actuators, design considerations for actuators (solenoid, pneumatic, hydraulic, digital field bus actuators).

Design of orifice plates and related international standards.

[07 hrs]

 Text Books

·         Process Control Systems , F. G. Shinskey, TMH.

·         Process Control , B. G. Liptak

·         Computer based Industrial control , Krishna Kant, PHI

·         Feedback controllers: Tuning, Applications & Design ,F. G. Shinskey.

·      Process Control Instrumentation. D. Johnson, PHI .

Reference Books

·         Batch Control ,T.G. Fisher,  ISA .

·         Distillation column control ISA Publication

·         ISA Handbook of Control Valves.

·         Process Instrumentation and control Handbook, Considine, MGH.

·         Continuous Process Control, ISA.