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Pressure Measurement

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Pressure Measurement

Simhadri Hari Narayana Rao Gedela


Control & Instrumentation Department
Simhadri Super Thermal Power Station
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Contents Click to edit Master title style

1 Terminology in Instrumentation 6 HART Concepts


Click to edit Master text styles

Failures , abnormalities & wrong


2 Pressure Measurement 7
readings

Types of Pressure Measurement 8


3 Review of the concepts
devices

4 Differential Pressure Measurement 9 References

5 Vacuum Measurement

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Terminology Click to edit Master title style
Instrument Zero and Span:
 Span: the range of measured variable that a sensor can measure.
 Consider a case in which the maximum temperature that is to be
measured is 600ºc and the minimum temperature is 0ºC.
 Then the zero is 0ºC and the span is 600ºc

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Least Count Click to edit Master title style

 Least-count: the smallest difference of measured variable that can be detected by a sensor / Instrument

 Sensitivity: the change in output of the sensor with the unit change in input variable to be measured; e.g., if a I-mV
recorder has a 5-cm scale length, its sensitivity would be 5 cm/ mV.

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Instrument repeatability edit Master title style
, Hysteresis

Hysteresis: A sensor exhibits hysteresis when there is a difference in readings depending on whether the values of
the measured variable are approached from above or below..

Repeatability refers to the ability of a Hysteresis is a sensor's ability to give


pressure sensor to provide the same the same output at a given
output with successive applications of temperature before and after a
the same pressure. temperature cycle.
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Sensor Accuracy Click to edit Master title style

 Accuracy: the deviation of the output of a sensor from a known measured input.
 Accuracy is usually expressed as a percentage of full scale reading (Percentage of full-scale(FS) reading / Percentage of
instrument span)
 Percentage of actual reading
 Measured variable:  absolute measured value
 e.g., a 100 Kg/cm2 pressure transducer having an accuracy of 1 % would be accurate within: 1 kg/cm2 over the entire
range.

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Contd Click to edit Master title style

 Threshold: If the input of a sensor is very gradually increased from zero, there will be some minimum value below which
no output can be detected.
 This minimum value is the threshold of the sensor.
 Resolution: the input increment that gives some small but definite numerical change in the sensor output.
 Thus resolution is the smallest measurable change, while threshold is the smallest measurable input.

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Typical plant overview

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Pressure DefinitionClick to edit Master title style

Force per unit area


Hydrostatic Pressure is pressure due to the weight of column of liquid
The shape of column of liquid does not have effect on hydrostatic pressure
Hydrostatic Pressure depends on density of liquid and height of the liquid column
A taller water column or denser liquids create greater pressure


Hydrostatic Pressure = ᵨ x hxg
ᵨ = Density
g = Gravitational Constant
h = Height of liquid column

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Pressure DefinitionClick to edit Master title style

Force per unit area


Pressure varies depending on altitude above sea level

The measure of pressure is, therefore, relative and pressure measurements are stated as
either gauge or absolute
 Atmospheric pressure : Pressure of one normal (standard) atmosphere
101325 Pa / 101.325 KPa / 1013.25 mbars / 14.696 psia / 29.921 In.Hg / 760 mm Hg @
0oC)
Gauge pressure :A gauge pressure device will indicate zero pressure when bled down to
atmospheric pressure (i.e., gauge pressure is referenced to atmospheric pressure).
Absolute Pressure:Absolute pressure includes the effect of atmospheric pressure with the
gauge pressure. It is denoted by an (a) at the end of the pressure unit
An absolute pressure indicator would indicate atmospheric pressure when completely
vented down to atmosphere - it would not indicate scale zero.

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Pressure DefinitionClick to edit Master title style


Hydrostatic Pressure = ᵨ x hxg
ᵨ = Density
g = Gravitational Constant
h = Height of liquid column

P = 1000 kg/m3 x 1 m x 9.81 m/s2 = 9810 kg/ms2 = 9.81 kpa


= 1000.341750801 mmwcl = 0.10003416 Kg/cm2

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Pressure DefinitionClick to edit Master title style

An absolute pressure measurement is one that is referred to absolute vacuum.


 The best example of an absolute referenced pressure is atmospheric or barometric pressure.
To produce an absolute pressure sensor the manufacturer will seal a high vacuum behind the sensing diaphragm.
 If the process pressure connection of an absolute pressure transmitter is open to the air, it will read the actual
barometric pressure.

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Review of conceptsClick to edit Master title style

Which of the following is true about hydrostatic pressure of a liquid?

a) The pressure exerted by a column of liquid depends on the shape / diameter of the column

b)It is calculated by multiplying the density of the liquid with surface area of the liquid

c)It is calculated by multiplying the weight of the liquid with surface area of the liquid

d) The pressure exerted by a column of liquid is independent of the shape of the column

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Units of Pressure Click to edit Master title style

SI system uses Pascal (Pa) as the basic unit of measurement of pressure
A Pascal represents a force of 1 Newton per Square Meter (m2)
Pa = 1N/m2
Pa= 1 Kg-m/s2
Other common units of pressure measurement are “Bar” , “ Kg/cm2” and mmwcl.
1 Kg/cm2 = 98.06 Kpa
 1 Bar = 100 Kpa
1 Psi = 6.89 Kpa

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Units of Pressure Click to edit Master title style

Atmospheric Pressure is also known as Barometric Pressure


It is the pressure due to the weight of the atmosphere above the point where it is measured.
 The atmosphere exerts a pressure of 101.3 Kpa at sea level.

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Units of Pressure Click to edit Master title style

At higher elevations the pressure decreases

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Units of Pressure Click to edit Master title style

Pressure is commonly measured w.r.t the atmosphere.


This is called gauge pressure
For example a guage reads 400 Kpa , then the gauge pressure is 400 Kpa, however as the earth is already surrounded by
atmospheric pressure the actual or absolute pressure is
400 Kpa + 101.3 Kpa (At sea level)
PAbsolute = Pgauge + Patmosphere

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Units of Pressure Click to edit Master title style

Negative Pressure measurements in our power plants use absolute pressure measurement
Absolute Pressure Measurements use an absolute pressure zero i.e perfect vacuum as zero reference point
If atmospheric Pressure is always 101.3 Kpa then O.K. , however practically atmospheric pressure changes with altitude
and weather conditions
So when we need very accurate measurement we take atmospheric pressure in to consideration.

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Units of Pressure Click to edit Master title style

Barometer

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Various Pressure Measurements title
a 500 MW style
Unit

Furnace Pressure
Drum Pressure
Main Steam Pressure
Hot Reheat steam Pressure
Gland Seal Pressure
PA Header Pressure
Turbine Throttle Pressure

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Various Pressure Measurements title
a 500 MW style
Unit

Measurement Units Range Limit Value

Furnace Pressure Very Low mmwcl < -175 mm WC


Furnace Pressure Very High +150 MMWC
mmwcl

Furnace to Wind Box DP mmwcl

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Various Pressure Measurements title
a 500 MW style
Unit

Measurement Units Range Limit Value

HP Bypass System Oil Supply pump for HP Kg/cm2 Pump off: >155 Kg/cm2
Bypass - Oil Pump discharge pressure Pump on: <110 Kg/cm2
Pressure too high: >160 Kg/cm2
Pressure too low: <100 Kg/cm2

Main Turbine Lub Oil Pressure Kg/cm2 < 1.2 Ksc

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Click to editinMaster
Various Pressure Measurements title
a 500 MW style
Unit

U Tube Manometer:
When Pressure is applied to one of its legs , the liquid is displaced by proportional amount
In this manometer design two measurements are taken one in each leg and added together to
determine the measured pressure.

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Various Pressure Measurements title
a 500 MW style
Unit

Well Type Manometer:


Applied pressure is spread across a much larger area
The scale in the column is graduated to give direct reading instead of taking from two legs

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Various Pressure Measurements title
a 500 MW style
Unit

How to read

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Review of conceptsClick to edit Master title style

In a U Tube manometer pressure reading is taken in the following way

a) Determine how far the liquid moved in the pressure column and divide it by two

b)Subtract the distance it moved from one column to the other

c)Determine how far the liquid moved in each column and then add the distances together.

d) The length travelled in pressure column is the pressure measurement

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Pressure Sensor Click to edit Master title style
Most pressure sensors translate pressure into physical motion that is in
proportion to the applied pressure
The basic pressure sensing elements are
A: C-shaped Bourdon tube
B: a helical Bourdon tube
C: flat diaphragm
D: convoluted diaphragm
E: capsule
F: a set of bellows

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Bourdon tube Click to edit Master title style

A sealed tube that deflects in response to applied pressure.& provide a fairly large
displacement
Useful in mechanical gauges and for electrical sensors that require a significant movement.
 Bourdon tubes are circular-shaped tubes with oval cross sections
 The pressure of the medium acts on the inside of the tube.
 The outward pressure on the oval cross section forces it to become rounded.Because of the
curvature of the tube ring, the bourdon tube then bends as indicated in the direction of the
arrow.
 Due to their robust construction, bourdon are often used in harsh environments and high
pressures, but can also be used for very low pressures; the response time however, is slower
than the bellows or diaphragm.

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Bellows Click to edit Master title style

Bellows type elements are constructed of tubular membranes that are


convoluted around the circumference (see Figure 3). The membrane is attached at one
end to the source and at the other end to an indicating device or instrument. The bellows
element can provide a long range of motion (stroke) in the direction of the arrow when
input pressure is applied. 5 to 500 Kpa

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Diaphragms Click to edit Master title style

A diaphragm is a circular-shaped convoluted membrane that is attached to


the pressure fixture around the circumference (refer to Figure 4). The
pressure medium is on one side and the indication medium is on the other.
The deflection that is created by pressure in the vessel would be in the
direction of the arrow indicated.
Diaphragms provide fast acting and accurate pressure indication.
However, the movement or stroke is not as large as the bellows

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Capacitive Pressure to edit Master title style
Transmitters

Typically use a thin diaphragm as one plate of a capacitor. Applied pressure causes the diaphragm to deflect and the
capacitance to change.
The change in capacitance may be used to control the frequency of an oscillator or to vary the coupling of an AC
signal through a network.
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Piezoelectric Pressure to edit Master title style
Sensors

Bi-directional transducers capable of converting stress into an


electric potential and vice versa.
Consist of metallized quartz or ceramic materials.
Dynamic effect, providing an output only when the input is
changing

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Strained Gauge Sensors
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A strain gauge measures the strain


in a material subjected to applied
stress
Signal due to deformation of the
material is small, on the order of
0.1% of the base resistance.

Uses a metal diaphragm with


strain gauges bonded to it.

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Manometer Click to edit Master title style

A simple pressure standard


May be used for gauge, differential, and absolute measurements with
a suitable reference.
Useful mainly for lower pressure work because the height of the
column of mercury will otherwise become unwieldy.
The difference in column heights gives the pressure reading

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Pressure Switch Click to edit Master title style

Used for protection / permissive / Interlock


Earlier designs critical protections were from 2 out of three pressure
switches

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Siphon MechanismClick to edit Master title style

When we measure steam pressure is used the Pressure gauge is to be


protected from the heat.
U Type siphon for vertical pipe
Pig Tail for horizontal pipe
The condensed steam fills the siphon
Also dampens the rapidly changing process pressure

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Snubber Mechanism

By Dampening the pressure changes the life of the instrument is increased

Glycerin or Silicone oil filled gauge helps dampen the vibration from piping system

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Review of conceptsClick to edit Master title style

What is used to prevent hot steam from coming in contact with the hot steam

a) Snubber

b)Glycerine

c)Siphon

d) Silicone oil

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Review of conceptsClick to edit Master title style

Which type of pressure sensor is curved and try to straiten when pressure is applied

a) C – Type Bourdon Tube

b) Diaphragm

c)Bellows

d) Snubber

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Failures, Abnormalities, to editreadings
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Over-Pressure
Pressure sensors are designed to operate over a rated pressure range.
Plant operating systems rely on these pressure sensors to maintain high accuracy over that given range.
 Instrument readings and control functions derived from these devices could place plant operations in jeopardy if the
equipment is subjected to over pressure (over range) and subsequently damaged
Diaphragms and bellows are usually the most sensitive and fast-acting of all pressure sensors.
They are also however, the most prone to fracture on over-pressuring.
Bourdon tubes are very robust and can handle extremely high pressures although, when exposed to over-pressure,
they become slightly distended and will read high. Very high over-pressuring will of course rupture the tube.

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Failures, Abnormalities, to editreadings
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Faulty Sensing Lines


Faulty sensing lines create inaccurate readings and totally misrepresent the actual pressure
When the pressure lines become partially blocked, the dynamic response of the sensor is naturally reduced and it
will have a slow response to change in pressure.
 Depending on the severity of the blockage, the sensor could even retain an incorrect zero or low reading, long after
the change in vessel pressure.
A cracked or punctured sensing line has the characteristic of consistently low readings. Sometimes, there can be
detectable down-swings of pressure followed by slow increases.
Loss of Loop Electrical Power:
The output of the Pressure / D/P transmitters will drop to zero or become irrational with a loss of power supply

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Click to edit Master title style
Head pressure measurement

Principle -a column of liquid will exert pressure whose value


depends only on the weight of liquid, density of liquid and
acceleration due to gravity and is totally
independent of the cross-sectional area of the column

If density remains constant then the height of liquid above a


datum (tapping) point is directly proportional to the pressure
measured at that datum point. Thus a pressure measuring
device can be scaled in units of level.

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USE OF DP TRANSMITTER
 P=S.H
 where
 P=Pressure ( Pa),  S=Weight density of the liquid ( N/m3)= ρ g
 H=Height of liquid column ( m),  ρ=Density (kg/m3)
 g=acceleration due to gravity ( 9.81 m/s2)

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Differential Pressure to edit Master title style
Transmitters

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Review of conceptsClick to edit Master title style

Which component in a capacitance type pressure transmitter is in touch with measuring pressure?

a) Bellows

b) Diaphragm

c)Capacitor plate

d) Strain Gauge

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USE OF DP TRANSMITTER
Specifications of a typical Pressure / ∆P Transmitter:
1.Application : This 2 wire Electronic Smart pressure and differential pressure Transmitters shall be used for the
measurement of pressure and differential pressure.
2.Service Fluid : Air with traces of nitric acid & organic fumes
3.Ambient Condition: Temp. : 10 – 50 deg. C RH : 30 – 90 %
4.Power Supply : 24 V DC
5. Type of Transmitters : The Transmitters shall be electronic smart type having Hart or H1 protocol and employ a 2
wire transmission System.
6. Load Resistance : Shall be 600 ohms minimum at 24 V DC power supply.
7. Communication : Remote Display and Configuration facility through hand held communicators shall be possible
for measuring range, damping, output mode , tag number , model number etc. Self diagnosis shall also be available
on the hand held Terminal.
8. Span : Shall be continuously variable from minimum to max.
9. Zero Suppression / Elevation: -5 to +/- 100% URL

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The case of Furnace to Box
/ Wind editDP
Master titlefailure
Transmitter style
There are 02 Nos. Furnace to Wind Box DP transmitters for controlling
secondary air flow to furnace through SADC. Deviation started between
these pressure transmitters and SADC control was often shifting to
manual.
The logic is such that even though we select a single transmitter and put on
auto , the other tracks and again on deviation the SADC control shifts to
manual. The problem was persisting from past two days. One day while
raising load , one FD fan tripped on over load and there was unit
disturbance..What could have happened?
Note:
The Furnace to Wind Box DP is controlled through Auxiliary air dampers
in auto and fuel dampers are controlled based on feeder speed.

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Review of conceptsClick to edit Master title style

Which of the following is the measurment range of Furnace Pressure Transmitter?

(A) ) -10 mm Water Column to + 10 mm Water Column

(B) 0 – 250 Kg/cm2

(C) -500 mm Water Column to + 500 mm Water Column

(D) 0 – 760 mmHg

In the above case Instrument zero is =


Instrument Span is =

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Review of conceptsClick to edit Master title style
- Accuracy

Consider the measurement of a known temperature of 100°C with a certain transducer.


Five observations are recorded, and the indicated values are 103, 105, 103, 105, and 103°C. These values
show that the accuracy of the transducer is

(A) 5% (5°C)

(B) 3% (3°C)

(C) 1% (1°C)

(D) 0%(0°C)

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Review of conceptsClick to edit Master title style

Fire Hydrant Header Pressure (running up to Drum Elevation) at 0 mtr elevation is 10 Kg/cm2. Now
the Fire Hydrant Pressure at Drum Elevation (75 mtrs) will be approximately.

(A) 2.5 Kg/cm2

(B) 12.5 Kg/cm2

(C) 7.5 Kg/cm2

(D) 10

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Review of conceptsClick to edit Master title style

Fire Water Pumps suction pressure gauge is showing 0.85 KG/CM2.The ultrasonic level transmitter is showing
10 mtrs.In this case the level Tx is showing

(A) More

(B) Less

(C) Accurate

(D) Can not be decided


L
Pressure T
Gauge

Fire Water
p/p

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Calibration Click to edit Master title style

Calibration refers to the checking and adjustment of an instrument so that its output faithfully corresponds to its
input throughout a specified range.
In order to calibrate an instrument, we must have some means of knowing the input and/or output quantities
associated with the instrument under test.
A substance or device used as a reference to compare against an instrument’s response is called a calibration
standard.
In one case, an instrument technician attempted to calibrate a pneumatic pressure transmitter to a tolerance of ±
0.25% of span using a test gauge that was only good for ± 1% of the same span.

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Calibration Click to edit Master title style

Calibration refers to the checking and adjustment of an instrument so that its output faithfully corresponds to its
input throughout a specified range.

In order to calibrate an instrument, we must have some means of knowing the input and/or output quantities
associated with the instrument under test.

A substance or device used as a reference to compare against an instrument’s response is called a calibration
standard.

In one case, an instrument technician attempted to calibrate a pneumatic pressure transmitter to a tolerance of ±
0.25% of span using a test gauge that was only good for ± 1% of the same span.

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Calibration Click to edit Master title style
Calibration and re-ranging : Every instrument has at least one input and one output. For a pressure
sensor, the input would be some fluid pressure and the output would (most likely) be an electronic
signal.

 For a loop indicator, the input would be a 4-20 mA current signal and the output would be a human-
readable display.

To calibrate an instrument means to check and adjust (if necessary) its response so the output
accurately corresponds to its input throughout a specified range. In order to do this, one must expose the
instrument to an actual input stimulus of precisely known quantity.

For a pressure gauge, indicator, or transmitter, this would mean subjecting the pressure instrument to
known fluid pressures and comparing the instrument response against those known pressure quantities.
One cannot perform a true calibration without comparing an instrument’s response to known, physical
stimuli.

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Calibration Click to edit Master title style

To range an instrument means to set the lower and upper range values so it responds with the desired
sensitivity to changes in input.

For example, a pressure transmitter set to a range of 0 to 200 PSI (0 PSI = 4 mA output ; 200 PSI = 20
mA output) could be re-ranged to respond on a scale of 0 to 150 PSI (0 PSI = 4 mA ; 150 PSI = 20 mA).
In analog instruments, re-ranging could (usually) only be accomplished by re-calibration, since the same
adjustments were used to achieve both purposes.

 In digital instruments, calibration and ranging are typically separate adjustments (i.e. it is possible to
re-range a digital transmitter without having to perform a complete recalibration), so it is important to
understand the difference.

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Calibration Click to edit Master title style
Electrical standards

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Pressure StandardsClick to edit Master title style

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Dead Weight TesterClick to edit Master title style

Used as primary standard

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Dead Weight TesterClick to edit Master title style

Used as primary standard – Pressure = F / A

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Calibration Standards
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Instruments calibrated at NABL accredited laboratories

National Accreditation Board for Testing and Calibration Laboratories (NABL)

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HART Click to edit Master title style
HART - Highway Addressable Remote Transducer
HART is a hybrid communication standard, with one variable
(channel) of information communicated by the analog value of a 4-
20 mA DC signal, and another channel for digital communication
whereby many other variables could be communicated using pulses
of current to represent binary bit values of 0 and 1.
It's called a hybrid protocol because it combines analog and
digital communication.
The digital information is carried by a low-level modulation
superimposed on the standard 4-to-20 mA current loop.

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HART – Two way communication
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 Using an analog signal, information is sent only one way, either from the device to the host (inputs) or from the host to
the device (outputs).
 Digital information, on the other hand, can travel in both directions using the HART digital communications signal.
 This opens the way for an instrument that traditionally only receives control-signal information from a host —- a valve
controller, for example — to also send the host information about what’s happening at the valve.
 Similarly, a transmitter that traditionally only sends a process variable to the host can now also receive information such
as configuration settings.

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HART – Two way communication
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 Traditional analogue and discrete devices communicate only a single process variable — and you typically have no easy
way to tell if the information they're sending is valid.
 With HART, 35-40 information information items are accessible from every HART device.
 Examples include
– Device Status & Diagnostic Alerts
– Process Variables & Units
– Loop Current & % Range
– Basic Configuration Parameters
– Manufacturer & Device Tag With additional information like this, HART devices that are digitally polled by a host
can tell you if they're correctly configured and operating correctly. This eliminates the need for most routine checks —
and helps you detect failure conditions before they cause a major process problem.

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HART Click to edit Master title style
A HART-compatible device “talks” digitally on a two-wire loop circuit, it produces tone bursts of AC current at 1.2
kHz and 2.2kHz. The receiving HART device “listens” for these AC current frequencies and interprets them as
binary bits.
An important consideration in HART current loops is that the total loop resistance (precision resistor values plus
wire resistance) must fall within a certain range: 250 ohms to 1100 ohms.

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Wired HART Simultaneous
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edit and Digitaltitle
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 The earliest HART Communications protocol was based


on the BELL 202 Telephone Communication Standard
and was operated using the Frequency Shift Key(FSK)
principle.
 The digital signal is made up of two frequencies: 1200
and 2200 Hz representing the 1 and 0 bits respectively.

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HART with DCS – Multi
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Contd Click to edit Master title style

 Upper Range Limit (URL): It is the highest pressure at which the transmitter was designed to measure considering the
sensor upper range limit
 Lower Range Limit (LRL): It is the lowest pressure at which the transmitter was designed to measure considering the
sensor upper range limit

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Turn down ratio of Click to edit
a Pressure Master title style
Transmitter

 Turn Down Ratio:


– Turn down Ratio : 100 to 1 means the same pressure transmitter can be configured for measurement range of 0-1
Kg/cm2 as well as for 0 – 100 Kg/cm2.
 Turn Down Ratio = URL / Calibrated Span

LRL URL
- 1000mmWCL LRV URV +1000mmWCL
- 100mmWCL + 100mmWCL

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Review of conceptsClick to edit Master title style

Turndown ratio of a pressure transmitter with range 0 – 10 Kg/cm2 is 10.This means that

(A) The same pressure transmitter can be used for range of 0 - 1 kg/cm2 and range of 0 – 1000 Kg/cm2

(B) The same pressure transmitter can be used for range of 0 – 0.1 kg/cm2 and range of 0 – 1 Kg/cm2

(C) The same pressure transmitter can be used for range of 0 - 1 kg/cm2 and range of 0 – 100 Kg/cm2

(D) The same pressure transmitter can be used for range of 0 - 1 kg/cm2 and range of 0 – 10 Kg/cm2

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Review of conceptsClick to edit Master title style

Primary Air Header Pressure very Low Pressure Switch has come up for calibration in C&I
Laboratory. The set point is 400 mmWCL falling. While calibrating the same, which of the following is
to be ensured.

(A)The pressure switch resetting is to be ensured at 900 mmwcl.

(B)The pressure switch resetting is to be ensured at 300 mmwcl

(C) The pressure Switch resetting to be ensured near about 500 mmwcl

(D) We have to ensure that the switch never resets

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Review of conceptsClick to edit Master title style

Furnace Pressure Transmitter will be calibrated with which of the following instrument

(A) Dead Weight Tester

(B) Hydraulic Comparator

(C) Manometer (Digital / Water Tube)

(D) Standard Thermometer

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Review of conceptsClick to edit Master title style

Will Barometric pressure be higher on top of a mountain or on the beach?

(A) Beach

(B) Mountain

(C)  It's always the same

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Review of conceptsClick to edit Master title style

Which of the following is not a unit of measure for pressure?

(A) PSI

(B) Bar

(C) Pascal

(D) Joule

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Review of conceptsClick to edit Master title style

Differential pressure transmitters measure level by inference from:

a) capacitance

b) conductivity

c) hydrostatic head

d) thermal energy

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Review of conceptsClick to edit Master title style

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References Click to edit Master title style

1. PMI Course Material

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THANK
YOU

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