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FUNDAMENTALS OF INSTRUMENTATION
CHAPTER – I
a. Accurate Measurement
b. Reliability
c. Repeatability
To Measure
Indicate
Record and
Control
a. Pressure
b. Level
c. Flow
d. Temperature
Static Pressure :
The term ‘ static pressure ‘ is widely used in the measurement of pressure liquid level and rate
of flow. Where the fluid in a process is still or static the measuring of the static pressure is
reasonably clear . when a fluid in motion is en countered however the meaning may not be so
obvious. For example, consider a pipe full of a fluid in motion . if a hole is drilled in the wall of
the pipe and a pressure gauge is installed to it, then the pressure indicated on the gauge is the
static pressure at the tapping.
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3.1 Instuments used for differential pressure measurements
a. Bourdon Type
b. Helical Type Bourdon Tube
c. Diaphragm Stacks And Bellows
The material of bourdon tube depend upon the pressure value and type of fluid.
For lower pressure measurement
Diaphragm stacks and bellows are used.
1. Mecleod Gauge
2. Pirani Gauge
3. Cold Cathode Magnetron Ionization Gauge
4. Hot Cathode Magnetron Ionization Gauge
5. Alpha Particle Ionization Gauge
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4.0 Liquid And Solids Level Measurement
Instruments for the measurement of liquid level in a tank can be classified under the
following headings :
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4.5 Nucleonic Type Instruments
The nucleonic type level instrument involves a radioactive source, a radiation detector and
electronic measuring circuits including amplifier etc.
The source is placed externally on one side of the tank and the detector on the opposite
external side of the tank. The liquid rising and falling inside and tank absorbs radiation and
the change in intensity received by the detector is measured and gives an indication of the
liquid level.
5. Flow Measurement
Fluid flow in industries under taking occurs in two general forms, either as a flow in a
pipe or as a flow in an open channel. In both cases the rate of the flow and the totalized
flow are important.
the rate of flow measuring instruments are broadly sub – divided into
1. Orfice Plate
2. Venturi Tube
3. Pitot Tube Etc.
Square Law Effect : When we talk of differential pressure measurement, we should know
the square law effect or square root effect.
This can be explained by taking a simple flow equation at maximum flow q-1
Q-1 = k _ h1 q2 = h2
At any other flow q-2 q1 h1
Q-2 = k _ h2 h2 = q2/2 x h1
q2/1
If q1 is 20,000 lbs per hour and h1 is 50 inches of water at maximum flow
100,000 lbs/hr.
H2 = ( 10,000 )2 x 50 = 12.5 inches of water.
( 20,000 )2
The square root effect is now apparent since for ½ the maximum flow we have only ¼ of the
differential pressure.
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5.1.1 The different type of flow instruments for differential pressure flow devices :
From the above flow instruments, we will get the rate of flow . The total quantity of fluid
passing ( flowing ) in a given period is obtained by having a integrator. The instruments
performing the totalizer operation are known as integrators.
In case of differential pressure flow the differential pressure head ‘h’ varies
With the flow. Where as in the variable area flow meter the differential pressure head ‘h’
is constant.
The differential type of variable area flow meters are given below:
The glass tube type measures from 2cc/min. Up to 3000 liters /min. of gas and 0.5 cc to
225 liters /min. of liquid.
the pressure drop will depend on the type of float being used and the nature of the fluid,
but varies between about 0.2 cm ( 0.078 inch water gauge ) for small gas flows and 3.5
cm ( 1.38 inch) water gauge for liquid flow.
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How to read correctly the rate of flow in Rotameter :
Always read the flow rate corresponding to the top edge of the float.
For larger flows than the glass type tube can accommodate, a conical
metal Tube pattern is introduced. Here the metal body is of gun metal, cast iron or
stainless steel with a stainless steel float. This type of meter has typically ranges
250 to 120,000 liters / min. for gas flow and 20 to 7000 liters / min. for liquid . The
maximum fluid working pressure is 500 lbs/ sq. Inch.
Another forms of area meter is the loaded plug type . This area meter is designed for
incorporation in a pipe line and comprises a flanged body casting through which the
liquid being metered passes. The metering plug and port assembly is designed in
such a manner that a constant pressure drop is maintained with different rate of flow.
Where working pressures higher than 500 lbs/ sq. inch or for corrosive
fluid a totally enclosed metal tube type of instruments with a magnetic coupling is
used. Typical flow ranges are from 30 to 120,000 liters / min. Of gas and 0.75 to
7000 liters / min. of liquids.
In the displacement type of flow meters which are volumetric in operation, the
stream of fluid can operate cyclically a movable member of the meter , provide a
means for measuring the total flow over a given period.
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Inferential type of flow meter measure the velocity of flow and from this measure
infer the volume of flow.
Ranges :
In view of the extensive use of these type of meters in the water and fuel supply
fields the range are extremely high. The range of the meter varies with meter size.
For example a 4 inch diameter meter has a range 0 – 7000 gallon/hour. The meter are
also suitable for very low liquid flow rates, eg. 4 gallons/hour.
In the electromagnetic flow meter the theory of faraday’s law of induction is used
,i.e. When an electrical conductor of length ‘l’ moves through a magnetic field of
strength ‘h’ at a velocity in a direction at right angles both to the magnetic field and
its length an e.m.f. Is generated of value :
E= KHLV
If we consider a very thin of an electrically conducting liquid, then ‘l’ is replaced
by ‘d’ the internal diameter of the pipe.
E = KHVd. K, d and h are constant.
E = KV
Q = VA. A is the area of the pipe.
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5.4.2 Disadvantages of the electromagnetic flow meter :
Ranges :
A meter has been constructed of 1/10 inch diameter with a flow range 0.002 to 0.2
gal/min. a typical large diameter meter has been 71 inches covering a range of 500
to 50,000 gal/min.
The system formed by a bulb capillary and bourdon being filled with a gas at high
pressure . gas expansion type thermometers work on the principle of ‘gas law’
PV = RT
Nitrogen is almost universally used as the filling gas. It is inert, has a high
cubical coefficient of expansion and is easily available. With gas expansion
thermometers the min . and max. measuring temperature is – 60 º f to 800 º f.
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6.3 Vapour pressure thermometers :
In a confined space , the vapour from a liquid exerts its own pressure ,
increasing with temperature . this characteristic of the vapour is used in the vapour
pressure thermometer.
The two important things to consider in the vapour pressure thermometers are:
6.6 Thermocouples :
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Positive & negative errors :
The current produced in the thermocouple circuit will flow from one wire to the other
at the cold junction .the wire from which the current flows is termed the positive wire
and the wire into which the current flows is the negative one.
material range
a. platinum 190 to 540 º c max.
b. nickel 200 to 300 º c max.
c. copper 50 to 120 º c max.
If the thermometer is considerably away from the instruments the resistance of the
connecting lead is of some significance since the measuring instrument bridge measures
the total resistance of the thermometer as well as lead wire resistance. By using three
leads from the thermometer, it is possible to compensate the lead wire resistance . this
was shown by sir . w. siemens.
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Thermistor thermometer :
This is the name loosely given to a class of thermometer constructed from pure
germanium or pure silicon crystals . the range can be –320 º f to 600 º f for a pure crystal
of silicon. The characteristics temperature resistance is positive and it is only slightly
non – linear. The response to the temperature is extremely fast. To reach 63 % of the
final temperature value , when a change take place required only 15 milli seconds and to
reach 90 % of the final value requires 40 milli seconds.
All hot bodies emit radiate energy, the intensity of which bears a relation to the absolute
temperature of the emitting surface. Heat radiation is a wave phenomena analogous to
light and occupies the definite space in the spectrum. Extending from about 1/ 100 th of
a micron to 100 microns.
There are the different types of pyrometers such as total radiation pyrometers, photocell
pyrometers, optical pyrometers and two colour or ratio pyrometers.
With optical pyrometer, the temperature can be measured with the error of :
3ºc at 1000 º c
6ºc at 2000 º c
40 º c at 4000 º c
All the thermometers are having one factor in common, i.e. they require the element
itself to be inserted in the medium , whose temperature is to be measured. This not
possible to measure any temperature with thermocouples above 2000 º c . this brings us
to the consideration of radiation pattern thermometer of pyrometers.
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CHAPTER - II
1. increased productivity
2. reduced costs
3. better and more uniform products
4. safety
These five elements can be inter connected in two ways . one in open loop, the other in
closed loop .
In the open loop control, the output has no effect on the input . in other words, no feed
back from output to input. E.g. if a home thermostat is installed outside, the room
temperature due to furnace heat i.e. input would have no effect on the furnace
temperature . however the temperature of furnace will not be controlled by the open loop
system if the room temperature is changed. Another eg. is automatic traffic signal .
If we close the system by bringing the thermostat inside the room, furnace heat
( output ) now does affects the in door temperature ( input ) this closed loop thermostat
system continue to operate until the indoor temperature reaches the desired value . in this
closed loop system , there is a feed back information from the output to the input and
there is the possibility of in stability through self excitation, where as open loop is
inherently stable because there is no self excitation.
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1.3.1 Manual and Auto control :
In the chemical industries, because of the completely of process, the operator has to
decide his attention over many controlled condition s. the task of the operator is made
easy by introducing automatic control. The automatic control relieve the operator from
dual duties and to give more opportunity to do their work effectively and intelligently .
In the feed back control system , the output has got the influence over the input, where as
the feed forward control not have a check on the results of its action . however, an
introduction to the feed forward control requires a precise knowledge of the behavior of
the process, otherwise it is impossible to adjust the controlling unit correctly. On the
other hand , the feedback control is not very critical and precise knowledge of the
process behavior is not required.
In two position control, we get ON /OFF action only, when the controlled variable
deviates from the set point the final control element will either open or close and hence it
is known as ON / OFF controller.
e.g. a float switch used for controlling a tank level.
Floating control is commonly known as single speed floating control. In this the final
control element moves at a constant speed in either direction whenever the controlled
variable deviates from the set point, where as in two position controller changes the
position of the final control element from ON/OFF .floating control has got an important
characteristics is that it always works to return the control variable to set point.
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1.4.4 Proportional control :
in proportional controller , the output from the controller is proportional to the input, in
other words there is a continuous linear relation between the value of the controlled
variable and the position of the final control element.
Proportional action :
When the controller has proportional action only, then the controller produces a
corrective action proportional to the size of the error signal ( deviation from the set
point).
Proportional gain :
The variation of the controller output per unit of deviation is called the proportional
again. A large proportional gain means that a small deviation causes a large correction
and a small proportional gain means a large deviation causes a small correction .
Proportional band of a controller is defined as the % of input needed to get the 100 %
output of the controller. E.g. if the proportional band dial is set at 10% for a process
deviation of 10% , the controller output will very by 100 %.
When the load changes, the proportional controller will not maintain the desired value
( set point ). This is called proportional drop or off-set.
Proportional control may be used alone provided the load changes are not great and the
off –set that results from these changes does not impair the quality of the product being
processed.
This integral mode of control can be used only with proportional controller.
What is reset ?
Reset or integral action is nothing but integrating the proportional action till the off-set is
eliminated .
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The reset combined with proportional control action, enables the controller always to
maintain variable such as temperature level or pressure at the desired value. The
proportional control mode provides a stabilizing influence while the reset mode provides
necessary action to continue automatically the output correction until the controlled
variable is brought back to the set – point .
The combination of proportional plus re – set action is most widely used for flow and
pressure control where the process has less time lag and require a wide band proportional
controller for stability.
The reset action is limited in the case of temperature control since the time lag with in
the process is large . hence, only a small amount of reset is permissible otherwise
oscillations will occur .
This control mode can be used only with proportional or proportional with reset
controller .
It performs the action on the valve that a operator would perform if he noted the rapid
change in measurement . e.g. in a a liquid level application, if the level were to raise
rapidly, a experienced operator would over correct the valve towards the closed position
to prevent the level from reaching excessive limits. In general, this is the type of action
provided by rate or derivative mode control . in other words the rate action provided by
rate or derivative mode control. In other words the rate action provides anticipated
corrective measures and normally over shoot the set point. It is also known as preact or
booster .
control action gives a three mode controller having the advantages of all control effects.
It comes close to duplicating the type of control expected from a good experienced
human operator . if the adjustments of the controller is properly done to suit a process ,
in case of any process disturbance, the controlled variable will not deviate excessively
and will return to the set point rapidly .
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