BEIA411 

Module Name INDUSTRIAL INSTRUMENTATION AND CONTROL 
Module Code BEIA411 
Level Four 
Credits 15  

Module Description and General Aims 

The objective in presenting this module is to introduce students to the basic principles of process instrumentation and control. The subject matter covered in this module will include: the underlying principles of measurement science, in conjunction with the principles of measurement of pressure, level, temperature, and flow; the fundamentals of control, including tuning loops; and an overview of advanced process control principles. The student will learn how identify, select and size control valves and to also have the knowledge to apply MATLAB/SIMULAB tools for different applications. 

Learning Outcomes 

On successful completion of this Module, students are expected to be able to: 

  1. Evaluate and apply the principles of measurement science. 

Bloom’s level 5 

  1. Specify, design, install, commission, and troubleshoot a range of instrumentation systems. 

Bloom’s Level 6 

  1. Identify, select, size and maintain control valves for different applications. 

Bloom’s Level 4 

  1. Evaluate the fundamentals of control and control systems. 

Bloom’s Level 5 

  1. Assess and apply MATLAB and SIMULINK tools in control applications. 

Bloom’s level 5 

  1. Examine the procedures used in loop tuning. 

Bloom’s Level 4 

Student Assessment 

Assessment Type When assessed Weighting (% of total module marks) Learning Outcomes Assessed 
Assessment 1  Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation  Topic:  Fundamentals of measurement, statistical analysis, pressure, level, temperature measurements.  Students may complete a quiz with MCQ type answers and solve some simple equations to demonstrate a good understanding of the fundamental concepts   Due after Topic 4    15%    1, 2 
Assessment 2  Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation Topic: Control valve sizing and selection, control basics. Students may provide solutions to simple problems on the listed topics    Due after Topic 6     20%     3, 4 
Assessment 3  Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation / Project / Report Topic: Closed loop stability, configurations, MATLAB, SIMULAB Students may complete a quiz with MCQ type answers or solve some simple problems or using software to complete a practical.   Due after Topic 10    20%    4, 5 
Assessment 4 Type: An examination covering all topics but with emphasis on control loop tuning Topic: All An examination with a mix of detailed report type questions and/or simple numerical problems to be completed in 3 hours.     Final Week     40%    1 to 6 
Attendance / Tutorial Participation              Example: Presentation, discussion, group work, exercises, self-assessment/reflection, case study analysis, application.  Continuous 5% 1 to 6 

Overall Requirements: Students must achieve a result of 40% or above in the exam itself to pass the exam and must pass the exam to be able to pass the module. An overall final module score of 50% or above must be achieved to pass the module once all assessment, including the exam, has been completed. 

Prescribed and Recommended Readings  

Suggested Textbook 

  • Manesis, S and Nikolakopoulos, G 2018, Introduction to Industrial Automation, ISBN: 13: 978-1-3510-6908-3. 
  • Singh, SK 2010, Industrial Instrumentation and Control, 3rd ed, Tata McGraw, ISBN-13: 978-0070678200 

Reference Materials 

  • Raymond F. Gardner, 2020, Introduction to plant automation and controls, 1st ed, CRC Press, ISBN: 9781000204360 
  • Frank Lamb, 2013, Industrial Automation, Hands-on, ISBN: 978-0-07-181647-2 
  • Peer reviewed Journals 
  • IDC Technologies publications 
  • Other material and online collections as advised during the lectures 

Module Content   

One topic is delivered per contact week.  

Topic 1: Introduction to Measurement Science 

  1. Fundamentals of measurement science (static characteristics calibration, accuracy, precision, repeatability; dynamic characteristics (response speed, lag, dynamic error, etc.)   
  1. Statistical analysis 
  1. Units and standards (unit conversion and some fundamental mathematics such as errors, correction factors, curve fitting and so on  

Topics 2: Pressure measurement and analytical analysis 

  1. Pressure units, characteristics, and types of pressure (Gauge, absolute, vacuum, etc.) 
  1. Methods of pressure measurement, calibration (manometers, force balance, etc.) 

Topic 3: Temperature measurement and analytical analysis 

  1. Temperature and Level measurement (direct and indirect methods, sight glass, float-type air bellows, calibration, maintenance, and repair, etc.) 
  1. Temperature scales, fixed points 
  1. Methods, characteristics, calibration (Thermometers, electrical temperature measurement, Pyrometers, fibre optic systems, and etc.) 

Topic 4: Flow measurement and analytical analysis 

  1. Flow measurement (inferential, quantity, mass)  
  1. Inferential flow methods and characteristics (variable head, magnetic, target, turbine, thermal, ultrasonic, and etc.) 
  1. Quantity methods and characteristics (positive displacement, metering) 
  1. Mass flow methods and characteristics, calibration, maintenance and repair 

Topic 5: Control Valve Sizing, Selection and Maintenance 

  1. Control valves theory 
  1. Valve types, materials and characteristics 
  1. High-pressure drop applications, and sizing 
  1. Actuators and positioners 
  1. Installation and maintenance 
  1. Quality standards (ASME, NACE, ISO9000, etc.) 

Topic 6: Fundamental of Process Control 

Process control (on/off, modulation, feed-forward, feedback, PID:P, I, D, and PID actions) (Note: while we are talking about control, the stability is an inseparable part of that, so this is inherently included) 

Topic 7: Tuning Control Loops (1) 

  1. Fundamentals of tuning loops (PID controllers and modes, load disturbances and offsets, speed, and stability issues, etc.) 
  1. Tuning control loops (PID controller (ZN, Simplified lambda),  
  1. Automated tuning (Self tuning and Adaptive control). 
  1. Tuning value controllers (Hysteresis, striction) 

Topic 8: Tuning Control Loops (2) 

  1. Tuning complex systems ((Multivariate, ratio, feed-forward, cascade and interactive loops)  
  1. Tuning valve controller 

Topic 9: Introduction to Matlab Control Toolbox and Simulink 

  1. Principles of Matlab and exercises in scripting 
  1. Block diagram models and transfer function manipulation 
  1. Frequency response testing methods 

Topic 10: Signal Conditioning and Error 

  1. Characteristics and linearization 
  1. Pneumatic signal conditioning 
  1. Electrical signal conditioning 

Topic 11: Other Sensors 

  1. Humidity, Density and Viscosity 
  1. pH measurement devices and applications 
  1. Gas and chemical sensors and smoke detectors in industry 
  1. Position sensors 
  1. Force, torques, load cells and balances 

Topic 12: Instrumentation Standard (safety instrumented systems), documentation and Symbols (Alarm and trip systems and documentation, PFD, and P&ID diagrams) 

Software/Hardware Used 

Software 

  • Software: MATLAB/SIMULINK 
  • Version: Student version 
  • Instructions: N/A 
  • Additional resources or files: N/A 

Hardware 

  • N/A