Industrial Instrumentation

An Introduction

AN OVERVIEW OF INDUSTRIAL MEASUREMENT AND CONTROL SYSTEMS

Level 1 Bryon Lewis

INDUSTRIAL MEASUREMENT AND CONTROL SYSTEMS

Level 1

Introduction
This course will introduce the methods to apply instrumentation and
control for use in industrial processes. It will show the proper way to
install and calibrate basic instruments, as well as the use of controllers,
control modes, and control loops.

Industrial instrumentation employees the use of applied physics to monitor

and regulate processes. Instrumentation can be found in any number of
the following industries, gas and petrochemical, food processing,
pharmacutical, paper and pulp, waste water and water treatment plants
are just a few examples.

Objectives
The objectives of this course will be as follows…
1. Read P&IDs (process and instrumentation diagrams).
2. Read instrument loop diagrams.
3. To be able to install and calibrate basic instruments.
4. Apply basic instrumentation to control an industrial process.
5. Apply simple design of control loops used in processes.
6. Understand feedback, feedfoward, cascade and ratio control.

Industrial Instrumentation 1 Bryon Lewis

Level 1 – 2002 all rights reserved
 INDUSTRIAL MEASUREMENT AND CONTROL SYSTEMS
Part 1 Course Objectives – Basic Instruments

1. Instrumentation Symbols and Terminology

a. Symbols, nomenclature and usage
b. P&IDs, Mechanical Flow Diagrams
c. Loop Diagrams

2. Basic Measurements
a. Basic Concepts
i. Standard signals used in instrumentation
ii. Instrument ranging and limitation
iii. Span, Upper range value and Lower range value
iv. Constant current and constant voltage
v. Static equilibrium in instrument measurements
vi. Open systems
vii. Closed systems

b. Pressure measurements
i. Static pressure and Head measurements
ii. Differential pressure and Head measurements
iii. Vacuum measurements
iv. Calibration

c. Level measurements
i. Wet Legs
ii. Suppressing the Zero
iii. Elevating the Zero

d. Temperature measurements
i. Thermocouples
1. J type, K type, E type, T type (most commonly used)
ii. RTD (resistance temperature detectors)
1. 100 ohm platinum (most commonly used)
2. Bridge measurement application
3. Constant current measurement application
iii. Capillary tubes and thermometers

e. Flow and Mass Flow measurements

i. Differential pressure and Head to measure flow
ii. Meter Types
1. Magnetic
2. Orifice
3. Venturi
4. Vortex
5. Turbine
iii. Mass Flow measurement
1. Electrical and Mechanical
2. Pressure + Delta Pressure + Temperature
3. Mass flow is proportional to Force measured

3. Open discussions of applications and experiences

Industrial Instrumentation 2 Bryon Lewis

Level 1 – 2002 all rights reserved
 INDUSTRIAL MEASUREMENT AND CONTROL SYSTEMS
Part 2 Course Objectives – Process Control

1. Control loops
a. Principles of operation and terminology
b. Open loop control
c. Closed loop control
d. Single loop controls
e. Cascade controls (outer and inter loop)
f. Wiring of instruments and controllers

2. Control Modes
g. PID control modes
i. Proportional control mode
ii. Integral control mode
iii. Derivative control mode
iv. Application of the three types of control modes
h. Differential Gap Control
i. Split Range Control
j. Time Proportioning Control

3. Final Correction Devices

k. Valves
i. Type of valves
ii. Valve terminology, trim, and characterization
iii. Applications of equal percentage, linear and quick opening vales
l. Pumps
i. Types
ii. Applications
iii. Control and interlocking to process controller
1. Alarms
2. Starting and stopping
3. Shutdown systems
4. Applications of measurement, process control and P&IDs

5. Open discussions of applications and experiences

End of Course

Industrial Instrumentation 3 Bryon Lewis

Level 1 – 2002 all rights reserved
 Section 1 – Basic Instruments
Loop Diagram Symbols and P&IDs

P&IDs AND LOOP DIAGRAMS

P&IDs and loop diagrams are construction and

documentation drawings that depict the flow
of the process and illustrate the
instrumentation control and measurement
interactions, wiring and connections to the
process. The process is illustrated in sections
or subsystems of the process called loops. A
loop diagram will detail the connections of
pneumatics and wiring from the field device
through any junction boxes or marshalling
cabinet to the controller or computer interface
which controls the process a single loop or a
cascade loop of the process.

This section will focus on the standard

symbols, identification tags and terminology
used in the industry.

In the areas of engineering, design, drafting,

installation and maintenance of an industrial
instrumentation and control system, a solid
understanding of the symbols and terminology
used to depict the process system is required.

This course will use the ISA/ANSI standards shown in this section for all process illustrations.
ISA (International Society of Automation) / ANSI (American National Standards Institute).

Instrument line symbols

ALL INSTRUMENT LINES ARE TO BE DRAWN FINE IN RELATION TO THE PROCESS PIPING LINES.

Common connecting lines

Connection to process, or instrument
supply:

Pneumatic signal:

Electric signal:
Capillary tubing (filled system):

Hydraulic signal:

Electromagnetic or sonic signal

(guided):
Internal system link
(software or data link):
Source: Data from ISA S5.1 standard

Industrial Instrumentation 4 Bryon Lewis

Level 1 – 2002 all rights reserved
 Section 1 – Basic Instruments
Loop Diagram Symbols and P&IDs
Tagging nomenclature

The following table illustrates standard tagging to use for instrument identification.

P&ID TAG DESIGNATIONS

TYPICAL TAG NUMBER
TIC 103 - Instrument Identification or Tag Number
T 103 - Loop Identification
103 - Loop number
TIC - Function Identification
T - First Letter (measured variable – see table 2)
- Succeeding Letters (modifier, readout or function)
IC

EXPANDED TAG NUMBER

10-PHA-5A - Tag Number
10 - Option Prefix
A - Option Suffix

Note: Hyphens are optional as separators

The top of the tag will identify the instrument type and the bottom will identify the loop number. Refer
to tagging nomenclature tables above. Remember the loop number is just a section or sub system of the
process.

General instrument or function symbols

Primary location Auxiliary location
accessible to Field mounted accessible to
operator operator

Discrete
instruments

Shared
display,
shared control

Computer
function

Programmable
logic control

1. Symbol size may vary according to the user's needs and the type of document.
2. Abbreviations of the user's choice may be used when necessary to specify location.
3. Inaccessible (behind the panel) devices may be depicted using the same symbol but with
a dashed horizontal bar.

Source: Data from ISA S5.1 standard

Industrial Instrumentation 5 Bryon Lewis

Level 1 – 2002 all rights reserved
 Section 1 – Basic Instruments
Loop Diagram Symbols and P&IDs
The table below shows the recommended tag identification letters for instruments and control element
designations used in P&IDs and Loop Diagrams.

Identification letters
First letter Succeeding letters

Measured or Readout or Output

Modifier Modifier
initiating variable passive function function
A Analysis Alarm
B Burner, combustion User's choice User's choice User's choice
C User's choice Control
D User's choice Differential
Sensor (primary
E Voltage
element)
Ration
F Flow rate
(fraction)
G User's choice Glass, viewing device
H Hand High
I Current (electrical) Indication
J Power Scan
Time rate of
K Time, time schedule Control station
change
L Level Light Low
Middle,
M User's choice Momentary
intermediate
N User's choice User's choice User's choice User's choice
O User's choice Orifice, restriction
Point (test
P Pressure, vacuum
connection)
Integrate,
Q Quantity
totalizer
R Radiation Record
S Speed, frequency Safety Switch
T Temperature Transmit
U Multivariable Multifunction Multifunction Multifunction
Vibration, mechanical Valve, damper,
V
analysis louver
W Weight, force Well
X Unclassified X axis Unclassified Unclassified Unclassified
Event, state, or Relay, compute,
Y Y axis
presence convert
Z Position, dimension Z axis Driver, actuator
Source: Data from ISA S5.1 standard

Industrial Instrumentation 6 Bryon Lewis

Level 1 – 2002 all rights reserved
 First Process Switches and
Controllers Readout Devices Transmitters Elements and Final Correction Devices
Letter Variable Alarm Devices
Self- Solenoids
Initiating Actuated Relays, Well Viewing
or Control Computing Primary Test or Device, Safety Final
Measured Variable Recording Indicating Blind Valves Recording Indicating High Low Comb Recording Indicating Blind Devices Element Point Probe Glass Devices Element
A Analysis ARC AIC AC AR AI ASH ASL ASHL ART AIT AT AY AE AP AW AV

B Burner/combustion BRC BIC BC BR BI BSH BSL BSHL BRT BIT BT BY BE BW BG BZ

C User' Choice

D User' Choice

Level 1 – 2002
E Voltage ERC EIC EC ER EI ESH ESL ESHL ERT EIT ET EY EE EZ

F Flow Rate FRC FIC FC FCV FR FI FSH FSL FSHL FRT FIT FT FY FE FP FG FV
FICV

FQ Flow Quantity FQRC FQIC FQR FQI FQSH FQSL FQRT FQIT FQT FQY FQE FQV

Industrial Instrumentation
FF Flow Ratio FFRC FFIC FFC FFR FFI FFSH FFSL

G User' Choice

H Hand HIC HC HS HV

I Current IRC IIC IR II ISH ISL ISHL IRT IIT IT IY IE IZ

J Power JRC JIC JR JI JSH JSL JSHL JRT JIT JT JY JE JZ

K Time KRC KIC KC KCV KR KI KSH KSL KSHL KRT KIT KT KY KE KV

L Level LRC LIC LC LCV LR LI LSH LSL LSHL LRT LIT LT LE LW LG LV

M User' Choice

N User' Choice

7
O User' Choice

P Pressure\Vacuum PRC PIC PC PCV PR PI PSH PSL PSHL PRT PIT PT PY PE PP PSV PV
PSE
Pressure PDRC PDIC PDC PDCV PDR PDI PDSH PDSL PDSHL PDRT PDIT PDT PDY PE PP PDV
PD
Differential

Q Quantity QRC QIC QR QI QSH QSL QSHL QRT QIT QT QY QE QZ

R Radiation RRC RIC RC RR RI RSH RSL RSHL RRT RIT RT RY RE RW RZ

S Speed\Frequency SRC SIC SC SCV SR SI SSH SSL SHHL SRT SIT ST SY SE SV

Loop Diagram Symbols and P&IDs

Temperature TRC TIC TC TCV TR TI TSH TSL TSHL TRT TIT TT TY TE TP TW TSE TV
Section 1 – Basic Instruments

T
TD Temperature TDRC TDIC TDC TDCV TDR TDI TDSH TDSL TDSHL TDRT TDIT TDT TDY TE TP TW TDV
Differential

U Multivariable UR UI UY UV

V Vibration\Machinery VR VI VSH VSL VSHL VRT VIT VT VY VE VZ

Analysis

W Weight/Force WRC WIC WC WCV WR WI WSH WSL WSHL WRT WIT WT WY WE WZ

WD Weight/Force WDRC WDIC WDC WDCV WDR WDI WDSH WDSL WDSHL WDRT WDIT WDT WDY WE WDZ

all rights reserved

Bryon Lewis
Differential

X Unclassified

Y Event/State/ YIC YC YR YI YSH YSL YT YY YE YZ

Presence ZRC ZIC ZC ZCV ZR ZI ZSH ZSL ZSHL ZRT ZIT ZT ZY ZE ZV

Z Position/Dimension

ZD Gauging Deviation ZDRC ZDIC ZDC ZDCV ZDR ZDI ZDSH ZDSL ZDRT ZDIT ZDT ZDY ZDE ZDV
 Section 1 – Basic Instruments
Loop Diagram Symbols and P&IDs

P&ID (process and instrumentation diagram)

MECHANICAL FLOW (simplified diagram)

Industrial Instrumentation 8 Bryon Lewis

Level 1 – 2002 all rights reserved
 Section 1 – Basic Instruments
Loop Diagram Symbols and P&IDs

This P&ID diagram illustrates the use of software data links between controllers. These controllers
communicate over a communications bus and pass variables back and forth between the IOP (input
output processor) sections of the DCS. The communications processor will then put the information in
memory for the control blocks of the program to use. Some controllers can use Ethernet or Field Bus to
communicate and pass the process variables back and forth. If the controllers are in the software of the
same DCS (distributed control system) IOP or in the same SCADA (supervisory control and data
acquisition) system RTU (remote terminal unit) or in a stand alone PLC (programmable logic controller)
the control variables would be passed in memory.

Blow-up of the P&ID

Industrial Instrumentation 9 Bryon Lewis

Level 1 – 2002 all rights reserved
 Section 1 – Basic Instruments
Loop Diagram Symbols and P&IDs

This Loop diagram illustrates flow loop FT-100 from field to PLC controller and the display.

Loop Diagram

Industrial Instrumentation 10 Bryon Lewis

Level 1 – 2002 all rights reserved
 Section 2 – Basic Instruments
Measurements and Calibration Procedures

Standard process signals

Industrial processes use standards for the measurement and control signals used throughout all
industries. The signals used in industrial instrumentation are unique. Processes are referred to or
measured as 0% to 100% of the process range. These signals also typically employee a live zero for 0%
of process measurement.

A live zero gives insight as to if the process loop is functioning within given parameters or if the control
loop is open or malfunctioning. If the loop is functioning in a proper manor, the signal will indicate a
measurement greater than zero for 0% percent of process. There is also a measurement greater than
zero for 100% percent of the process. For example if the process was using a signal of 3 PSI to 15 PSI,
the range of the process is 3 to 15 PSI.

In the representation of the process, 3 PSI represents 0% of the process and 15 PSI represents 100% of
the process. The span of the process is 12 PSI. The span is where the process takes place in a range of
measurement.

Upper Range Value (URV) – Lower Range Value (LRV) = Span

SPAN
-25% 0% 100%

0 psi 3 psi 15 psi

RANGE

It can be seen from the chart above that if the process signal equaled 0 PSI or –25%, the loop is open
or malfunctioning. This is a great advantage in industrial measurement for the troubleshooting of the
process loop and identification and elimination of elements that are not associated with the source of the
problem.

The chart below shows some of the various standard signals used for industrial instrumentation.

Measurement Sensor PV / MV PV / MV
mV (millivolts) 0 -100 0-100
V (volts) 0-10 1-5 0-10
mA (milliamperes) 20 4-20 10-50
in H20 0-100
PSI 3-15 6-30
kPa 20-100

Industrial Instrumentation 11 Bryon Lewis

Level 1 – 2002 all rights reserved
 Section 2 – Basic Instruments
Constant voltage and constant current signals

Industrial electrical control signals are typically constant current or constant voltage. These signals obey
ohm’s law but are not the same as a resister connected in series or parallel with the voltage supply.
Ohm’s Law E = I x R

With a constant current control device one or more resistive loads may be connected in series with
the control device. The current flowing through the circuit will remain at a constant value of current
even if the resistance of one or more of the resistive loads is varied at any period of time or frequency.
Ohm’s law still applies to this type of circuit. The voltage supply of the circuit must be equal to or
greater than the sum of all maximum resistances in the circuit in ohms multiplied by the maximum
current of the circuit in amperes.

[20mA x (Rwire + Rdevice1 + Rdevice2 + Rn…] ≤ Vs (power supply voltage)

250
1% Precision
Wire

- + - +
Constant +
Current + Power
Control PV 4-20mA Supply
Device - - +24 VDC
+ - + -

Current
Meter 250
1% Precision

Notice the 1% precision resistors. The resistor will produce a 1-5 volt signal for the recorder and
controller to read as input. (4mA x 250Ω = 1v, 20mA x 250Ω = 5v)

With a constant voltage control device one or more resistive loads may be connected in parallel with
the control device. The applied voltage across the resistances throughout the circuit will remain at a
constant value of voltage even if the resistance of one or more of the resistive loads is varied at any
period of time or frequency. Ohm’s law still applies to this type of circuit. The voltage supply of the
circuit must be equal to or greater than the sum of all maximum resistances in the circuit in ohms
multiplied by the maximum current of the circuit in amperes.

[20mA x {1/(1/Rwire +1/Rdevice1 + 1/Rdevice2 + 1/Rn…)}] ≤ Vs (power supply voltage)

Wire
Wire Wire
Wire

++ ++ -- ++ -- ++
++ ++ Constant
Constant
Current
Current ++ Power
Power
1-5V
1-5V PV
PV Control Supply
Supply
-- Control --
-- -- Device
Device +24
+24 VDC
VDC
--
Volt
Volt Device
Device ++ -- ++ --
Meter
Meter Wire
Wire Wire
Wire

Notice the devices and the voltmeter are in parallel. The transmitter is sending a low power output
constant voltage signal typically 1-5 volt. Notice the wire resistance. The devices must be kept close as
possible not to produce significant error due to voltage drop.

Industrial Instrumentation 12 Bryon Lewis

Level 1 – 2002 all rights reserved
 Section 2 – Basic Instruments

Static equilibrium in instrument measurements

Most industrial instrument measuring devices use static equilibrium to measure the error in the process.
The error is the difference between the setpoint (SP), the desired value of the process, and the process
variable (PV), the actual value of the process.

The sum of forces must equal zero to be in static equilibrium (ΣF = 0). Most mechanical instruments
can be thought of as a balance beam.

F1 – F2 = 0 F1 – F2 ≠ 0
Static equilibrium – no error An error exists in the process

F1 represents the setpoint (SP) and F2 represents the process variable (PV). When the sum of the
setpoint and the process variables equal zero (SP – PV = 0), the measuring instrument is in static
equilibrium. This applies to the controller as well. When the error is zero SP – PV = E (error), the process
is said to be at steady state. It is exactly where it should be, but in the real world this is extremely hard
to achieve. There are constantly disturbances on the system and this is why constant monitoring of the
process needed. With constant monitoring and correction of the process, the process can be regulated
with extremely little or negligible error. The desired process value will be exactly what it should be within
the tolerances of the system and it’s components.

Open and closed systems

Industrial processes use tanks, device and instruments that are referred to as open and closed systems.
These are not to be confused with open and closed control loops.

The following examples illustrate the application of open and closed systems. Take a look at the open
systems first, then the closed system. Both level transmitters are in static equilibrium when the tanks are
empty. The same applies to flow transmitters. We can measure the unbalanced pressure when a fluid is
flowing in the pipes or a level exists in the tanks. This method reveals the energy in the system, stored
or kinetic.

ONLY THE (HEAD) PRESSURE IS MEASURED IN THE TANKS USING STATIC EQUILIBRIUM

CLOSED TO OPEN TO
ATMOSPHERE ATMOSPHERE
30 PSI–30 PSI = 0 ∆P = 0
∆P = 0

∆ (HEAD) PRESSURE IS USED FOR FLOW RATE AND STATIC PRESSURE USING STATIC EQUILIBRIUM

∆P = THE SQUARE OF ∆P = THE PROCESS

THE PROCESS STATIC PRESSURE
FLUID’S VELOCITY
LOW SIDE IS OPEN TO
ATMOSPHERE

CLOSED SYSTEMS OPEN SYSTEMS

Industrial Instrumentation 13 Bryon Lewis

Level 1 – 2002 all rights reserved
 Section 2 – Basic Instruments

Pressure measurements
The most common measurement used in most industrial processes is pressure. The pressure
measurement can be used to measure flow, level, mass, weight, and work. This type of measurement is
an inferred measurement. An inferred measurement is proportional to the potential and kinetic energy in
the system.

By first learning methods to measure pressure, then temperature and then differential pressure, it
possible to control about any type of industrial process.

The illustration to left is a simple pressure

meter. It uses a voltage divider to output a
voltage that is proportional to the process
pressure. At the 50% position it is in static
equilibrium and the voltage out is equal to 0
volts. At the 0% position the voltage is equal to
–5 volts. At the 100% position the voltage is
equal to +5 volts. This design will indicate if the
pressure is positive or negative. Pressure is
typically referred to as a positive measurement
but not always.

Potentiometric Pressure Transducer

The following illustration is of the bourdon tube design. This design is a very popular design for use in
pressure gauges.

Bourdon Tube Designs

The following illustration is of sealed diaphragms. This method is very popular in the design of pressure
transducers for process measurement.

Pressure Sensor Diaphragm Designs

Section 2 – Basic Instruments

Industrial Instrumentation 14 Bryon Lewis
Level 1 – 2002 all rights reserved
 Pressure measurements

The following example is of a strain gauge type

measurement. Incorporating the diaphragm
shown previously and sandwiching a strain gauge
in between the two diaphragms it produces a
sensor capable of measuring differential pressure.
Notice the high and low sides of the transducer.
The high side is designed to withstand a much
higher pressure than the low side of the transducer
to protect the sensor.

Strain-Gage Based Pressure Cell

This design is the technology behind the

Rosemount Omega cell differential pressure
transducer. When the transducer is mounted in a
housing complete with signal transmitting and
conditioning electronics it is called a transmitter.

The pressure transmitter typically conditions the

pressure signal and converts the signal to a 1-5
volt or the very popular and most widely used 4-
20 milliamp signal. As discussed earlier in this
book, the 4-20 mA signal does not vary with
change in resistance of wire or resistance of series
components. Later on this book the we will
continue this discussion of signals and ohm’s law
applied to signal limitations.

Capacitance-Based Pressure Cell

The following table illustrates typical pressure ranges for various pressure transducers. Consult the
manufacture’s technical data for actual ranging capabilities and limitation of the instrument for the
application of the process.

This range table is only

offered as a guideline.
Consult manufacturer.

Electronic Pressure Sensor Ranges

Industrial Instrumentation 15 Bryon Lewis

Level 1 – 2002 all rights reserved
 Section 2 – Basic Instruments

Introduction to ∆ Pressure measurements with Flow and Level applications

The most common measurement used in most industrial processes is pressure. The pressure
measurement can be used to measure flow, level, mass, weight, and work. This type of
measurement is an inferred measurement. An inferred measurement is proportional to the
potential and kinetic energy in the system.

By first learning the methods to measure pressure, differential pressure, and temperature it is
possible to control about any type of industrial process.

Example of a Static Pressure Transducer

Measuring the flow of liquids is a critical need in many industrial plants. In some operations, the ability
to conduct accurate flow measurements is so important that it can make the difference between making
a profit or taking a loss.

With most liquid flow measurement instruments, the flow rate is determined inferentially by measuring
the liquid's velocity or the change in kinetic energy. Bernoulli determined that an increase in the velocity
of a flowing fluid increases its kinetic energy while decreasing its static energy. It is for this reason that
a flow restriction causes an increase in the flowing velocity and also causes a drop in the static pressure
of the flowing fluid.

Velocity depends on the pressure differential that is forcing the liquid through a pipe or conduit. Because
the pipe's cross-sectional area is known and remains constant, the average velocity is an indication of
the flow rate. The basic relationship for determining the liquid's flow rate in such cases is: Q = V x A

Laminar and turbulent flow are two types normally

encountered in liquid flow Measurement operations. Most
applications involve turbulent flow with R values above
3000. Viscous liquids usually exhibit laminar flow with R
values below 2000. The transition zone between the two
levels may be either laminar or turbulent.

The flow rate and the specific gravity are the inertia
forces, and the pipe diameter and viscosity are the drag
forces. The pipe diameter and the specific gravity remain
constant for most liquid applications.

Industrial Instrumentation 16 Bryon Lewis

Level 1 – 2002 all rights reserved
 Section 2 – Basic Instruments

Flow measurements

Measuring the flow of liquids is a critical need in many industrial plants. In some operations, the ability
to conduct accurate flow measurements is so important that it can make the difference between making
a profit or taking a loss.

With most liquid flow measurement instruments, the flow rate is determined inferentially by measuring
the liquid's velocity or the change in kinetic energy. Bernoulli determined that an increase in the velocity
of a flowing fluid increases its kinetic energy while decreasing its static energy. It is for this reason that
a flow restriction causes an increase in the flowing velocity and also causes a drop in the static pressure
of the flowing fluid.

Velocity depends on the pressure differential that is forcing the liquid through a pipe or conduit. Because
the pipe's cross-sectional area is known and remains constant, the average velocity is an indication of
the flow rate. The basic relationship for determining the liquid's flow rate in such cases is: Q = V x A

Q = liquid flow through the pipe

V = average velocity of the flow
A = cross-sectional pipe area
ß = beta ratio
(pipediameter/orfice diameter)
2
Ke = kinetic energy = V /2g
2=
V Δ P/SG

Figure 1-2

The permanent pressure loss through a flowmeter is expressed either as a percentage of the total
pressure drop or in units of velocity heads, calculated as V2/2g, where V is the flowing velocity and g is
the gravitational acceleration (32.2 feet/second2 or 9.8 meters/second2 at 60° latitude). For example, if
the velocity of a flowing fluid is 10 ft/s, the velocity head is 100/64.4 = 1.55 ft. If the fluid is water, the
velocity head corresponds to 1.55 ft of water (or 0.67 psi). If the fluid is air, then the velocity head
corresponds to the weight of a 1.55-ft column of air.

The permanent pressure loss through various flow elements can be expressed as a percentage of the
total pressure drop (Figure 1-1), or it can be expressed in terms of velocity heads. The permanent
pressure loss through an orifice is four velocity heads; through a vortex shedding sensor, it is two;
through positive displacement and turbine meters, about one; and, through flow venturis, less than 0.5
heads. Therefore, if an orifice plate (Figure 1-2) with a beta ratio of 0.3 (diameter of the orifice to that
of the pipe) has an unrecovered pressure loss of 100 in H 2O, a venturi flow tube could reduce that
pressure loss to about 12 in H2O for the same measurement.

Industrial Instrumentation 17 Bryon Lewis

Level 1 – 2002 all rights reserved
 Section 2 – Basic Instruments
Flow measurements

Differential Pressure measurements

Measuring the flow of liquids is a critical need in many industrial plants. In some operations, the ability
to conduct accurate flow measurements is so important that it can make the difference between
making a profit or taking a loss.

The calculation of fluid flow rate by reading the pressure loss across a pipe restriction is perhaps the
most commonly used flow measurement technique in industrial applications The pressure drops
generated by a wide variety of geometrical restrictions or "head" flow elements come in a wide variety
of configurations, each with specific application strengths and weaknesses. Variations on the theme of
differential pressure (d/p) flow measurement include the use of pitot tubes and variable-area meters
(rotameters).

The pressure differential (h) developed by the flow element is measured, and the velocity (V), the
volumetric flow (Q) and the mass flow (W) can all be calculated using the following generalized
formulas:

k is the discharge coefficient of the element (which also reflects the units of measurement), A is the
cross-sectional area of the pipe's opening, and D is the density of the flowing fluid. The discharge
coefficient k is influenced by the Reynolds number (see Figure 1-5) and by the "beta ratio," the ratio
between the bore diameter of the flow restriction and the inside diameter of the pipe.

The d/p transmitter

should be located as
close to the primary
element as possible.
Lead lines should be
as short as possible
and of the same
diameter. In clean
liquid service, the
minimum diameter is
G", in condensable
vapor service, the
minimum diameter is
0.4". In steam service,
the horizontal lead
lines should be kept as

possible and be tilted so that condensate can drain back into the pipe. In clean liquid or gas service, the
lead lines can be purged through the d/p cell vent or drain connections, and they should
be flushed for several minutes to remove all air from the lines. Entrapped air can
offset the zero calibration.
Industrial Instrumentation 18 Bryon Lewis
Level 1 – 2002 all rights reserved
 Section 2 – Basic Instruments
Flow measurements

Orifice plates

The orifice plate is commonly used in clean liquid, gas, and steam service. It is available for all pipe
sizes, and if the pressure drop it requires is free, it is very cost-effective for measuring flows in larger
pipes (over 6" diameter). The orifice plate is also approved by many standards organizations for the
custody transfer of liquids and gases.

The traditional orifice is a thin circular plate (with a tab for handling and for data), inserted into the
pipeline between the two flanges of an orifice union. This method of installation is cost-effective, but it
calls for a process shutdown whenever the plate is removed for maintenance or inspection.

In order for the velocity profile to fully develop (and the pressure drop to be predictable), straight pipe
runs are required both up- and downstream of the d/p element. The amount of straight run required
depends on both the beta ratio of the installation and on the nature of the upstream components in the
pipeline.

For example, when a single 90° elbow precedes an orifice plate, the straight-pipe requirement ranges
from 6 to 20 pipe diameters as the diameter ratio is increased from 0.2 to 0.8. In order to reduce the
straight run requirement, flow straighteners (Figure 2-2) such as tube bundles, perforated plates, or
internal tabs can be installed upstream of the primary element.

Metering errors due to incorrect installation of the primary element can be substantial (up to 10%).
Causes of such errors can be the condition of the mating pipe sections, insufficient straight pipe runs,
and pressure tap and lead line design errors.

To minimize error (and the need for density correction) when dealing with compressible fluids, the ratio
of differential pressure (h) divided by upstream pressure (P) should not exceed 0.25 (measured in the
same engineering units).
Industrial Instrumentation 19 Bryon Lewis
Level 1 – 2002 all rights reserved
 Section 2 – Basic Instruments
Flow measurements

Differential pressure meters

Venturi tubes are available in sizes up to 72", and can pass 25 to 50% more flow than an orifice
with the same pressure drop. The short form venturi (Figure 2-7A). The universal venturi (Figure 2-7B).
The flow nozzle (Figure 2-7C) is often been used to measure high flowrates of superheated steam.

Pitot Tubes are used to measure air flow in pipes, ducts, and stacks, and liquid flow in pipes, weirs,
and open channels for industrial applications (Figure 2-9).

Rotameter it’s main application is to control small gas or liquid purge streams.

Industrial Instrumentation 20 Bryon Lewis

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 Section 2 – Basic Instruments
Flow measurements

Mechanical flowmeters

Positive displacement meters provide high accuracy (±0.1% of actual flow rate in some
cases) and good repeatability (as high as 0.05% of reading). Accuracy is not affected by pulsating flow
unless it entrains air or gas in the fluid. PD meters do not require a power supply for their operation and
do not require straight upstream and downstream pipe runs for their installation. The process fluid must
be clean. Particles greater than 100 microns in size must be removed by filtering. PD meters operate
with small clearances between their precision-machined parts; wear rapidly destroys their accuracy.

Turbine meters consists of a multi-bladed rotor mounted at right angles to the flow and
suspended in the fluid stream on a free-running bearing. The diameter of the rotor is very slightly less
than the inside diameter of the metering chamber, and its speed of rotation is proportional to the
volumetric flow rate. Turbine rotation can be detected by solid state devices (reluctance, inductance,
capacitive and Hall-effect pick-ups) or by mechanical sensors (gear or magnetic drives).

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 Section 2 – Basic Instruments
Flow measurements
Electronic flowmeters
Magmeters can detect the flow of conductive fluids only.The magnetic flowmeter consists of a non-
magnetic pipe lined with an insulating material. A pair of magnetic coils is situated as shown in Figure
4-1, and a pair of electrodes penetrates the pipe and its lining.
If a conductive fluid flows through a pipe of diameter (D) through a magnetic field density (B)
generated by the coils, the amount of voltage (E) developed across the electrodes--as predicted by
Faraday's law--will be proportional to the velocity (V) of the liquid (E=kV). The voltage that develops
at the electrodes is a millivolt signal. This signal is typically converted into a standard current (4-20 mA)
or frequency output (0-10,000 Hz) at or near the flowtube.

Vortext meters use piezoelectric or capacitance-type sensors to detect the pressure oscillation
around the bluff body and respond to the pressure oscillation with a low voltage output signal which
has the same frequency as the oscillation.
Vortex shedding frequency is directly proportional to the velocity of the fluid in the pipe, and therefore
to volumetric flow rate. The shedding frequency is independent of fluid properties such as density,
viscosity, conductivity, etc., except that the flow must be turbulent for vortex shedding to occur. The
relationship between vortex frequency and fluid velocity is St = f(d/V) Where St is the Strouhal
number, f is the vortex shedding frequency, d is the width of the bluff body, B is
the blockage factor and V is the average fluid velocity. Q = AV = (A f d B)/St

Industrial Instrumentation 22 Bryon Lewis

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 Section 2 – Basic Instruments
Flow measurements
Ultra Sonic Meters
The speed at which sound propagates in a fluid is dependent on the fluid's density. If the density is
constant, however, one can use the time of ultrasonic passage (or reflection) to determine the velocity
of a flowing fluid.
Some transducer systems
that operate in the shear-
mode, sending a single
pulse and receiving a
single pulse in return.
Narrow-beam systems
are commonly subject to
walk-away (the signal
completely missing the
downstream transducer).
The wide-beam systems
overcome the beam
refraction and work
better in changing liquid
density and temperature.

Doppler Shift flowmeter transducers operate at 0.640 MHz (in clamp-on designs) and at 1.2
MHz in wetted sensor designs. The transducer sends an ultrasonic pulse or beam into the flowing
stream. The sound waves are reflected back by such acoustical discontinuities as particles, entrained
gas bubbles, or even by turbulence vortices (Figure 4-7A). For clamp-on designs, measurement
inaccuracy ranges from ±1% to ±5% full scale (FS).
The meter detects the velocity of the discontinuities, rather than the velocity of the fluid, in calculating
the flow rate. The flow velocity (V) can be determined by: V = (f0-f1)Ct/2f0 cos(a). Where Ct is the
velocity of sound inside the transducer, f0 is the transmission frequency, f1 is the reflected frequency,
and a is the angle of the transmitter and receiver crystals with respect to the pipe axis. Because Ct
/2f0cos(a) is a constant (K), the relationship can be simplified to: V = (f0-f1)K
Thus, flow velocity V (ft/sec) is directly proportional to the change in frequency. The flow (Q in gpm) in
a pipe having a certain inside diameter (ID in inches) can be obtained by:
Q = 2.45V(ID)2 = 2.45[(f0-f1)K](ID)2

Transit Time Measurement, the time of flight of the ultrasonic signal is measured between
two transducers--one upstream and one downstream (Figure 4-7B). The difference in elapsed time
going with or against the flow determines the fluid velocity. When the flow is zero, the time for the
signal T1 to get to T2 is the same as that required to get from T2 to T1. When there is flow, the effect is
to boost the speed of the signal in the downstream direction, while decreasing it in the upstream
direction. The flowing velocity (Vf) can be determined by the following equation: Vf = Kdt/TL . where
K is a calibration factor for the volume and time units used, dt is the time differential between
upstream and downstream transit times, and TL is the zero-flow transit time.
Industrial Instrumentation 23 Bryon Lewis
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 Section 2 – Basic Instruments
Flow measurements
Mass flowmeters
Mass flow measurement is the basis of most recipe formulations, material balance determinations,
and billing and custody transfer operations throughout industry. With these being the most critical flow
measurements in a processing plant, the reliability and accuracy of mass flow detection is very
important.

In the past, mass flow was often calculated from the outputs of a volumetric flowmeter and a
densitometer. Density was either directly measured (Figure 5-1A), or was calculated using the outputs of
process temperature and pressure transmitters. These measurements were not very accurate, because
the relationship between process pressure or temperature and density are not always precisely known--
each sensor adds its own separate error to the overall measurement error, and the speed of response of

Figure 5.1
such calculations is usually not sufficient to detect step changes in flow.
One of the early designs of self-contained mass flowmeters operated using angular momentum (Figure
5-1B). It had a motor-driven impeller that imparted angular momentum (rotary motion) by accelerating
the fluid to a constant angular velocity. The higher the density, the more angular momentum was
required to obtain this angular velocity. Downstream of the driven impeller, a spring-held stationary
turbine was exposed to this angular momentum. The resulting torque (spring torsion) was an indication
of mass flow.

These meters all had moving parts and complex mechanical designs. First developed for the
measurement of aircraft fuel, some are still in use. However, because of their complex nature and high
maintenance costs, they are gradually being replaced by more robust and less maintenance-demanding
designs.

Mass flow also can be measured by batch weighing or by combining an accurate level sensor with a
densitometer. Another method is to mount two d/p transmitters on the lower part of an atmospheric
tank at different elevations. In this case, the output of the top d/p cell will vary with the level in the
tank, while the lower one will measure the hydrostatic head over a fixed elevational distance. This
pressure differential yields the density of the material in the tank. Such systems have been used to
measure the total mass flow of slurries.

Industrial Instrumentation 24 Bryon Lewis

Level 1 – 2002 all rights reserved
 Section 2 – Basic Instruments
Flow measurements
Mass flowmeters
Coriolis Mass Flowmeters artificially introduce a Coriolis acceleration into the flowing stream
and measure mass flow by detecting the resulting angular momentum.

When a fluid is flowing in a pipe and it is subjected to Coriolis acceleration through the mechanical
introduction of apparent rotation into the pipe, the amount of deflecting force generated by the Coriolis
inertial effect will be a function of the mass flow rate of the fluid. If a pipe is rotated around a point
while liquid is flowing through it (toward or away from the center of rotation), that fluid will generate an
inertial force (acting on the pipe) that will be at right angles to the direction of the flow.

Figure 5-2

With reference to Figure 5-2, a particle (dm) travels at a velocity (V) inside a tube (T). The tube is
rotating about a fixed point (P), and the particle is at a distance of one radius (R) from the fixed point.
The particle moves with angular velocity (ω) under two components of acceleration, a centripetal
acceleration directed toward P and a Coriolis acceleration acting at right angles to ar:
ar (centripetal) = ω2r
at (Coriolis) = 2ωv
In order to impart the Coriolis acceleration (at) to the fluid particle, a force of at (dm) has to generated
by the tube. The fluid particle reacts to this force with an equal and opposite Coriolis force:
Fc = at(dm) = 2ωv(dm)
Then, if the process fluid has density D and is flowing at constant speed inside a rotating tube of cross-
sectional area A, a segment of the tube of length x will experience a Coriolis force of magnitude:
Fc = 2ωvDAx
Because the mass flowrate is dm = DvA, the Coriolis force Fc = 2w(dm)x and, finally:

Mass Flow = Fc/(2ωx)

This is how measurement of the Coriolis force exerted by the flowing fluid on the rotating tube can
provide an indication of mass flowrate. Naturally, rotating a tube is not practical when building a
commercial flowmeter, but oscillating or vibrating the tube can achieve the same effect. Coriolis
flowmeters can measure flow through the tube in either the forward or reverse directions.
In most designs, the tube is anchored at two points and vibrated between these anchors.
This configuration can be envisioned as vibrating a spring and mass assembly. Once placed in motion, a
spring and mass assembly will vibrate at its resonant frequency, which is a function of the mass of that
assembly. This resonant frequency is selected because the smallest driving force is needed to keep the
filled tube in constant vibration.

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 Section 2 – Basic Instruments
Flow measurements
Tube Designs can be of a curved or straight form, and some designs can also be self-draining when
mounted vertically (Figure 5-3). When the design consists of two parallel tubes, flow is divided into two
streams by a splitter near the meter's inlet and is recombined at the exit. In the single continuous tube
design (or in two tubes joined in series), the flow is not split inside the meter.
In either case, drivers vibrate the tubes. These drivers consist of a coil connected to one tube and a
magnet connected to the other. The transmitter applies an alternating current to the coil, which causes
the magnet to be attracted and repelled by turns, thereby forcing the tubes towards and away from one
another. The sensor can detect the position, velocity, or acceleration of the tubes. If electromagnetic
sensors are used, the magnet and coil in the sensor change their relative positions as the tubes vibrate,
causing a change in the magnetic field of the coil. Therefore, the sinusoidal voltage output from the coil
represents the motion of the tubes.
When there is no flow in a two- tube design (Figure 5-3A), the vibration caused by the coil and magnet
drive results in identical displacements at the two sensing points (B1 and B2). When flow is present,
Coriolis forces act to produce a secondary twisting vibration, resulting in

Figure 5-3
a small phase difference in the relative motions. This is detected at the sensing points. The deflection of
the tubes caused by the Coriolis force only exists when both axial fluid flow and tube vibration are
present. Vibration at zero flow, or flow without vibration, does not produce an output from the meter.
The natural resonance frequency of the tube structure is a function of its geometry, materials of
construction, and the mass of the tube assembly (mass of the tube plus the mass of the fluid inside the
tube). The mass of the tube is fixed. Since mass of the fluid is its density (D) multiplied by its volume
(which is also fixed), the frequency of vibration can be related to the density of the process fluid (D).
Therefore, the density of the fluid can be determined by measuring the resonant frequency of oscillation
of the tubes. (Note that density can be measured at zero flow, as long as the tubes are filled with fluid
and vibrating.) can detect the flow of conductive fluids only.The magnetic flowmeter consists of a non-
magnetic pipe lined with an insulating material. A pair of magnetic coils is situated as shown in Figure 4-
1, and a pair of electrodes penetrates the pipe and its lining.
Industrial Instrumentation 26 Bryon Lewis
Level 1 – 2002 all rights reserved
 Section 2 – Basic Instruments
Flow measurements
Strain Gauges for weight measurement

The most common way to measure weight is with a strain gauge transducer. The “S” hook shaped load cell
or the cantilever load cell are the most popular used in industrial measurement.

NOTE:
Always replace the load cell
with a dummy load cell or
attach a #6 awg wire from
beam to beam where the
load cell is to be mounted
between these beams, when
any welding is to be done.

This will prevent the load cell

form being damaged due to
high current running through
the metal of the load cell
and burning out the strain
gauges.
Cantilever Load Cells Reduce Staying Requirements

The following illustration on the left shows a typical weighting platform such as one used to measure the
weight of a container or vehicle. The illustration on the right shows the cantilever load cell used to
measure the weight of mixing materials either for a continuous or batching process.

The “S” type strain gauge could be used for a batching process similar to that on the right. The hopper
would be suspended from the above structure and the strain gauge would be connected in between the
above structure and the hopper. The weight of the hopper would be measured by the strain on the
metal making up the “S” shaped strain gauge.

End-Loaded Shear-Beam Installation Load Cell Configurations for Solids Batching

Important note: Each load cell measuring the tank weight must be of equal resistance when the tank
is in place. This is why a summing box with trimming resistors is used. The trimming resistor is put in
series with the load cell’s strain gauge. After calibrating the trimming resistor each load cell will have the
exact same resistance. The voltage drop across each load cell will be the same for an equally distributed
load on the tank. These voltages will be summed to produce the total force on the tank. The tank’s tare
weight will equal 0% when the transmitter is calibrated. ISO (international standards origination)
weights will be placed on the tank and the span for 100% will be calibrated.

Industrial Instrumentation 27 Bryon Lewis

Level 1 – 2002 all rights reserved
 Section 2 – Basic Instruments
Level Measurments
The relationship between level and tank volume is a function of the cross-sectional shape of the tank.
With vertical tanks, this relationship is linear, while with horizontal or spherical vessels, it is a non-linear
relationship (Figure 6-1).

If the level in a tank is to be inferred using hydrostatic pressure measurement, it is necessary to use
multi-transmitter systems when it is desirable to:
Detect the true level, while either the process temperature or density varies;
Measure both level and density; and
Measure the volume and the mass (weight) in the tank.

By measuring one temperature and three pressures, the system shown in Figure 6-2 is capable of
simultaneously measuring volume (level), mass (weight), and density, all with an accuracy of 0.3% of
full span.

Sludge, Foam, & Molten Metals

When the process fluid is a
sludge, slurry, or a highly
viscous polymer, and the
goal is to detect the level at
one point, the design
shown in Figure 6-5A is
commonly considered. The
ultrasonic or optical signal
source and receiver
typically are separated by
more than six inches so
that the process fluid drains
freely from the intervening
space. After a high-level
episode, an automatic
washing spray is activated.

Industrial Instrumentation 28 Bryon Lewis

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 Section 2 – Basic Instruments
Level Measurements

Pressure/Density Level Instrumentation

One of the primary principles underlying industrial level measurement is that different materials and
different phases of the same material have different densities. This basic law of nature can be utilized to
measure level via differential pressure (that at the bottom of the tank relative to that in the vapor space
or to atmospheric pressure) or via a float or displacer that depends on the density differences between
phases.

Level measurement based on pressure measurement is also referred to as hydrostatic tank gaging
(HTG). It works on the principle that the difference between the two pressures (d/p) is equal to the
height of the liquid (h, in inches) multiplied by the specific gravity (SG) of the fluid (see Figure 7-1):

By definition, specific gravity is the liquid's density divided by the density of pure water at 68° F at
atmospheric pressure. A pressure gage or d/p cell can provide an indication of level (accurate to better
than 1%) over wide ranges, as long as the density of the liquid is constant. When a d/p cell is used, it
will cancel out the effects of barometric pressure variations because both the liquid in the tank and the
low pressure side of the d/p cell are exposed to the pressure of the atmosphere (Figure 7-1B).
Therefore, the d/p cell reading will represent the tank level.

Dry & Wet Leg Designs

When measuring the level in pressurized tanks, the same d/p cell designs (motion balance, force
balance, or electronic) are used as on open tanks. It is assumed that the weight of the vapor column
above the liquid is negligible. On the other hand, the pressure in the vapor space cannot be neglected,
but must be relayed to the low pressure side of the d/p cell. Such a connection to the vapor space is
called a dry leg, used when process vapors are non-corrosive, non-plugging, and when their
condensation rates, at normal operating temperatures, are very low (Figure 7-1C). A dry leg enables the
d/p cell to compensate for the pressure pushing down on the liquid's surface, in the same way as the
effect of barometric pressure is canceled out in open tanks.

It is important to keep this reference leg dry because accumulation of condensate or other liquids would
cause error in the level measurement. When the process vapors condense at normal ambient
temperatures or are corrosive, this reference leg can be filled to form a wet leg. If the process
condensate is corrosive, unstable, or undesirable to use to fill the wet leg, this reference leg can be filled
with an inert liquid.

In this case, two factors must be considered. First, the specific gravity of the inert fluid (SG wl) and the
height (hwl) of the reference column must be accurately determined, and the d/p cell must be depressed
by the equivalent of the hydrostatic head of that column [(SGwl)(hwl)]. Second, it is desirable to provide
a sight flow indicator at the top of the wet leg so that the height of that reference leg can be visually
checked.

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 Section 2 – Basic Instruments
Level Measurements

Pressure D/P cells

The motion balance cell is well suited for remote locations where instrument air or electric power are not
available. If a bellows is used as the sensing element in a motion balance d/p cell, an increase in the
pressure on either side causes the corresponding bellows to contract (Figure 7-3A). The bellows is
connected to a linkage assembly that converts the linear motion of the bellows into a rotary indicator
motion, which can be calibrated to indicate the tank level.

In a force-balance type of d/p cell, the sensing element (often a diaphragm) does not move. A force bar
is provided to maintain the forces acting on the diaphragm in equilibrium (Figure 7-3B). In pneumatic
d/p cells, this is often achieved by the use of a nozzle and flapper arrangement that guarantees that the
pneumatic output signal will always be proportional to the differential pressure across the cell. The
output of pneumatic d/p cells is linear and is usually ranged from 3 to 15 psig. The levels represented by
such transmitted signals (pneumatic, electronic, fiberoptic or digital) can be displayed on local indicators
or remote instruments. Pneumatic transmitters require a compressed air (or nitrogen) supply.

Electronic d/p cells provide ±0.5% of span or better precision typically conveyed via a 4-20 mA
signal. The range of these simple and robust cells can be as narrow as a draft range of 0- 1/2 inH2O or
as wide as 0-1,000 psid. Some electronic d/p cells can operate at line pressures up to 4,500 psig at
250°F. The drift and inaccuracy of some of these units have been tested for periods of up to 30 months,
and the errors did not exceed the ±0.5% of span limit.

Pressure Repeater If it is desired to keep the process vapors in the tank, a pressure repeater can
be used. These devices repeat
the vapor pressure (or vacuum)
and send out an air signal
identical to that of the vapor
space. The measurement side of
the repeater is connected to the
vapor space and its output signal
to the low pressure side of the
d/p cell. If the tank connection is
subject to material build-up or
plugging, extended diaphragm
Type 1:1 repeaters can be
considered for the service (Figure
7-2).

Industrial Instrumentation 30 Bryon Lewis

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 Section 2 – Basic Instruments
Level Measurements

Bubbler Tubes

Bubbler Tubes provide a simple and inexpensive but less accurate (±1-2%) level measurement system
for corrosive or slurry-type applications. Bubblers use compressed air or an inert gas (usually nitrogen)
introduced through a dip pipe (Figure 7-4A). Gas flow is regulated at a constant rate (usually at about
500 cc/min). A differential pressure regulator across a rotameter maintains constant flow, while the tank
level determines the back-pressure. As the level drops, the back-pressure is proportionally

reduced and is read on a pressure gage calibrated in percent level or on a manometer or transmitter.
The dip pipe should have a relatively large diameter (about 2 in.) so that the pressure drop is negligible.
The bottom end of the dip pipe should be located far enough above the tank bottom so that sediment or
sludge will not plug it. Also, its tip should be notched with a slot or "V" to ensure the formation of a
uniform and continuous flow of small bubbles. An alternative to locating the dip pipe in the tank is to
place it in an external chamber connected to the tank.

In pressurized tanks, two sets of dip pipes are needed to measure the level (Figure 7-4B). The two back-
pressures on the two dip pipes can be connected to the two sides of a u-tube manometer, a differential
pressure gage or a d/p cell/transmitter. The pneumatic piping or tubing in a bubbler system should be
sloped toward the tank so that condensed process vapors will drain back into the tank if purge pressure
is lost. The purge gas supply should be clean, dry, and available at a pressure at least 10 psi greater
than the expected maximum total pressure required (when the tank is full and the vapor pressure is at
its maximum).

An alternative to a continuous bubbler is to use a hand pump (similar to a bicycle tire pump) providing
purge air only when the level is being read.

Bubblers do consume inert gases, which can later accumulate and blanket processing equipment. They
also require maintenance to ensure that the purge supply is always available and that the system is
properly adjusted and calibrated. When all factors are considered, d/p cells typically are preferred to
bubblers in the majority of applications.

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 Section 2 – Basic Instruments
Level Measurements

Floats and Displacers

Floats are motion balance devices that move up and down with liquid level. Displacers are force balance
devices (restrained floats), whose apparent weight varies in accordance with Archimedes' principle: the
buoyant force acting on an object equals the weight of the fluid displaced. As the level changes around
the stationary (and constant diameter) displacer float, the buoyant force varies in proportion and can be
detected as an indication of level. Regular and displacer floats are available as both continuous level
transmitters and point-sensing level switches.

In industrial applications, displacer floats are often favored because they do not require motion.
Furthermore, force can often be detected more accurately than position. However, regular floats are also
used, mostly for utilities and in other secondary applications.

Float switches
The buoyant force
available to operate a
float level switch (that
is, its net buoyancy) is
the difference between
the weight of the
displaced fluid (gross
buoyancy) and the
weight of the float.
Floats are available in
spherical (Figure 7-
6A), cylindrical (Figure
7-6B), and a variety of
other shapes (Figure 7-
6C). They can be made
out of stainless steel,
Teflon®, Hastelloy,
Monel, and various
plastic materials.

Typical temperature and pressure ratings are -40 to 80°C (-40 to 180° F) and up to 150 psig for rubber
or plastic floats, and -40 to 260°C (-40 to 500°F) and up to 750 psig for stainless steel floats. Standard
float sizes are available from 1 to 5 inches in diameter. Custom float sizes, shapes, and materials can be
ordered from most manufacturers. The float of a side-mounted switch is horizontal; a permanent
magnet actuates the reed switch in it (Figure 7-6B).

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 Section 2 – Basic Instruments
Level Measurements

Floats switches continued

Floats should always be lighter than the minimum expected specific gravity (SG) of the process fluid. For
clean liquids a 0.1 SG difference might suffice, while for viscous or dirty applications, a difference of at
least 0.3 SG is recommended. This provides additional force to overcome the resistance due to friction
and material build-up. In dirty applications, floats should also be accessible for cleaning.

Floats can be attached to mechanical arms or levers and can actuate electrical, pneumatic, or
mechanical mechanisms. The switch itself can be mercury (Figures 7-6A and 7-6C), dry contact (snap-
action or reed type, shown in Figure 7-6B), hermetically sealed, or pneumatic. The switch can be used

to actuate a visual display, annunciator, pump, or valve. The electric contacts can be rated light-duty
(10-100 volt amps, VA) or heavy-duty (up to 15 A @ 120 Vac). If the switch is to operate a circuit with a
greater load than the rating of the switch contacts, an interposing relay needs to be inserted. If the
switch is to be inserted in a 4-20 mA dc circuit, gold-plated dry contacts should be specified

In top (or bottom) mounted magnetic float switches (Figure 7-8B), the magnet is in the cylindrical float
that travels up or down on a short vertical guide tube containing a reed switch. The float's motion is
restrained by clips and can be only 1/2 in or less. These float and guide tubes are available with multiple
floats that can detect several levels. The switch assembly itself can be either inserted directly into the
tank or side-mounted in a separate chamber.

A magnetic piston operated switch also can be mounted in an external chamber (Figure 7-8C). As the
magnet slides up and down inside a non-magnetic tube, it operates the mercury switch outside the tube.
These switches are completely sealed and well suited for heavy duty industrial applications up to 900
psig and 400°C (750°F), meeting ASME code requirements.

These switches can be side, top, or cage mounted (Figure 7-9) and can serve both alarm and control
functions on steam drums, feedwater heaters, condensate pots, gas/oil separators, receivers, and
accumulators. Light-duty caged float switches are also available for service ratings up to 250 psig at
200°C (400°F) and 400 psig at 40°C (100°F)--suitable for many boilers, condensate receivers, flash
tanks, day tanks, holding tanks, and dump valve controls. The cages can be provided with level gages.
Multiple switches are available for multiple-switching applications such as boiler level alarms and
controls.

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 Section 2 – Basic Instruments
Level Measurements

Displacer level transmitters and switches

Whereas a float usually follows the liquid level, a displacer remains partially or completely submerged.
As shown in Figure 7-10A, the apparent weight of the displacer is reduced as it becomes covered by
more liquid. When the weight drops below the spring tension, the switch is actuated. Displacer switches
are more reliable than regular floats on turbulent, surging, frothy, or foamy applications. Changing their
settings is easy because displacers can be moved anywhere along the suspension cable (up to 50 ft).
These switches are interchangeable between tanks because changing the tension of the support spring
can accommodate differences in process density, and a force of only one ounce is needed.

Testing the proper functioning of a regular float switch may require filling the tank to the actuation level,
while a displacer switch can be tested simply by lifting a suspension (Figure 7-10A). Displacer switches
are available with heavy-duty cages and flanges for applications up to 5000 psig at 150°C (300°F),
suitable for use on hydraulic accumulators, natural gas receivers, high pressure scrubbers, and
hydrocarbon flash tanks.

Displacers are popular as level transmitters and as local level controllers, particularly in the oil and
petrochemical industries. However, they are not suited for slurry or sludge service because coating of
the displacer changes its volume and therefore its buoyant force. They are most accurate and reliable
for services involving clean liquids of constant density. They should be temperature-compensated,
particularly if variations in process temperature cause significant changes in the density of the process
fluid.
When used as a level transmitter, the displacer, which is always heavier than the process fluid, is
suspended from the torque arm. Its apparent weight causes an angular displacement of the torque tube
(a torsion spring, a frictionless pressure seal). This angular displacement is linearly proportional to the
displacer's weight (Figure 7-10B).
Standard displacer volume is 100 cubic inches and the most commonly used lengths are 14, 32, 48, and
60 in. (Lengths up to 60 ft are available in special designs.). Displacer units are available with both
pneumatic and electronic outputs and can also be configured as local, self-contained controllers. When
used in water service, a 100 cubic inch displacer will generate a buoyant force of 3.6 pounds. Therefore,
standard torque tubes are calibrated for a force range of 0-3.6 lbf and thin-walled torque tubes for a 0-
1.8 lbf range.

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 Section 2 – Basic Instruments
Level Measurements

Capacitive level transmitters and switches

Capacitance level detectors are also referred to as radio frequency (RF) or admittance level sensors.
They operate in the low MHz radio frequency range, measuring admittance of an alternating current (ac)
circuit that varies with level. In this chapter, the term capacitance level sensor will be used instead of RF
or admittance.

Figure 8-2

Figure 8-3

A capacitor consists of two conductors (plates) that are electrically isolated from one another by a
nonconductor (dielectric). When the two conductors are at different potentials (voltages), the system is
capable of storing an electric charge. The storage capability of a capacitor is measured in farads. As
shown in Figure 8-1, the capacitor plates have an area (A) and are separated by a gap (D) filled with a
nonconducting material (dielectric) of dielectric constant (K).

The dielectric constant of a substance is proportional to its conductivity. The lower the dielectric
constant, the lower the conductivity of the material (that is, the less conductive it is). Capacitance (C) is
calculated as: C = KA/D

If the area (A) of and the distance (D) between the plates of a capacitor remain constant, capacitance
will vary only as a function of the dielectric constant of the substance filling the gap between the plates.
If a change in level causes a change in the total dielectric of the capacitance system, because (as
illustrated in Figure 8-1B) the lower part of area (A) is exposed to a liquid (dielectric Kl) while the upper
part is in contact with a vapor (dielectric Kv, which is close to 1.0), the capacitance measurement will be
proportional to level.

Applying an RF signal between the conductive probe and the vessel wall results in a minute current flow
through the dielectric process material in the tank from the probe to the vessel wall. When the level in
the tank drops and the probe is exposed to the even less conductive vapors, the dielectric constant
drops.

This change is detected by the level switch's internal circuitry and translated into a change in the relay
state of the level switch. In the case of continuous level detectors (vertical probes), the output is not a
relay state, but a scaled analog signal.

The total area is the combined area of the level sensor probe and the area of the conductive vessel wall
(A = A1 + A2), and the distance (D) is the shortest distance between the sensor probe and the vessel
wall. Both of these values are fixed. The conductivity of vapors = (K1), the process material = (K2):
Change in C = (K2-K1)(A/D)
The sensitivity of a capacitance sensor is expressed in pico-farads (pF). In most level-sensing
applications, the reference material is air (K1 = 1.0). Table 7 gives the K2 values of a variety of process
materials. As the dielectric constant of the process material gets close to that of air (K 2) the
measurement becomes more difficult.

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 Section 2 – Basic Instruments
Level Measurements

Radiation-Based Level Gages

An entire class of level instrumentation devices is based on a material's tendency to reflect or absorb
radiation. For continuous level gages, the most common types of radiation used are radar/microwave,
ultrasonic, and nuclear.

Both radar signals and microwaves travel at the speed of light, but are distinguished by their frequencies
(FM radio broadcast frequency is from 88 to 108 MHz, while microwaves range from 1-300 GHz) and by
their power levels (radar is around 0.01 mW/cm2, while microwaves range from 0.1-5 mW/cm2).
Because microwaves operate at a higher energy level, they can withstand more coating than can radar-
type sensors.
Radar sensors consist of a transmitter, an antenna, a receiver with signal processor, and an operator
interface. The transmitter is mounted on top of the vessel. Its solid-state oscillator sends out an
electromagnetic wave (using a selected carrier frequency and waveform) aimed downward at the
surface of the process fluid in the tank. The frequency used is typically 10 GHz.

The signal is radiated by a parabolic dish or horn-type antenna (Figure 9-1A) toward the surface of the
process liquid (Figure 1B). A portion is reflected back to the antenna, where it is collected and routed to
the receiver. Here, a microprocessor calculates the time of flight and calculates the level. Time of flight
is the period between the transmission of the radar pulse and the reception of the return echo. It is
determined by the radar detector, which is simultaneously exposed to both the sent and the reflected
signal. The detector output is based on the difference.

The frequency-modulated (FM) signal varies from 0 to 200 Hz as the distance to the process fluid
surface varies between 0 and 200 ft. Because this measurement takes place in the frequency domain, it
is reasonably free of noise interference.
The depth of the vapor space (the distance between the datum point and the level in the tank, identified
as "d" in Figure 9-1B) is calculated from the time of flight (t) and the speed of light (c = 186,000
miles/sec): d = t/2c

The level (L in Figure 9-1B) is calculated by figuring the difference between the total tank height (E) and
the vapor space depth (d): L = E-d

Knowing the signal velocity (c) and the dielectric constant (dc) of the vapor (that is, the relative ability
of the vapor to oppose and reflect electromagnetic waves), the velocity of the radar wave transmission
0.5
(V) can be calculated: V = c/(dc)

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 Section 2 – Basic Instruments
Level Measurements

Nuclear Level Gages

The penetrating power of nuclear radiation is identified by its photon energy, expressed in electron volts
(eV) and related to wavelength (Figure 9-7). The most common isotope used for level measurement is
Cesium 137, which has a photon energy level of 0.56 MeV. As any isotope decays, it loses strength--the
time it takes to lose half of its strength is called its half-life. In about 5 years, the source must be
replaced. This means not only the expense of purchasing a new source, but also the cost of disposing of
the old one.

Gamma rays exhibited mysterious properties--they could pass through a seemingly solid, impenetrable
mass of matter. In the passage, however, the gamma rays lost some of their intensity. The rays were
predictably affected by the specific gravity and total thickness of the object, and by the distance
between the gamma ray source and the detector.

For example, if radiation from Cesium 137 is passing through an 3-in thick steel object, 92% of the
radiation energy will be absorbed and only 8% will be transmitted. Therefore, if the observer can hold all
variables except thickness constant, the amount of gamma transmission can be used to measure the
thickness of the object. Assuming that the distance between the source and detector does not change,
an accurate measurement of either thickness (level), or, if thickness dose not change, then of the
density of a process material.
NOTE:
Calibration and the
opening of nuclear
sensors require a
Nuclear Regulatory
Commission (NRC)
license.

Radiation level gages

typically are considered
when nothing else will
work, or when process
penetrations required
by a traditional level
sensor present a risk to
human life, to the
environment, or could
do major damage to
property. The liquids
and bulk solids
measured by nuclear
gages are among the
most dangerous, highly
pressurized, toxic,
corrosive, explosive,
and carcinogenic
materials around.

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 Section 2 – Basic Instruments

Temperature measurements

Temperature can be measured by a number of sensors types. All of them infer temperature
by sensing some change in a physical characteristic. Six types with which the engineer is likely
to come into contact are: thermocouples, resistive temperature devices (RTDs and
thermistors), bimetallic devices, and liquid expansion devices.

Thermocouples

Thermocouples consist essentially of two strips or wires

made of different metals and joined at one end.
Changes in the temperature at that juncture induce a
change in electromotive force (emf) between the other
ends. As temperature goes up, this output emf of the
thermocouple rises, though not necessarily linearly. This
voltage is measured and interpreted by a thermocouple
thermometer.

Thermocouples need what is referred to as a cold

junction reference. The cold junction is typically
an ice bath or an electronic circuit that will
produce a reference voltage the same as if the
thermocouple were in an ice bath.

This electronic ice bath or reference junction

circuit typically incorporates a 500-ohm precision
resistor to measure the ambient air temperature.

Sheathed thermocouple probes are available with one of three junction types: grounded,
ungrounded or exposed. At the tip of a grounded junction probe, the thermocouple wires are
physically attached to the inside of the probe wall.

Grounded Ungrounded Exposed

Common sheathing materials for thermocouples and RTDs

Maximum Application Atmosphere

Material
Temperature Oxidizing Hydrogen Vacuum Inert

900°C Very Very

304 SS Very Good Good
(1650° F) Good Good
Inconel 1148°C Very Very
Very Good Good
600 (2100°F) Good Good

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 Section 2 – Basic Instruments
Temperature measurements

TC THERMOCOUPLE RANGE USEFUL TC COLORS

TYPE MATERIAL FOR CALIB. RANGE
DEG F DEG F

Chromel (+)
E -300 to 1830 200 to 1650
Constantan (-)

Iron (+) 200 to 1400

J -320 to 1400
Constantan (-) (300 TO 800)

Chromel (+)
K -310 to 2500 200 to 2300
Alumel (-)

Platinum 13% Rhodium (+)

R 0 to 3100 1600 to 2640
Platinum (-)

Platinum 10% Rhodium (+)

S 0 to 3200 1800 to 2640
Platinum (-)

Copper (+)
T -310 to 750 -310-660
Constantan (-)

RTD (resistance temperature detector) & Thermistors

RTDs are typically a DIN 100 ohm resister that comes in a sheathing as previously disscussed
with thermocouples. At a glance they look the same but are much different. As the name
indicates, RTDs rely on resistance change in a metal, with the resistance rising more or less
linearly with temperature. Thermistors are based on resistance change in a ceramic
semiconductor; the resistance drops nonlinearly with temperature rise.

RTDs are more stable than thermocouples. On the other hand, as a class, their temperature
range is not as broad: RTDs operate from about -250 to 850°C whereas thermocouples range
from about -270 to 2,300°C. Thermistors have a more restrictive span, being commonly used
between -40 and 150°C, but offer high accuracy in that range.

Because RTDs are passive resistive devices,

you must pass a current through the RTD to
produce a voltage that can be measured. RTDs
have relatively low resistance (100 ohms at °C)
that changes only slightly with temperature
(less than 0.4 ohms/°C), so you might need to
use special configurations that minimize errors
from lead wire resistance.

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 Section 2 – Basic Instruments
Temperature Measurements
For example, consider the measurement of a 2-wire RTD. With this RTD, labeled R T, the voltage
drops caused by the excitation current, IEXC, passing through the lead resistance, RL, add to the
measured voltage, VO.

For longer lead length, the 4-wire RTD in Figure 4 is a better choice. With a 4-wire RTD, one pair
of wires carries the excitation current through the RTD; the other pair senses the voltage across
the RTD. Because only negligible current flows through the sensing wires, the lead resistance
error is very small.

2-Wire RTD Measurement 4-Wire RTD Measurement

Industrial Thermometers

A thermometer are used for temperature measurement in many

industrial applications. The liquid-in-glass design is typically used
due to low cost and ease of use.

Thermometers come in the four classes as follows…

Class I, Liquid-filled systems
These systems are filled with a liquid other than mercury. The
filling liquid is usally an inhert hydrocarbon such as xylene. The
liquid will typically expand six times that of mercury resulting in
smaller bulbs.

Class II, Vapor-filled systems

These systems are filled with a medium in both liquid and
gaseous form.
Class IIA - the bulb will be mostly filled with gas, capillary liquid.
Class IIB - the bulb will be mostly filled with liquid, capillary gas.
Class IIC - measures both side of ambient but use larger bulb.
Class IID – uses non-volatile fuild as a hydraulic transmitter.

Class III, Gas-filled systems

Nitrogen is the favorite fill because it is inhert and inexpensive.

Class IV, Mercury-filled systems

Mercury offers rapid response, accuracy and plenty of power for
operating control elements. The incompressible nature of
mercury makes temperature compensation less of a problem.

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 Section 2 – Basic Instruments
Temperature Measurements
Thermowells

Thermowells are used to insert the thermocouple or RTD into the process fluid or stream. This
way the process is isolated from the out side enviroment and the temperature sensor can be
removed or replaced without interrupting the process operation.

Screw Type Thermowells

TAPERED STEM WELL STRAIGHT STEM WELL

STEPPED STEM WELL LIMITED SPACE STEPPED STEM WELL

Flange Type Thermowells

STRAIGHT STEM FLANGED THERMOWELL TAPERED STEM SANITARY WELD

THERMOWELL

TAPERED STEM FLANGED THERMOWELL STEPPED STEM FLANGED THERMOWELL

STEPPED STEM SOCKET WELD STRAIGHT STEM VAN STONE

THERMOWELL THERMOWELL

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 Section 2 – Basic Instruments
Calibration Procedures

Calibration connection on transmitters

The following illustrates the basic pneumatic connection for calibration a transmitter standard or smart.

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 Section 2 – Basic Instruments
Calibration Procedures

Power Supply and Line Resistance

The following illustrates the basic electrical connection for calibration a transmitter standard or smart.

NOTE:
Ohm’s law still holds true here.
It is important to note the
listed maximum voltage of the
instrument as well. The supply
voltage of the power supply
cannot exceed the working or
rated voltage of the instrument
or damage will occur.

The typical supply voltage for

instrumentation is 24 volts DC
and 42 volts DC.

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 Section 2 – Basic Instruments
Calibration Procedures

Typical ranges for industrial instrumentation

The following illustrates the basic connection for calibration a transmitter (standard or smart).

Industrial Instrumentation 44 Bryon Lewis

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 Section 2 – Basic Instruments
Calibration Procedures
The following illustrates the electrical connections to transmitters for general calibration with smart
calibrator.

Constant Current 4-20 mA

Constant Voltage 1-5 volts

Bus Configuration

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 Section 2 – Basic Instruments
Calibration Procedures

Calibration calculations

Pressure measurements are zero or non-zero based. The illustration on the right is a zero based
measurement. That is the transmitter is level with the bottom of the fluid to be measured or at zero
elevation. The transmitter to the left is non-zero based. The transmitter is below the zero or bottom
elevation of the fluid to be measured.

The illustration on the left will have to be calibrated with what is referred to as an elevated zero. The
measurement will start at 2.0 PSI equal to 0% or 4 mA. The illustration on the right will start with 0.0 PSI
equal to 0% or 4 mA and the span is 7.0 PSI for 100% level in the tank.

The left tank will read the same span of 7.0 PSI at 100% for the same contents in the tank because the 2.0
PSI below the tank has already been subtracted from the measurement.

HEAD Pressure
Head pressure is independent of the tanks height or area. The transmitter measures head pressure. Head
pressure is the measure of potential energy in the system. It will measure from how high the fluid is falling.
The distance the fluid will falls will dictate the force generated (F=ma). This is why the density of the fluid
must be known to calibrate a pressure transmitter for a process.

To illustrate these facts we will start with one gallon of water. The gallon of water equals exactly 231 cubic
inches and weights approximately 8.342 pounds. Pressure is measured in PSI (POUNDS PER INCH
SQUARED). The only area that needs to be measured is 1 square inch to calculate the height of the water
and the force it will excerpt.

Stack the 231 cubic inches of water on top of each other to form a tall column of water with a base of 1
square inch. The column of water will be 231 inches tall. Divide the height of the column of water, 321
inches, by the weight of the water, 8.342 pounds. The result will be 27.691 inches of water per pound. In
plain words a column of water 27.691 inches tall will produce a force of 1 pound per inch squared or 1 PSI.

By knowing the height of the fluid multiplied by its density at time of calibration, the pressure can be
calculated. Therefore the height of the fluid or level can be calculated from its head pressure regardless if
the tank is 5 ft in diameter or 20 ft in diameter. This pressure is typically measured in inches of water for
low-pressure measurements and psi for large pressure measurements.

In instrumentation it is common to measure in inches rather than feet of water for calibration purposes.

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 Calibration Procedures
Calibration calculations

The Wet Leg

Another non-zero based application is the tank on the
right. This measurement uses what is referred to as a
wet leg. As remember the wet leg is used to equalize the
pressure across the transmitter in a pressurized tank.
Because of condensation the wet leg eventually will fill
up and the transmitter will no longer be in static
equilibrium and a constant varying error will exist over
time. The solution is to fill the wet leg up with the
product to be used in the tank or an antifreeze product.
This is where the name “WET LEG” comes from.

Sample Calculations

Tank Level = 0 to 100 inches Tank Level = 0 to 100 inches

S.G. = 1.1 S.G = 0.9
(switch jumper to normal zero) (switch jumper to suppress zero)
0” x 1.1 = 0” = 4 mA 20” x 0.9 = 18” = 4 mA
100” x 1.1 = 110” = 20 mA 100” x 0.9 = 90”= 20 mA
Calibrated span from 0” to 110” H2O Calibrated span from 18” to 90” H2O

Tank Level = 0 to 100 inches Tank Level = 0 to 100 inches

S.G. = 1.0 Wet Leg Fill Height = 120” S.G. = 0.8 Wet Leg Fill Height = 140”
(switch jumper to elevate zero) (switch jumper to elevate zero)
(Apply 120” to low side of instrument for 0%) (Apply 96” to low side of instrument for 0%)
(- 120” + 0”) x 1.0 = -120” = 4mA (-140” + 20”) x 0.8 = -96” = 4 mA

(Apply 100” to high side with low side connected for 100%) (Apply 80” to high side with low side connected for 100%)
100” x 1.0 = 100” = 20 mA 100” x 0.8 = 80” = 20 mA
Calibrate span from 0” to 100” H2O Calibrated span from 0” to 80” H2O
OR OR
(Apply 20” to low side with high side disconnected for 100%) (Apply 20” to low side with high side disconnected for 100%)
– 120” + 100” = -20” = 20 mA ( – 140” + 120”) x 0.8 = -16” = 20 mA
Calibrated span from 0” to 100” H2O Calibrated span from 0” to 80” H2O

Industrial Instrumentation 47 Bryon Lewis

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 Section 2 – Basic Instruments
Calibration Procedures

Industrial Instrumentation 48 Bryon Lewis

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 Section 1 – Process Control
Control Loops

Open Loop

Open loop means there is no feedback in the process to maintain the desired setpoint of the process due to
disturbances. A setpoint is set in the controller and not changed. The process operates at that setpoint. The
setpoint can be as an example: temperature, speed or a flow rate. A change will occur in the process due to
disturbances.

As in the previous examples: for temperature, the water may become colder going into the process and
therefore the process cannot heat the water to the desired temperature. For speed, a conveyor belt may be
carrying gravel. Excess gravel is loaded on the belt, making it load heavier. The belt will then be slowed
down from the desired speed. For flow rate, a liquid traveling through a pipe may have its pressure
decreased or an increase the pressure drop due extra valves and pipe will cause the flow rate to decrease.

Closed Loop

Closed loop means there is a feedback device in the process somewhere and the feedback device is
connected to the controller. Now when there is a disturbance to the process, the feedback controller senses
the disturbance and corrects for it automatically. For the temperature, the heater element will increase its
output until the setpoint or desired temperature is reached. For the gravel conveyor, the motor will increase
in speed until the desired speed is met. For the flow rate, the pump will speed up until the desired flow rate
is met.

In the picture above, the top picture is a closed loop, while the bottom is an open loop.

Industrial Instrumentation 49 Bryon Lewis

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 Section 2 – Process Control
Control Modes
Typical process control falls into four main categories: Feedback, feedforward, cascade and differential Gap.

Differential Gap

Differential Gap is also known as bang-bang control. It uses two points for discrete control.

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Feedback

Open loop means there is no feedback in the process to maintain the desired setpoint of the process due to
disturbances. A setpoint is set in the controller and not changed. The process operates at that setpoint. The
setpoint can be as an example: temperature, speed or a flow rate. A change will occur in the process due to
disturbances.

As in the previous examples: for temperature, the water may become colder going into the process and
therefore the process cannot heat the water to the desired temperature. For speed, a conveyor belt may be
carrying gravel. Excess gravel is loaded on the belt, making it load heavier. The belt will then be slowed
down from the desired speed. For flow rate, a liquid traveling through a pipe may have its pressure
decreased or an increase the pressure drop due extra valves and pipe will cause the flow rate to decrease.

Feedforward

Closed loop means there is a feedback device in the process somewhere and the feedback device is
connected to the controller. Now when there is a disturbance to the process, the feedback controller senses
the disturbance and corrects for it automatically. For the temperature, the heater element will increase its
output until the setpoint or desired temperature is reached. For the gravel conveyor, the motor will increase
in speed until the desired speed is met. For the flow rate, the pump will speed up until the desired flow rate
is met.

In the picture above, the top picture is a closed loop, while the bottom is an open loop.

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Cascade

Open loop means there is no feedback in the process to maintain the desired setpoint of the process due to
disturbances. A setpoint is set in the controller and not changed. The process operates at that setpoint. The
setpoint can be as an example: temperature, speed or a flow rate. A change will occur in the process due to
disturbances.

As in the previous examples: for temperature, the water may become colder going into the process and
therefore the process cannot heat the water to the desired temperature. For speed, a conveyor belt may be
carrying gravel. Excess gravel is loaded on the belt, making it load heavier. The belt will then be slowed
down from the desired speed. For flow rate, a liquid traveling through a pipe may have its pressure
decreased or an increase the pressure drop due extra valves and pipe will cause the flow rate to decrease.

Differential Gap

Closed loop means there is a feedback device in the process somewhere and the feedback device is
connected to the controller. Now when there is a disturbance to the process, the feedback controller senses
the disturbance and corrects for it automatically. For the temperature, the heater element will increase its
output until the setpoint or desired temperature is reached. For the gravel conveyor, the motor will increase
in speed until the desired speed is met. For the flow rate, the pump will speed up until the desired flow rate
is met.

In the picture above, the top picture is a closed loop, while the bottom is an open loop.

Industrial Instrumentation 52 Bryon Lewis

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 Section 3 – Process Control
Final Correction Devices

Valves

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 Control Valve Flow Characteristics

Trim design will affect how the valve capacity changes as the valve moves through its
complete travel. Because of the variation in trim design, many valves are not linear in
nature. THE RELATIONSHIP BETWEEN VALVE CAPACITY AND VALVE
TRAVEL IS KNOWN AS THE FLOW CHARACTERISTIC OF THE VALVE. Valve
trims are specially designed, or characterized, in order to meet the large variety of control
application needs. This is necessary because most control loops have some inherent
nonlinearities, which you can compensate for when selecting control valve trim.
Charts similar to Figure 1 (see below) are used to illustrate various control valve flow
characteristics. The percent of full flow through the valve is plotted against valve stem
position. The curves shown are typical of those available from valve manufacturers.
These curves are based on CONSTANT PRESSURE DROP across the valve and are
called INHERENT FLOW CHARACTERISTICS.
The quick-opening characteristic provides large changes in flow for very small changes
in lift. It usually has too high a valve gain for use in modulating control. So it is limited to
on-off service, such as sequential operation in either batch or semi-continuous processes.
The majority of control applications are valves with linear, equal-percentage, or
modified-flow characteristics.
 Linear - flow capacity increases linearly with valve travel.
 Equal percentage - flow capacity increases exponentially with valve trim travel;
equal increments of valve travel produce equal percentage changes in the existing
Cv.
 A modified parabolic characteristic is approximately midway between linear
and equal-percentage characteristics. It provides fine throttling at low flow
capacity and approximately linear characteristics at higher flow capacity.

When valves are installed with a pump, pipes, fittings, and other process equipment,
the pressure drop across the valve will vary as the plug moves through its travel. When
the actual flow in a system is plotted against valve opening, the curve is called the
INSTALLED FLOW CHARACTERISTIC.

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 Linear Valve Features
 TORTUOUS FLOW PATH
 LOW RECOVERY
 CAN THROTTLE SMALL FLOW RATES
 OFFERS VARIETY OF SPECIAL TRIM
DESIGNS
 SUITED TO HIGH-PRESSURE
APPLICATIONS
 USUALLY FLANGED OR THREADED
 SEPARABLE BONNET

Rotary Valve Features

 STREAMLINED FLOW PATH
 HIGH RECOVERY
 MORE CAPACITY
 LESS PACKING WEAR
 CAN HANDLE SLURRY AND ABRASIVES
 FLANGELESS
 INTEGRAL BONNET
 HIGH RANGEABILITY

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 Control Valve Classification

Direct-Acting and Reverse-Acting Positioners

The terms "direct" and "reverse" are frequently used when discussing control valves,
positioners, and controllers. While the definitions of direct and reverse seem pretty
straightforward, they cause quite a bit of confusion - especially when split-ranging is
done.
The key to working with control valves and controllers is to remember that there must
always be a balance maintained in the system. "Direct" and "reverse" are kind of like
"positive" and "negative" in that where you find one you will usually find the other.
While control valve bodies and control valve actuators can be described as being
direct acting or reverse acting, thinking about such things when working through a
system problem only adds to the confusion. Therefore, it is always best to consider the
FAIL SAFE mode of the valve and simply let the control valve be what it may be.
Positioners, 99% of the time, will usually mimic the input signal from the controller.
That is, they will be DIRECT ACTING.

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 Direct-Acting Positioners

Input Decreases
Input Increases Output Decreases
Output Increases
Equals
Equals
Decreasing
Decreasing
Increasing Signal Increasing Output Signal
Output From
from Controller from Positioner From
Positioner
Controller

Another reason the direct-acting pneumatic positioner is so popular is that it can be

by-passed and the control valve will respond to the input signal from the controller as
though the positioner were in the control loop. If a positioner malfunction occurs or if the
positioner causes the control valve to become unstable, it can be easily by-passed. Many
control valves in the field are operating with a by-passed positioner.
Reverse-acting positioners are sometimes used on control valves, but their appearance
is rare. Occasionally one will be found in a split-ranging sequence.
Reverse-Acting Positioner

Input Decreases
Input Increases Output Increases
Output Decreases
Equals
Equals
Decreasing
Increasing
Increasing Signal Decreasing Output Signal
Output From
from Controller from Positioner From
Positioner
Controller

Direct-Acting and Reverse-Acting Controllers

Controllers can be set up in either direct or reverse modes. It was stated that 99% of
the positioners are direct acting, and it follows that if a balance is to be maintained in the
control loop that 99% of the controllers will be reverse acting. If the control valve and its
controller are not in balance, the control valve will either go to the wide-open position
and stay there, or it will stay closed and act as though it is not responding. This situation
can normally be corrected by reversing the action of the controller.

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 Direct-Acting Controller

Setpoint Increases Setpoint Decreases

Output Increases Output Decreases

Equals Equals

Increase Increase Decrease Decrease

in in in in
Setpoint Output Setpoint Output

Reverse-Acting Controller

Setpoint Increases Setpoint Decreases

Output Decreases Output Increases

Equals Equals

Increase Decrease Decrease Increase

in in in in
Setpoint Output Setpoint Output

Two of the more common control valve uses are for pressure control. In both
instances, the controllers are reverse acting. Most pressure-reducing valves will be fail-
closed and most back-pressure control valves will be fail-open. If the pressure-reducing
valve were fail-open or the back-pressure valve fail-closed, then the controllers would
have been direct acting.

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 Control Valve "Fail-Safe" Positions

Cause of Fail-Safe Condition: Loss of Air Pressure

A. LINEAR SPRING/DIAPHRAGM ACTUATORS. Used with sliding stem

control valves: i.e. globe-style valves. Can be accomplished two ways:
1. Fixed seat ring/plug orientation. Springs are interchanged to either above or
below actuator diaphragm.

2. Fixed spring orientation. Plug and seat ring positions are reversed relative
to each other. In the Fail Open design, plug travel is above the valve seat. In
the Fail Closed design, plug travel is below the seat.

Rotary Spring/Diaphragm Actuators

Used with rotary control valves; i.e. butterfly, eccentric plug. Reversing the fail
mode for this type of valve is normally accomplished by reversing the location of
lever arm and plug. In order to maintain consistency, ATO-FC action will be
considered as "Reverse" action for rotary or sliding-stem control valves.

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 Actuators

Feature Comparison
Spring and Diaphragm
Advantages Disadvantages
Lowest Cost Limited Output Capability
Can Throttle Without a Positioner Large Size and Weight

Simplicity

Inherent Fail-Safe Action

Low Supply Pressure Required

Adjustability

Easily Maintained

Pneumatic Piston
Advantages Disadvantages
Fail-Safe Requires Accessories or Addition of
High Torque Capability
Spring
Compact Positioner Required for Throttling
Lightweight Higher Cost
Adaptable to High Ambient
High Supply Pressure Required
Temperature

Fast Stroking Speed

Relatively High Actuator Stiffness

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 Electric Motor
Advantages Disadvantages
Compactness High Cost
Very High Stiffness Lack of Fail-Safe Action
High Output Capability Limited Duty Cycle

Slow Stroking Speed

Electrohydraulic
Advantages Disadvantages
High Output Capability High Cost
High Actuator Stiffness Complexity and Maintenance Difficulty
Excellent Throttling Ability Large Size and Weight
Fast Stroking Speed Fail-Safe Action Only With Accessories

F1 - (Flow Recovery Coefficient)

F1 = The valve pressure recovery factor, a dimension less quantity. (Measured when
valve is not choked.)

The Vena Contracta is the place along the axis of flow, just beyond the orifice, where
the jet steam contracts to its minimum cross-sectional area. Note: It is at this point that
the velocity is at its highest, and the fluid pressure is at its lowest.

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 F1 - Pressure Recovery Factor
LOW-RECOVERY RATE: A valve design that dissipates a considerable amount of
flow-stream energy due to turbulence created by the contours of the flow path.
Consequently, pressure downstream of the valve vena contracta recovers to a lesser
percentage of its inlet value than a valve with a more streamlined flow path. The F1
factor does not vary with travel to any significant degree.
HIGH-RECOVERY RATE: A valve design that dissipates relatively little flow-stream
energy due to streamlined internal contours and minimal flow turbulence. Therefore,
pressure down stream of the valve vena contracta recovers to a high percentage of its
inlet value. The F1 factor of a high recovery valve will vary with its plug travel.

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 Pressure vs. Temperature for Selected Metals

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Industrial Instrumentation 64 Bryon Lewis
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 Pressure Products

Model 3051S Series of Instrumentation

The World's First Truly Scalable Measurement
Architecture

Model 3051 w/ Foundation Fieldbus

Model 3051 Smart Pressure Transmitter
The World's Most Preferred Transmitter - One
Million Units Sold Worldwide!

Model 3095FB Multivariable Transmitter

w/Modbus™ Protocol
The Best Solution for Gas Metering!

Model 1151 Pressure Transmitter

Model 1151 Smart Pressure Transmitter
The industry standard for 30 Years

Model 2088 Gage or Absolute Transmitter

Model 2090P Flush Mount Pulp and Paper
Transmitter
Model 2090F Tri-Clamp Food and Pharmaceutical
Transmitter
Need a Low Cost Pressure Measurement?

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 Temperature Products

NEW! Model 3144P Smart Temperature

Transmitters
The Ultimate Temperature Transmitter for Control
and Safety Applications.

Model 3244MV Multivariable Temperature

Transmitter with FOUNDATION fieldbus
Among the world's first devices to be registered
with the Fieldbus Foundation.

Model 644H and 644R Smart Temperature

Transmitters
High Accuracy and Reliability for Control and
Safety Applications.

Model 244EH and 244ER Programmable

Temperature Transmitters
Low cost transmitter with RTD and Thermocouple
inputs for Temperature Monitoring Applications.

Model 144H PC-Programmable Temperature

Transmitter
Low cost transmitter with RTD inputs for
Temperature Monitoring Applications.

Model 444 Analog Temperature Transmitter

Field Mount Transmitter available with Low-Power
and Fast Turn-on Options.

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 Flow Products
Vortex Flowmeters Mass Flow Transmitters
Volumetric Insertion
Magnetic Flowmeters
Flowmeter

Model 8800C Smart Vortex Flowmeter

Designed for your toughest applications

Model 8800C Vortex Flowmeter

Now available with FOUNDATION™ fieldbus

Model 3095MV™ Multivariable Mass Flow Transmitter

The Best Solution for Gas and Steam!

Probar Flowmeter
Cost-effective volumetric flow measurements for gas and
liquid streams

Proplate and Mass ProPlate Flowmeters

In-line flowmeter systems for ½ to 1½" service applications

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 Flow Products
Vortex Flowmeters Mass Flow Transmitters
Volumetric Insertion
Magnetic Flowmeters
Flowmeter

Model 405P Compact Orifice

When a low-cost, reliable solution is required, the Model 405P
is the ideal measurement device.

Model 8705 Magnetic Flowtube

Perfect for harsh, corrosive or other difficult to measure
substances

Model 8712C/U/H Magnetic Flow Transmitter

Remote mount flow transmitter

Model 8732 Magnetic Flowmeter Transmitter

Obstructionless flow measurement ideal for any conductive
fluid.

Coriolis Mass Flowmeters from Micro Motion

High accuracy mass flowmeters

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