INSTRUMENTATION

Why Instrumentation?

For measurement of physical parameters in the

process and control of these parameters.

Instrumentation
Measurement
Control
Process System
Control
Physical Quantities For Measurement

 Temperature
 Pressure
 Flow
 Level
 Speed
 Weight
 Displacement
 Gas Analysis
Types Of Controls

 On/Off Control
 Continuous Control

Control Elements:
 Pneumatic Control Valves
 Electrical Control Valves
 Hydraulic Cylinders
Types Of Control Systems

 Open Loop Control System

 Closed Loop Control System
 MEASUREMENTS
Temperature Measurement

The temperature of a substance or medium is a

phenomenon expressing its degree of hotness or
coldness.
Various primary effects with respect to change in
Temperature can be utilised for measurement:
 Change in physical or chemical state
 Variation in electrical parameters
 Generation of EMF
 Change in intensity of radiation
 MEASUREMENTS
Temperature Measurement
Measuring Elements

Thermometers  Expansion Thermometers

 Filled System Thermometers

Electrical Instruments  Thermocouples

 Resistance Thermometers
 Thermistor

Pyrometers  Radiation Pyrometers

 Optical Pyrometers
 MEASUREMENTS
Temperature Measurement
Most Commonly Used Measuring Elements:
THERMOCOUPLES
PRINCIPLE : A current flows in a closed circuit made up of two
dissimilar metals if the junctions of the two metals
are kept at different temperatures.

Thus the EMF generated is proportional to the

temperature difference in a predictable manner.
This phenomenon is known as Seebeck effect.

Thermocouple

Transmitter
 MEASUREMENTS
Temperature Measurement
Most Commonly Used Measuring Elements:
THERMOCOUPLES
Typical Arrangement:
 MEASUREMENTS
Temperature Measurement
Most Commonly Used Measuring Elements:
RTDs
(Resistance Temperature Detectors)
PRINCIPLE : The resistivity of metals increases or decreases
with increase in temperature.
Such variations can be measured precisely with
suitable electrical circuits
Used for low temperature, high accuracy
measurements.

RTD

Transmitter
 MEASUREMENTS
Temperature Measurement
RTDs

3-Wire System 4-Wire System

V V

RTD RTD
 MEASUREMENTS
Temperature Measurement
RTDs

Typical Arrangement:
 MEASUREMENTS
Temperature Measurement
Selection Criteria
Temp Range Type of transducer Type

900 degC RTD Platinum

400 degC RTD Nickel

700 degC Thermocouple T (Cu-Constantan)

900 degC Thermocouple Y (Fe-Constantan)

1370 degC Thermocouple K (NiCr-Ni)

1700 degC Thermocouple R (Pt87,Rh13-Pt)

S (Pt90,Rh10-Pt)
 
3700 degC Radiation Pyrometer
 MEASUREMENTS

Pressure Measurement

Pressure is defined as the amount of force applied

to a surface or distributed over it.

It is measured as force per unit area.

Different types of pressure:

 Gauge Pressure: Atmosphere pressure is considered as zero point.
 Absolute Pressure: Atmosphere pressure is included.
 Vacuum Pressure: Pressure below zero.
 Differential Pressure: Difference in two pressure heads.
 MEASUREMENTS
Pressure Measurement
Measuring Elements

Manometers

Elastic Transducers

Electrical Transducers
 MEASUREMENTS
Pressure Measurement
Most Commonly Used Measuring Elements:
MANOMETERS
Principle:
Orifice

Flow

High Pressure Tap P1 h2

h
h1 Low Pressure Tap P2

Scale

P= (- 1) g h Where = Density of fluid in U tube

1= Density of fluid in pipe
h = h2-h1
g = acceleration due to gravity
 MEASUREMENTS
Pressure Measurement
Most Commonly Used Measuring Elements:
DIAPHRAM TRANSDUCERS
Principle:

PRESSURE
 MEASUREMENTS
Pressure Measurement
Most Commonly Used Measuring Elements:
DIAPHRAM TRANSDUCERS
Principle:
DIFFERENTIAL PRESSURE
 MEASUREMENTS
Pressure Measurement
Most Commonly Used Measuring Elements:
Typical Arrangement:
 MEASUREMENTS

Flow Measurement

Determination of proportions and amount of

materials flowing in or out of a process.

Various Methods For Flow Measurement:

 Variable head or differential
 Variable Area
 Magnetic
 Thermal
 Ultrasonic
 MEASUREMENTS
Flow Measurement
Most Commonly Used Measuring Elements:
DIFFERENTIAL FLOWMETERS
Principle:
Orifice

Flow

P

Flow   P
 MEASUREMENTS
Flow Measurement
Most Commonly Used Measuring Elements:
MAGNETIC FLOWMETERS
Principle: Uses Faraday’s Law Of Electromagnetic Induction-

‘Whenever a conductor moves through a magnetic field of

given strength, a voltage is induced in the conductor which
is proportional to velocity between the conductor and the
magnetic field’
In case of magnetic flow meter, electrically conductive flowing liquid acts as
a conductor.
 MEASUREMENTS

Level Measurement
Measuring Methods

Direct Methods  Hook Type

 Sight Glass
 Float Type

Indirect Methods  Hydrostatic Type  Pressure Type

 Bubbler Type

 Electrical Type  Capacitance Type

 Radiation Type
 MEASUREMENTS
Level Measurement
Most Commonly Used Measuring Elements:
PRESSURE TYPE
Principle:

Pressure Differential
Transmitter Pressure
Transmitter

OPEN TANK CLOSED TANK

 MEASUREMENTS
Level Measurement
Most Commonly Used Measuring Elements:
BUBBLER TYPE
Principle:

Fixed
Nitrogen/ Air Differential
Flow Pressure
Transmitter
 MEASUREMENTS
Level Measurement
Most Commonly Used Measuring Elements:
CAPACITANCE TYPE
Principle: The probe acts as one of the terminal of a large earthed
capacitor
Insulated Capacitance Probe
Electric Wires

Metal Tank

Liquid (as dielectric)

Capacitance measuring
Instrument calibrated
In terms of level

C=K . A/D Where C = Capacitance

K = Dielectric Constant
A = Area Of Plate
D = Distance Between Plates
 MEASUREMENTS
Level Measurement
Most Commonly Used Measuring Elements:
CAPACITANCE TYPE
Typical Arrangement:
 MEASUREMENTS
Level Measurement
Most Commonly Used Measuring Elements:
RADIATION TYPE

Electric Wires

Source
Operating range of Level
Co-60

Detector
 MEASUREMENTS

Speed Measurement
Measuring Elements

Tacho Generators

Contactless Tachometers
 MEASUREMENTS
Speed Measurement
Most Commonly Used Measuring Elements:
AC TACHO GENERATORS
Principle: AC input

Primary Winding

Output
ROTOR

Secondary Winding
 MEASUREMENTS
Speed Measurement
Most Commonly Used Measuring Elements:
DC TACHO GENERATORS
Principle:

Brush

Rotor Winding

Output N S

Shaft
Permanent
Magnet
 MEASUREMENTS
Speed Measurement
Most Commonly Used Measuring Elements:
NONCONTACT TACHOMETERS
Principle: Toothed Gear

Magnetic Pick-up Winding

Output Voltage
Final Conversion Element

Motor
 MEASUREMENTS
Weight Measurement
LOADCELLS
PRINCIPLE: The change in resistance of strain gauge is proportional to the
weight supported by the cell

Loadcell Button
Diaphrams

Electric Wires

Strain Gauge
Housing

Gauge Factor F = R/R Where R= Change In Resistance

L/L L = Change In Length
 MEASUREMENTS
Displacement Measurement
LVDT
(Linear Voltage Differential Transducer)
AC Input

Primary Winding

Armature

Displacement

Secondary Winding

E1 E2

E
 MEASUREMENTS
Gas Analysis
Most Commonly Used Measuring Elements:

CO-Analysers
Infrared Source

Chopper

Sample In

Reference Cell Sample Cell

Sample Out

Detector

Signal
Diaphram
Conditioner
 MEASUREMENTS
Gas Analysis
Most Commonly Used Measuring Elements:

O2-Analysers

Balancing Weight
Restoring Current

Mirror

% O2
Source Lamp

Permanent
Magnet
Amplifier

Dual Photocell
 CONTROL ELEMENTS

General Assembly

Actuator

Positioner / Solenoid

Valve
 CONTROL ELEMENTS

Valves

BALL BUTTERFLY PLUG GATE GLOBE

VALVE VALVE VALVE VALVE VALVE

FULL BORE HALF BORE RUBBER METAL FINE FLOW DISC KNIFE FLOW
SEAT SEAT CONTROL APPLICATION

WATER DUST
SLURRY

WATER GAS (HIGH TEMP)

GAS (LOW TEMP)
180 Deg 360 Deg
 CONTROL ELEMENTS
Valves
Most Commonly Used Control Elements:
BUTTERFLY VALVES

Stem
Valve Body

Seat

Flap

Fixing Holes

Closed Open
 CONTROL ELEMENTS
Valves
Most Commonly Used Control Elements:
BALL VALVES

Stem
Valve Body

Ball

Closed Fixing Holes Open

 CONTROL ELEMENTS
Actuators
Typical Arrangement
Pneumatic Actuators :
UNACTUATED ACTUATED
Air Inlet Penion Air Inlet Penion
Vent

Spring Gear Spring Gear

 CONTROL ELEMENTS
Actuators
Typical Arrangement
Hydraulic/Pneumatic Cylinder:
To Open To Close
Shaft

Electrical Actuator:
 CONTROL ELEMENTS
Actuating Instruments
Solenoids (On/Off Control)

Solenoid (3/2 Way)

Cylinder/Actuator

Voltage

Air / Oil Inlet

2 Way Direct Acting Solenoid:

 CONTROL ELEMENTS
Actuating Instruments
Positioners Or I to P Converters
(Continuous Control)
Pneumatic Positioners

Signal Cable
Air In
Air Out
Vent
 CONTROL SYSTEM
Open Loop Control System

Reference Control
Or Comparator Controller Process
Element
Set-point
 CONTROL SYSTEM
Closed Loop Control System

Reference Error Control

Or Comparator Controller Process
Element
Set-point
Measuring
Element

Feedback
 Control Field
Digital Output
Analog Output

ACTION
CONTROL
Analog Input-POSITION

Digital Input-CLOSE
Butterfly

Digital Input-OPEN
Control Valve
Example

Digital Input-CLOSE
CONTROL SYSTEM

Digital Input-OPEN
Shut-Off
Ball Valve
Orifice
Flow Transmitter

Analog Input-FLOW
 CONTROL SYSTEM
Typical Arrangement
Signals Signals Signals Signals
From To From To
Field Field Field Field

Inputs Outputs Inputs Outputs MMI (Man Machine Interface)

Signal Processing Signal Processing Process Process

& & Displays Displays
Control Logic Control Logic

DCS-1 DCS-2

Network Bus