Engineering Institute of Technology

 

Unit Name

PROCESS INSTRUMENTATION AND CONTROL

Unit Code

BIA 108S

 

Unit Duration

Term

Award

Bachelor of Science (Engineering)

 

Duration 3 years

Year Level

One

Unit Creator/Reviewer

 

Core/Sub-discipline

Sub-discipline

Pre/Co-requisites

BSC101C

Credit Points

3

 

Total Program Credit Points 81 (27 x 3)

Mode of Delivery

Online and On-campus

Unit Workload

(Total student workload including “contact hours” = 10 hours per week)

Pre-recordings / Lecture – 1.5 hours Tutorial – 1.5 hours

Guided labs / Group work / Assessments – 2 hours

Personal Study recommended - 5 hours

Unit Description and General Aims

The objective in presenting this unit is to introduce students to the basic principles of process instrumentation and control. The subject matter covered in this unit 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 Unit, students are expected to be able to:

  1. Evaluate and apply the principles of measurement science.

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

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

  4. Evaluate the fundamentals of control and control systems.

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

  6. Examine the procedures used in loop tuning.

Professional Development

Completing this unit may add to students professional development/competencies by:

  1. Fostering personal and professional skills and attributes in order to:

    1. Conduct work in a professionally diligent, accountable and ethical manner.

    2. Effectively use oral and written communication in personal and professional domains.

    3. Foster applicable creative thinking, critical thinking and problem solving skills.

    4. Develop initiative and engagement in lifelong learning and professional development.

    5. Enhance collaboration outcomes and performance in dynamic team roles.

    6. Effectively plan, organise, self-manage and manage others.

    7. Professionally utilise and manage information.

    8. Enhance technologist literacy and apply contextualised technologist skills.

  2. Enhance investigatory and research capabilities in order to:

    1. Develop an understanding of systematic, fundamental scientific, mathematic principles, numerical analysis techniques and statistics applicable to technologists.

    2. Access, evaluate and analyse information on technologist processes, procedures, investigations and the discernment of technologist knowledge development.

    3. Foster an in-depth understanding of specialist bodies of knowledge, computer science, engineering design practice and contextual factors applicable to technologists.

    4. Solve basic and open-ended engineering technologist problems.

    5. Understand the scope, principles, norms, accountabilities and bounds associated with sustainable engineering practice.

  3. Develop engineering application abilities in order to:

    1. Apply established engineering methods to broadly-defined technologist problem solving.

    2. Apply engineering technologist techniques, tool and resources.

    3. Apply systematic technologist synthesis and design processes.

    4. Systematically conduct and manage technologist projects, work assignments, testing and experimentation.

Engineers Australia

The Australian Engineering Stage 1 Competency Standards for Engineering Technologists, approved as of 2013. This table is referenced in the mapping of graduate attributes to learning outcomes and via the learning outcomes to student assessment.

 

Stage 1 Competencies and Elements of Competency

1.

Knowledge and Skill Base

1.1

Systematic, theory based understanding of the underpinning natural and physical sciences and the engineering fundamentals applicable to the technology domain.

1.2

Conceptual understanding of the, mathematics, numerical analysis, statistics, and computer and information sciences which underpin the technology domain.

1.3

In-depth understanding of specialist bodies of knowledge within the technology domain.

1.4

Discernment of knowledge development within the technology domain.

1.5

Knowledge of engineering design practice and contextual factors impacting the technology domain.

1.6

Understanding of the scope, principles, norms, accountabilities and bounds of sustainable engineering practice in the technology domain.

2.

Engineering Application Ability

2.1

Application of established engineering methods to broadly-defined problem solving within the technology domain.

2.2

Application of engineering techniques, tools and resources within the technology domain.

2.3

Application of systematic synthesis and design processes within the technology domain.

2.4

Application of systematic approaches to the conduct and management of projects within the technology domain.

3.

Professional and Personal Attributes

3.1

Ethical conduct and professional accountability.

3.2

Effective oral and written communication in professional and lay domains.

3.3

Creative, innovative and pro-active demeanour.

3.4

Professional use and management of information.

3.5

Orderly management of self and professional conduct.

3.6

Effective team membership and team leadership.

Graduate Attributes

Successfully completing this Unit will contribute to the recognition of attainment of the following graduate attributes aligned to the AQF Level 7 criteria, Engineers Australia Stage 1 Competency Standards for Engineering Technologists and the Sydney Accord:

 

Graduate Attributes

(Knowledge, Skills, Abilities, Professional and Personal Development)

EA Stage 1 Competencies

Learning Outcomes

A. Knowledge of Science and Engineering Fundamentals

A1. Breadth of knowledge of engineering and systematic, theory-based understanding of underlying principles, and depth of knowledge across one or more engineering sub- disciplines

 

1.1, 1.3

 

1, 2, 3, 6

A2. Knowledge of mathematical, statistical and computer sciences appropriate for engineering technology

 

1.2

 

1, 3, 4, 5

A3. Discernment of knowledge development within the technology domain

1.4

2, 3, 6

A4. Knowledge of engineering design practice and contextual factors impacting the technology domain

 

1.5

 

2

B. Problem Solving, Critical Analysis and Judgement

B1. Ability to research, synthesise, evaluate and innovatively apply theoretical concepts, knowledge and approaches across diverse engineering technology contexts to effectively solve engineering problems

 

1.4, 2.1, 2.3

 

2, 3

B2. Technical and project management skills to design complex systems and solutions in line with developments in engineering technology professional practice

 

2.1, 2.2, 2.3, 3.2

 

C. Effective Communication

C1. Cognitive and technical skills to investigate, analyse and organise information and ideas and to communicate those ideas clearly and fluently, in both written and spoken forms appropriate to the audience

 

3.2

 

2, 3

C2. Ability to engage effectively and appropriately across a diverse range of cultures

3.2

 

D. Design and Project Management

D1. Apply systematic synthesis and design processes within the technology domain

2.1, 2.2, 2.3

2

D2. Apply systematic approaches to the conduct and management of projects within the technology domain

 

2.4

 

6

E. Accountability, Professional and Ethical Conduct

E1. Innovation in applying engineering technology, having regard to ethics and impacts including economic; social; environmental and sustainability

 

1.6, 3.1, 3.4

 

E2. Professional conduct, understanding and accountability in professional practice across diverse circumstances including team work, leadership and independent work

 

3.3, 3.4, 3.5, 3.6

 

2, 3, 6

Unit Competency and Learning Outcome Map

This table details the mapping of the unit graduate attributes to the unit learning outcomes and the Australian Engineering Stage 1 Competency Standards for the Engineering Technologist.

 

 

 

Graduate Attributes

A1

A2

A3

A4

B1

B2

C1

C2

D1

D2

E1

E2

 

Engineers Australia Stage 1 Competency Standards for Engineering Technologist

1.1

 

 

 

 

 

 

 

 

 

 

 

1.2

 

 

 

 

 

 

 

 

 

 

 

1.3

 

 

 

 

 

 

 

 

 

 

 

1.4

 

 

 

 

 

 

 

 

 

 

1.5

 

 

 

 

 

 

 

 

 

 

 

1.6

 

 

 

 

 

 

 

 

 

 

 

2.1

 

 

 

 

 

 

 

 

 

2.2

 

 

 

 

 

 

 

 

 

 

2.3

 

 

 

 

 

 

 

 

 

2.4

 

 

 

 

 

 

 

 

 

 

 

3.1

 

 

 

 

 

 

 

 

 

 

 

3.2

 

 

 

 

 

 

 

 

 

3.3

 

 

 

 

 

 

 

 

 

 

 

3.4

 

 

 

 

 

 

 

 

 

 

3.5

 

 

 

 

 

 

 

 

 

 

 

3.6

 

 

 

 

 

 

 

 

 

 

 

 

Unit Learning Outcomes

LO1

 

 

 

 

 

 

 

 

 

 

LO2

 

 

 

 

 

LO3

 

 

 

 

 

 

LO4

 

 

 

 

 

 

 

 

 

 

 

LO5

 

 

 

 

 

 

 

 

 

 

 

LO6

 

 

 

 

 

 

 

 

Student assessment

 

Assessment Type

When assessed

Weighting

 

(% of total unit 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

 

Week 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

 

Week 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.

 

Week 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

Prescribed and Recommended Readings

Suggested Textbook

  • Singh, SK 2010, Industrial Instrumentation and Control, 3rd edn, Tata McGraw, ISBN- 13: 978-0070678200

    Reference Materials

  • Whitt, MD 2012. Successful Instrumentation and Control Systems Design, 2nd edn, ISA, ISBN 978-1-62198-550-1 Online version available at: http://app.knovel.com/hotlink/toc/id:kpSICSDE06/successful- instrumentation/successful-instrumentation

     

  • Meier, FA. Meier, CA.2011. Instrumentation and Control Systems Documentation. (2nd edn. ISA. Online version available at: http://app.knovel.com/hotlink/toc/id:kpICSDE006/instrumentation- control/instrumentation-control

     

  • Peer reviewed Journals

  • Knovel library: http://app.knovel.com

  • IDC Technologies publications

  • Other material and online collections as advised during the lectures

 

Unit Content

One topic is delivered per contact week, with the exception of part-time 24-week units, where one topic is delivered every two weeks.

Topic 1

 

Introduction to Measurement Science

 

  1. Fundamentals of measurement science (static characteristics calibration, accuracy, precision, repeatability; dynamic characteristics (response speed, lag, dynamic error, and etc.)

  2. Statistical analysis

  3. Units and standards

 

Topics 2, 3 and 4

 

Pressure, Level, Temperature and Flow

 

  1. Pressure units, characteristics and types of pressure (Gauge, absolute, vacuum, and etc.)

  2. Methods of pressure measurement, calibration (manometers, force balance, and etc.)

  3. Level measurement (direct and indirect methods, sight glass, float-type air bellows, calibration, maintenance and repair, and etc.)

  4. Temperature scales, fixed points

  5. Methods, characteristics, calibration (Thermometers, electrical temperature measurement, Pyrometers, fibre optic systems, and etc.)

  6. Flow measurement (inferential, quantity, mass)

  7. Inferential flow methods and characteristics (variable head, magnetic, target, turbine, thermal, ultrasonic, and etc.)

  8. Quantity methods and characteristics (positive displacement, metering)

  9. Mass flow methods and characteristics, calibration, maintenance and repair

Topic 5

Control Valve Sizing, Selection and Maintenance

  1. Control valves theory

  2. Valve types, materials and characteristics

  3. High pressure drop applications, and sizing

  4. Actuators and positioners

  5. Installation and maintenance

  6. Quality standards (ASME, NACE, ISO9000, and etc.)

 

Topics 6, 7, 8

Fundamentals of Control

 

  1. Basic concepts of control (on/off, modulation, feed-forward, feedback, PID)

  2. Stability in closed loops (causes, PID control modes)

  3. Compare alternative closed loop configurations (cascade, feedforward, combined feedback and feed-forward)

 

Topic 9

Introduction to Matlab Control Toolbox and Simulink

  1. Principles of Matlab and exercises in scripting

  2. Block diagram models and transfer function manipulation

  3. Frequency response testing methods

 

Topics 10 and 11

Tuning Control Loops

 

  1. Fundamentals of tuning loops (PID controllers and modes, load disturbances and offsets, speed and stability issues, and etc.)

  2. Tuning rules (Pessen, Ziegler Nichols, simplified lambda, and etc.)

  3. Tuning value controllers (Hysteresis, striction)

  4. Automated tuning (Self tuning, adaptive control)

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

Topic 12

Unit Review

In the final week students will have an opportunity to review the contents covered so far. Opportunity will be provided for a review of student work and to clarify any outstanding issues.