Pressure Measurement
Pressure Measurement
Pressure Measurement
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..
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
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
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
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Pressure DefinitionClick to edit Master title style
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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
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Units of Pressure Click to edit Master title style
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Units of Pressure Click to edit Master title style
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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
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Various Pressure Measurements title
a 500 MW style
Unit
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
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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
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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
a) Determine how far the liquid moved in the pressure column and divide it by two
c)Determine how far the liquid moved in each column and then add the distances together.
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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
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Diaphragms Click to edit Master title style
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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
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Strained Gauge Sensors
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Manometer Click to edit Master title style
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Pressure Switch Click to edit Master title style
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Siphon MechanismClick to edit Master title style
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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
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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Head pressure measurement
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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
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
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- Accuracy
(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.
(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
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
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Dead Weight TesterClick to edit Master title style
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Calibration Standards
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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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HART with DCS – Multi
ClickDrop Network
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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
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.
(C) The pressure Switch resetting to be ensured near about 500 mmwcl
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Furnace Pressure Transmitter will be calibrated with which of the following instrument
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(A) Beach
(B) Mountain
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(A) PSI
(B) Bar
(C) Pascal
(D) Joule
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a) capacitance
b) conductivity
c) hydrostatic head
d) thermal energy
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References Click to edit Master title style
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