Question I am new to this area...I have known that we can connect 2-wire transmitters in series up to 15nos..

how to connect them (an electrical diagram help me most)? What is the difference between the 2wire vs 4-wire and when they are used at what condition? Ans1. Four wire process transmitters/control elements are typically powered by a separate source supply. Therefore, 2 wires are for supply power and 2 wires are used for measurement signal (voltage or current). Because of the variations in the power for these devices, isolated inputs/outputs are typically used. Two wire transmitters/control elements on the other hand are powered by the same two wires which carry the measurement/driving signal. In some cases these transmitters are powered directly by the device which is reading the measurement or controlling the output action. In other cases a separate power supply is wired in series with the signal wires and the device reading/driving the signal. In this case a common supply can be used to power several loops. Ans2Two wire devices are typically preferred when available. They eliminate the need for separate power runs and the associated power distribution, circuit protection etc. to the device. As stated previously, they also often allow the use of a single power supply to power several loops, singleended connection to input cards, and typically more inputs per card, decreasing the cost per point. Some devices, typically analyzers etc., may only be available as four wire devices, so you don't get a choice. A 4-wire device may actually need to be located remote from the process, or additional precautions taken depending on the area classification of the process area, if the device is not available suitable for that particular area. Where the same type device (with equivalent specs.) is available as either 2-wire or 4-wire, the 2-wire device is typically preferred. There are other reasons to choose 4-wire devices depending on the particular installation. One case may be where there are a cluster of instruments at a particular location somewhat remote from the control system and it may be important to isolate supply power from the devices locally. An alternative in this instance though may also be to use 2-wire transmitters with a local common loop power supply. A lot depends on what is standard in a particular plant and what is available from approved manufacturers. For the measurement or control signal itself, current signals are typically preferred over voltage signals, when available, due to concerns over voltage drop in long cable runs and the potential to be affected by surrounding noise sources. Depending upon the size and layout of your system, you may also want to consider the use of Hart communications to your devices or one of several Fieldbus systems now available. Hart and the field busses like Devicenet, Profibus, Foundation Fieldbus etc. typically allow for remote configuration and diagnostics, not available with stand-alone devices.

When to use derivative Is derivative control just used on temperature loops?

Question: Almost all controllers on my chemical plant DCS are PI with no derivative. There are a few on temperature control that do have derivative. All, PI and PID, seem to be working well. Is derivative appropriate for temperature control? Answer: Yes, derivative is appropriate for temperature control. Back in the days of analog control, you could order a PI controller or a PID controller for slightly more money. You had to choose up front, and justify even a small difference in cost. Many engineering firms specified PID control for temperature loops and PI control for all other loops. With a DCS you can choose, at the time you are tuning the loop, whether or not to use derivative. However, the old rule of thumb: derivative on temperature, is still often followed. There are several reasons for the old rule of thumb: derivative usually should be used on loops with very little noise. Temperature loops were usually very smooth and without noise. Derivative helps most when there are multiple lags in the process, again, typical of temperature loops. Derivative can be used on other loops, and, with DCSs it does not add any cost or require a decision before the startup. You can try it. If it helps; use it; if it hurts, don't use it.

Why use derivative on process What is the advantage of derivative on process rather than on error?
Question: Some controllers offer the option of derivative on the error or on the input only. What is the difference and why should I use one or the other?

Answer: The traditional PID equation, in its simplest form, is: Error = Set point - Input

In this equation the derivative applies to the error. The problem is that a change in set point is treated the same as a change in the process measurement. However, it is likely that the operator will make a set change in the set point. This is particularly likely with digital control systems when the operator types in a new set point and hits enter. Suddenly there is a step change in set point and error. The derivative of a step change is a spike that goes to infinity. The controller cant take the output to infinity, but it will drive the output to its limit momentarily, likely causing an upset in the rest of the process. To eliminate this problem, many controllers offer the option of derivative on input rather than derivative on error. The equation is changed to:

The derivative will apply to changes in process input and to the feedback loop. It will have all the advantages of derivative, including allowing the use of a higher gain with the same stability. However, it will not spike the output when the operator makes a set point change. There are times that derivative on error is appropriate. If the secondary loop of a cascade pair has derivative (e.g. jacket temperature on reactor temperature control) and the set point is only going to be adjusted by the primary controller, then the step change is not a problem and the derivative on the set point changes can provide an advantage.

How to wire fail safe limit switches Fail Safe Level Switch Connections
Friday, December 05, 2003

Question:

We are putting two level switches on a storage tank (in addition to a level transmitter) for alarm purposes. The switches will be located at a high and low level and will be input into the DCS. Logic in the DCS will display the words HIGH, NORMAL, and LOW on the screen, with the HIGH and LOW shown as alarms (red, flashing until acknowledged). We are considering two types of level switch. The cheaper type is loop powered (simple switch with no electronics). These switches have a three screw terminal strip, with the terminals labeled Normally Closed, Normally Open, Common. They connect to a flanged connection on the tank with a float sticking into the tank. When the float rises the switch changes state. They have up and down side labels for correct mounting. The other type of switch requires separate power and uses ultrasonic means to determine if there is liquid on the other side of the tank wall. It can be mounted anywhere on the tank (the reason for considering a more expensive level switch). That switch has the same NC,NO, Common terminal strip and also a switch marked failsafe with the positions labeled High and Low. One switch will alarm if the level is too high, the other will alarm if the level is too low. Can you explain how to connect to these devices? I assume normally open or normally closed is the position corresponding to neither low nor high. Answer: First, lets discuss the meaning of Normally Closed and Normally Open. Normal refers to the shelf or out of the box state of the contact. In the case of the float based switch normal should refer to the position of the contact when the switch is not exposed to liquid. That is, if the liquid level is below the switch the common terminal will be connected to the Normally Closed terminal. As the liquid rises above the switch, the Normally Open terminal is connected to common. In your case (high and low level) you should arrange your logic so that the high input is open when the level is above the higher switch, and the low input is open when the level is below the lower switch. This fail safe approach will assure that the most likely failure, loss of the circuit due to a power supply failure, blown fuse, or broken wire will cause an alarm. If the level is in the normal range--between the switches--both loops are conducting. Therefore, you should wire the low input to the normally open contact and high level input to the normally closed contact. Your logic should provide four possible states.

High Switch - connected to Normally Open Low Switch - connected to Normally Closed High Low State Input Input Off On HIGH On On NORMAL On On LOW Off Off FAILURE (level is both high and low, so there must be some failure) For the unpowered switches normal is the shelf or out of the box condition. Whether you select the Normally Open or Normally Closed contact depends upon whether the shelf state is the safer or less safe state. If the switch is powered, then the normal state is the power off state. That is, with no power to the instrument the relay will be de-energized. The Normally Open contact will be open and the Normally Closed contact will be closed. Such instruments usually have a fail safe switch or jumper. This determines whether the relay will be de-energized if the level is above or below the probe. To achieve the results from the table above the fail safe switch is placed in the position that would represent an alarm. So in the above (high and low switch example) the fail safe position for the upper switch would be High and for the lower switch would be Low. The configuration would be different if the switches were both used for high level, the lower for High and the upper for High-High (emergency high). In that configuration both the high and high-high switches are wired to the normally open switch. If the switch is powered, then both fail safe switches would be in the High position.