Instrumentation and control involve the use of process control instruments and software tools to measure, analyze, and control industrial process variables such as temperature, pressure, flow, and level. This includes the utilization of sensors, analyzers, electrical and mechanical actuators, Human-Machine Interfaces (HMI), Piping and Instrumentation Diagram (P&ID) systems, automated control systems and more for the purpose of optimizing system performance.
What Is Instrumentation and Control Engineering?
Control engineering involves the application of control theory to the design, monitoring, and regulation of industrial processes in order to maximize productivity, ensure repeatability, and uphold industrial health and safety standards. This is achieved through the use of Electrical/Electronic engineering principles, such as sensors, actuators, and controllers, as well as software tools and algorithms.
What Is Process Control Instrumentation?
Process control instrumentation focuses on the measurement and regulation of process variables within an industrial setting using hardware, software tools, and mathematical models. This includes techniques such as proportional–integral–derivative (PID) control and fuzzy logic, which are designed and implemented to ensure optimal performance and safety of the system.
The Role of the Engineer
Control and instrumentation engineers are responsible for managing and operating instrumentation and control systems within industrial facilities. This includes designing, developing, and operating control devices and systems to monitor, analyze, and regulate process variables such as temperature, pressure, flow, and level. This is achieved through the use of hardware, software tools, and mathematical models, with the goal of optimizing system performance and safety.
Why Is Instrumentation and Process Control Essential?
Instrumentation and process control are essential for all industrial and manufacturing activities. Such systems provide the necessary tools to measure, analyze, and adjust process variables in order to optimize and ensure the safety of production processes. This is achieved through the use of sensors, actuators, controllers, and software.
For example, temperature monitoring and control systems are essential in petrochemical plants, where they prevent temperatures from reaching critical levels and causing an explosion. Without these systems, there is a risk of loss of human lives and destruction of assets.
Industries that Need Instrumentation and Process Control
Industries such as Oil & Gas, Petrochemical, Wastewater Treatment, Food & Beverage, and Manufacturing all require industrial process instrumentation and process control equipment in order to ensure repeatable and safe production.
Common Industrial Process Control Equipment
Instrumentation and control systems are essential for ensuring optimal efficiency and productivity of production equipment in various industries. Examples of such systems include pressure transmitters, ultrasonic level sensors, optical fiber sensors, and temperature controllers.
Essential process control instrumentation systems include:
- Level Control & Monitoring
- Pressure Control & Monitoring
- Automated Control Systems
- Temperature Control & Monitoring
- Supervisory Control & Data Acquisition (SCADA)
Level Control & Monitoring
Flow monitoring and control equipment are used to detect and regulate the level of solids, fluids, or gases in tanks, vessels, and compartments. Level-detecting sensors relay information to a control panel or monitor, which allows a control engineer to activate an electrical or mechanical actuator to adjust the flow rate. Common industrial control pressure devices include Coriolis flow meters, Orifice flow meters, and Turbine flow meters.
Pressure Control & Monitoring
Pressure control systems detect changes in process pressure, displaying the measurements in Bar, KPa, or other relevant units. These systems use pressure sensors to monitor and regulate pressure and can be either mechanical or electrically-operated. Pressure monitoring and control devices are essential for ensuring the safety of personnel and assets in industrial operations, especially those that involve pressurized fluids, liquids, and gases.
Automated Control Systems
Automated control systems are designed to manage industrial processes that require a high degree of accuracy or safety. A control engineer can monitor these systems, but does not need to intervene to return the variables to predefined values, as the system is programmed to self-adjust under divergent conditions. These systems are often used in hazardous processes, such as those involving high temperatures, pressures, and hazardous gases.
Automated control systems offer superior reliability for highly-repeatable industrial processes, eliminating the human error factor. High-precision equipment must be used to ensure safety and prevent catastrophic failure of equipment. IFS provides best-in-class automation and control systems to the Oil & Gas, Power generation, and Air quality industries.
Temperature Control & Monitoring
Temperature monitoring and control devices are used to detect variations in ambient temperature or temperature within measured environments such as compartments, vessels, tanks, pipes, and other equipment. Through Human-Machine Interfaces (HMI) or P&ID systems, the control and instrumentation engineer can view the temperature readings on a dashboard or monitor and take any necessary actions to adjust one or more process variables or shut down devices or the entire plant in order to prevent critical equipment failure or fire hazards.
Supervisory Control & Data Acquisition (SCADA)
SCADA systems are employed in a wide range of industries like power generation, air purification, wastewater treatment, and manufacturing plants to synergize multiple equipment and systems which monitor and collect information about on-going processes at industrial plants. SCADA systems relay information to the control engineer via feedback from sensors and Programmable Logic Controllers (PLCs) and use HMIs for human interfacing and control.
