i n The third edition of Instrumentation and Control, AWWA Manual M2, s Instrumentation t r has valuable information for operators of large or small water utilities u m who do not necessarily have a technical background but who are searching e for basic explanations and general information. The manual discusses equip- n ment, terms, and expressions that an operator encounters wherever electrical t a systems, automation, and instrumentation are found in water distribution, ti & Control o treatment, and storage systems. n & c o n t r o l M 2 M Manual of Water Supply practiceS 2 Third Edition AWWA is the authoritative resource for knowledge, information and advocacy to improve the quality and Advocacy supply of water in North America and beyond. AWWA is the largest organization of water professionals in Communications the world. AWWA advances public health, safety and welfare by uniting the efforts of the full spectrum of Conferences the entire water community. Through our collective strength we become better stewards of water for the Education and Training greatest good of the people and the environment. Science and Technology Sections 3P-3E-POD-30002-3/10-LS The Authoritative Resource on Safe Water ® M2.indd 1 3/1/2010 11:14:51 AM Instrumentation and Control AWWA MANUAL M2 Third Edition FOUNDED 1881 American Water Works Association MANUAL OF WATER SUPPLY PRACTICES—M2, Third Edition Instrumentation and Control Copyright © 2001 American Water Works Association All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording, or any information or retrieval system, except in the form of brief excerpts or quotations for review purposes, without the written permission of the publisher. Library of Congress Cataloging-in-Publication Data Instrumentation and control.-- 3rd ed. p. cm. -- (AWWA manual ; M2) New ed. of: Automation and instrumentation. c1983. Includes bibliographical references and index. ISBN 1-58321-125-X 1. Waterworks--Automation. I. American Water Works Association. II. Automation and instrumentation. III. Series. TD491 .A49 no. M2 2001 [TD487] 628.1 s--dc21 [628.1] 2001055311 Printed in the United States of America American Water Works Association 6666 West Quincy Avenue Denver, CO 80235 ISBN 1-58321-125-X Printed on recycled paper Contents List of Figures, v List of Tables, xi Foreword, xiii Acknowledgments, xv Chapter 1 Introduction 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Water Utility System, 1 How to Use This Manual, 3 Reference, 4 Chapter 2 Hydraulics and Electricity 5 . . . . . . . . . . . . . . . . . . . . . . . Hydraulics, 5 Electricity, 18 References, 39 Chapter 3 Motor Controls 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction, 41 Motors, 41 Variable Speed Motor Control, 49 Variable Speed Motor Control Systems, 50 Motor Control Logic, 52 Chapter 4 Flowmeters 67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter Categories, 67 Meter Coefficient of Discharge, 68 Venturi Flowmeters, 69 Modified Venturis, 74 Orifice Plate Flowmeters, 74 Magnetic Flowmeters, 76 Turbine and Propeller Flowmeters, 80 Sonic Flowmeters, 84 Vortex Flowmeters, 86 Averaging Pitot Flowmeters, 89 Variable Area Flowmeters, 92 Open Channel Flow, 94 General Installation Precautions, 98 Signal Output and Transport, 99 References, 100 Chapter 5 Pressure, Level, Temperature, and Other Process Measurements 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure, Level, and Temperature, 102 Electric Power and Equipment Status, 110 Process Analyzers, 112 General Considerations, 119 References, 119 iii Chapter 6 Secondary Instrumentation 121 . . . . . . . . . . . . . . . . . . . . . Introduction, 121 Signal Standardization, 121 Signal Power and Transmission, 122 Transmitters, 124 Controllers, 124 Recording and Indicating Hardware, 126 Function Modules, 128 Converters, 129 Chapter 7 Telemetry 131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Telemetry, 133 Tone Multiplexing, 137 Amplitude Modulation Tone, 137 Frequency Shift Keying Tone, 138 Communication Media and Channels, 138 Reference, 142 Chapter 8 Final Control Elements 143 . . . . . . . . . . . . . . . . . . . . . . . . Valves, 144 Valve Summary, 153 Pumping Systems, 154 Miscellaneous Final Control Elements, 157 Chapter 9 Basics of Automatic Process Control 161 . . . . . . . . . . . . . . . Feedforward Control, 162 Feedback Control, 163 Feedforward vs. Feedback Control, 164 Manual vs. Automatic Control, 165 Automatic Feedforward Control Methods, 166 Automatic Feedback Control Methods, 168 References, 178 Chapter 10 Digital Control and Communication Systems 179 . . . . . . . . . Digital Control Systems, 180 Communication Systems, 188 Applications and Site Planning, 194 Technology Trends, 196 References, 197 Chapter 11 Instrument Diagrams 199 . . . . . . . . . . . . . . . . . . . . . . . . Glossary, 207 Index, 215 List of AWWA Manuals, 225 iv Figures 2-1 Pressure in a tank, 7 2-2 Pressure in containers of various shapes, 7 2-3 Water level in an unpressurized system, 8 2-4 Fluid levels in a vacuum system, 8 2-5 Flow velocity as a function of cross-sectional area, 9 2-6 Flow–velocity profiles, 9 2-7 Determination of static pressure, 9 2-8 Water in pipe with pressure, no flow, 10 2-9 Total head, 11 2-10 Elevation head, 11 2-11 Flowing without friction, 12 2-12 Velocity head, 12 2-13 Flowing with friction, 13 2-14 Flowing with friction, 15 2-15 Mechanical leverage compared to hydraulic force, 16 2-16 Hydraulic force, 17 2-17 Differential areas, 17 2-18 Transformer symbol, 24 2-19a Delivery voltage at 480 VAC using electric utility’s transformer, 25 2-19b Delivery voltage at 21,000 VAC using water utility’s transformer, 25 2-20 Main substation with switchgear, 26 2-21 Complete one-line with load center and motors, 28 3-1 Induction motor rotors, 43 3-2 Motor starter contactor coil, 53 3-3 Motor starter circuit with one switch, 53 3-4 Motor starter circuit with two switches, 54 3-5 Maintained contact switch symbol, 54 3-6 Momentary contact switch symbols, 54 3-7 Momentary start switch circuit, 55 3-8 Control relay coil symbol, 55 3-9 Control relay contact symbols, 55 3-10 Three-wire motor control circuit, 56 v 3-11 Three-wire motor control circuit with two control locations, 57 3-12 Ladder diagram with line numbers, 57 3-13 Status indicating light symbol, 58 3-14 Motor circuit with indicating lights, 58 3-15 Selector switch symbol, 58 3-16 Motor circuit with local–remote switch, 59 3-17 Hand-off–auto switch, 59 3-18 HOA motor circuit, 60 3-19 Float-operated level switch symbol (closes on rising level), 60 3-20 Float-operated level switch symbol (opens on rising level), 60 3-21 Automatic pump control off of a float switch, 61 3-22 Three-wire control using two level switches, 61 3-23 Three-wire control using two level switches with lock-out–stop switch, 63 3-24 Three-wire control using two level switches with lock-out–stop switch and a low-level interlock switch, 64 3-25 Electrical ladder diagram symbol legend, 65 4-1 The Venturi tube, 69 4-2 Venturi meter and flow tube, 70 4-3 Troubleshooting guide for a differential pressure transducer, 72 4-4 Orifice plate, 75 4-5 Magnetic flowmeter, 77 4-6 Example of a troubleshooting flowchart, 78 4-7 Propeller and turbine meters, 81 4-8 Troubleshooting procedures for turbine meter, 82 4-9 Ultrasonic time-of-flight flowmeter, 84 4-10 Vortex flowmeter, 87 4-11 Vortex flowmeter troubleshooting guide, 88 4-12 Averaging Pitot flowmeter insertion tube, 90 4-13 Variable area flowmeter, 92 4-14 Common types of weirs, 95 4-15 Free flow over a weir, 96 4-16 Parshall flume, 97 4-17 Typical flow straighteners, 99 5-1 Bourdon, bellows, and diaphragm pressure sensors, 103 5-2 Typical LVDT application, 103 5-3 Diaphragm seal, 104 vi 5-4 Variable capacitance pressure sensor, 104 5-5 Float-type, level-sensing system, 105 5-6 Stage recorder, 106 5-7 Bubbler, 106 5-8 Admittance probe, 107 5-9 Variable resistance level sensor, 108 5-10 Ultrasonic level sensor, 108 5-11 Typical temperature elements, 109 5-12 Thermowell, 110 5-13 Motor current sensor, 111 5-14 Light scatter turbidity, 113 5-15 Surface scatter, 114 5-16 pH system, 114 5-17 Immersion and flow-through pH systems, 115 5-18 Chlorine membrane probe, 116 5-19 Amperometric chlorine residual analyzer, 117 5-20 CO buffering, 117 2 5-21 Particle counter, 118 5-22 Streaming current monitor, 118 6-1 Typical single compressor system, 124 6-2 Power supply, 125 6-3 Basic controller, 125 6-4 Analog indicator, 126 6-5 Analog and digital indicator, 126 6-6 Circular recorder, 127 6-7 Strip chart recorder, 127 7-1 Telemetering, 132 7-2 Typical digital telemetering system, 134 7-3 Schematic of a typical PDM system, 135 7-4 Nomenclature of frequencies, 140 8-1 Components of control, 144 8-2 Solenoid with cylinder actuator, 145 8-3 Solenoid with details, 145 8-4 Single-phase motor, 146 8-5 Pneumatic positioner cut away, 147 vii 8-6 Electronic positioner circuitry, 147 8-7a Rotary valve requires torque, 148 8-7b Linear valve requires thrust, 148 8-8 Piping configurations, 149 8-9 Control characteristics, 151 8-10 Butterfly valve, 151 8-11 Plug valve, 152 8-12 Gate valve, 152 8-13 Globe valve, 152 8-14 Discharge pressure control via series valve, 156 8-15 Discharge pressure control via bypass valve, 157 8-16 Pneumatic conveying system, 158 8-17 Chemical feed system (liquid), 158 8-18 Chemical feed system (dry), 159 8-19 Typical rotary paddle volumetric feeder, 159 8-20 Screw-type volumetric feeder, 160 8-21 Gravimetric feeder (belt type), 160 9-1 Generic control loop, 162 9-2 Feedforward control of chlorine contact channel, 163 9-3 Feedback control of chlorine contact channel, 164 9-4 Compound control of chlorine contact channel, 166 9-5 Generic feedback control timing graph, 169 9-6a On–off control of a reservoir, 170 9-6b On–off control timing graph, 170 9-7a Gap-action control of a reservoir, 171 9-7b Gap-action control timing graph, 171 9-8 Proportional control input/output relationship, 172 9-9a Proportional control of a reservoir, 173 9-9b Proportional control timing graph, 173 9-10a Integral control of a reservoir, 175 9-10b Integral control timing graph, 175 9-11a Proportional-plus-derivative control of a reservoir, 177 9-11b Proportional-plus-derivative control timing graph, 178 10-1 Digital control system, 181 10-2 Operating system, 187 viii 10-3 Layers of communications, LAN, WAN, 190 10-4 Reference model for open system interconnection, 190 10-5 Networks, 192 11-1 General instrument or function symbols, 201 11-2 Function designations for relays, 202 11-3 Standard instrument line symbols, 203 11-4 Example of PI&D loop description, 205 ix