‭INDUSTRIAL INSTRUMENTATION - II‬

‭UNIT - 1‬

‭SCENARIO - 1‬

‭Venturimeter‬
‭Assertion: Venturimeter can be installed in the vertical position‬
‭Reason: Flow rate is proportional density of the liquid used for the measurement‬

‭ oth Assertion and Reason are TRUE and the Reason is NOT the correct explanation of the‬
B
‭Assertion‬

‭SCENARIO - 2‬

‭Pitot Tube‬

‭Steps to measure flow in Pitot Tube‬

‭1.‬ ‭Identify the stagnation point‬

‭2.‬ ‭Take a pressure at the stagnation point‬

‭3.‬ ‭Take another pressure at the impact point‬

‭4.‬ ‭Convert the flow into differential pressure‬

‭5.‬ ‭Signal conditioning (Conversion and Manipulation)‬

‭6.‬ ‭Convert Differential pressure into electrical signal using suitable transducer‬
 ‭7.‬ ‭Standardizing the output.‬

‭Port Type‬ ‭Pressure‬ ‭Velocity‬

‭Impact Pressure Port‬ ‭High‬ ‭High‬

 ‭Static Pressure Port‬ ‭Low or Equal to Ambient‬ ‭Zero‬

‭Justify the reason for stagnation point V2 = 0 occurs in the center of the pipeline and what‬

‭will be the dynamic changes happened for Pressure P2 at that point ?‬

‭The stagnation point V2=0 occurs at the center of the pipeline because the fluid must decelerate‬

‭to zero velocity upon impacting the stationary Pitot tube. At this point, kinetic energy is‬

‭converted to pressure energy, resulting in increased stagnation pressure P2.‬

‭SCENARIO - 3‬

‭Orifice Meter‬
‭1.‬ ‭Concentric type - used for clean fluids.‬
 ‭2.‬ ‭Eccentric or segmental type - dirty fluids, slurries and fluids containing‬

‭solids.‬

‭Position of Taps in Orifice‬

‭1.‬ ‭Flange Taps‬

‭2.‬ ‭Vena Contracta Taps‬

‭3.‬ ‭Radius Taps‬

‭4.‬ ‭Corner Taps‬

‭5.‬ ‭Pipe or Full Flow Taps‬

‭Pressure Pipe Layout‬

‭1.‬ ‭Liquids and Steam‬

‭2.‬ ‭Air and Gases‬

‭3.‬ ‭Liquids and Steam‬
‭4.‬ ‭Air and Gases‬
‭UNIT - 2‬

‭SCENARIO - 1‬

‭Rotameter‬

‭Assertion: The Rotameter is a type of restriction flow meter‬

‭Reason: In the rotameter the area is changing according to the movement of the float‬

‭Both Assertion and Reason are TRUE and the Reason is the correct explanation of the Assertion‬
‭SCENARIO - 2‬

‭Identify Reciprocating piston meter and classify under the which type from the list given‬

‭below and justify the answer‬

‭●‬ ‭They are a type of positive displacement flow meter.‬

‭●‬ ‭These meters operate using pistons or plungers that reciprocate (move back and forth).‬
 ‭●‬ ‭It measures flow by passing a precise volume of fluid.‬

‭●‬ ‭Reciprocating piston meters are suitable for handling a wide variety of liquids.‬

‭●‬ ‭They are volumetric flow measurement instruments.‬

‭●‬ ‭Measure non corrosive liquid and Oil.‬

‭What‬ ‭are‬ ‭the‬ ‭necessary‬ ‭arrangements‬ ‭to‬ ‭be‬ ‭modified‬ ‭to‬ ‭convert‬ ‭the‬ ‭reciprocity‬ ‭piston‬

‭meter to be used as a pump?‬

‭●‬ ‭Reciprocating‬ ‭piston‬ ‭meters‬ ‭can‬ ‭function‬ ‭as‬ ‭both‬ ‭meters‬ ‭and‬ ‭pumps,‬ ‭but‬ ‭some‬

‭arrangements are needed.‬

‭●‬ ‭For‬‭metering-only‬‭applications,‬‭the‬‭focus‬‭is‬‭on‬‭translating‬‭piston‬‭movement‬‭into‬‭flow‬‭rate‬

‭readings.‬

‭●‬ ‭For‬‭pump‬‭use,‬‭valves‬‭are‬‭incorporated‬‭to‬‭control‬‭the‬‭flow‬‭direction‬‭and‬‭create‬‭a‬‭pressure‬

‭differential for pushing fluids.‬

‭Compare Variable area and Variable Head‬

‭Positive Displacement Flow Meters‬

 ‭Major application areas of a reciprocating piston meter include viscous fluid services like oil‬

‭metering on engine test stands, specifically where turndown ratio is not considered much crucial.‬

‭Also these meters can be employed on residential water service‬

‭In an oval gear meter, the rotation of gear shafts causes a fixed amount of liquid to pass through‬

‭the meter. By monitoring the number of shaft rotations, one can calculate liquid flow rate.‬

‭These types of meters prove to be very accurate when slippage between the housing and the‬

‭gears is set very small.‬

‭Universally, they are employed as residential water meters‬

 ‭Their typical size range varies from 5/8-in to 2-in sizes. They are ideal for pressure ranges‬

‭around 150-psig with an upper limit of 300 psig‬

‭Based upon the construction material, maximum pressure and maximum temperature limits of‬

‭rotary vane meters are 350°F and 1,000 psig respectively‬

‭Both the rotors are geared together and there is a very small clearance between the rotors and the‬

‭casing.‬
‭UNIT - 3‬
‭1.‬‭Sand water, coal powder, sewage, wood pulp‬‭- They are Competent enough to measure‬

‭intricate and corrosive liquids and slurries , It is Preferable for conducting liquid‬

‭Justification : Corrosive liquids, Conductive‬

‭2.‬‭Hot fluids, high viscous fluids especially in food processing industries‬‭- It Consists of no‬

‭moving parts; hence there are no restrictions to the flow‬

‭Justification : No moving parts‬

‭3.‬‭Cryogenic fluids‬ ‭- Electromagnetic flow meter can be used for larger pipe diameter‬

‭Justification : Large pipe diameter‬

‭Assertion: The magnetic flow meter consists of an electrically insulated or non-conducting‬

‭pipe such as fiber glass.‬

‭Reason: If a metal pipe is used, an electrically insulating liner is provided to the inside of‬

‭the pipe‬

‭Assertion is TRUE but the Reason is FALSE‬

‭SCENARIO - 1‬

‭Electromagnetic flow meter‬

‭Ultrasonic Flow Meter‬
‭Justify the effect of the operation in the ultrasonic flow meter, if the electronic oscillator is‬

‭not working well or it is removed from the arrangement‬

‭1.‬ ‭No Ultrasonic Signal Generation‬

‭2.‬ ‭No Signal Transmission/Reception‬

‭3.‬ ‭Inaccurate or No Flow Measurement‬

‭4.‬ ‭System Malfunction or Shutdown‬

‭Thermal Flow Meter‬

‭●‬ ‭Two thermocouples (or resistance thermometers) TI and T2 are placed at each side of the‬
‭heater .‬
‭●‬ ‭The thermocouple TI measures the temperature of fluid before it is heated, while the‬
‭thermocouple T2 measures the temperature so after.‬
‭●‬ ‭The power supply to the heater equals the heat transferred to the fluid, i e. Q, and is measured‬
‭by a wattmeter. Thus by measuring the values of Q, TI and T2 the flow rate W of liquid is‬
‭determined from the above equation‬

‭Q = W Cp (T2 - T1)‬

‭●‬ ‭Q = hat transfer,‬

‭●‬ ‭W = mass flow rate of fluid‬
‭●‬ ‭Cp = Specific heat of the fluid‬
‭●‬ ‭T1 = initial temperature of fluid after heat has been transferred‬
‭●‬ ‭T2 = final temperature of fluid after heating the fluid.‬

‭UNIT - 4‬

‭SCENARIO - 1‬
‭The Closed tank level measurement using DP transmitter two pressures are taken one from‬

‭top of the tank and another from bottom of the tank, If the tank is open tank this same‬

‭system can be adopted? Justify the changes to be done.‬

‭In an open tank, connect the high-pressure port of the DP transmitter to the tank bottom and‬

‭leave the low-pressure port open to the atmosphere to measure the differential pressure relative‬

‭to atmospheric pressure.‬

‭The closed tank level measurement technique is preferable for which of the following liquid‬

‭mediums. Justify the answer.‬

‭Non Volatile Liquids -‬

‭●‬ ‭Due to the need for vapor containment‬

‭●‬ ‭Stability of pressure and temperature‬

‭●‬ ‭Adherence to safety regulations.‬

‭Fill the box‬

‭SCENARIO - 2 & 3‬

‭Boiler System‬
‭1. A boiler Drum is a closed tank system , Identify which type of level Transducer is‬

‭preferable in the Level transmitter (LT)‬

‭Preferred Level Transducer for Boiler Drum: Differential Pressure (DP) Transmitter.‬

‭●‬ ‭High Accuracy and Linearity‬

‭●‬ ‭Robust and Durable‬

‭●‬ ‭Non-contact Operation‬

‭●‬ ‭High Resolution‬

‭2. The final measurable parameter must be electrical parameters, Using which of the‬

‭following transducers may prefer for the conversion from displacement to electric‬

‭parameter and Justify the same. (LVDT , RVDT, Load cell, Strain gauge)‬

‭Preferred Transducer for Displacement to Electrical Parameter Conversion : Linear Variable‬

‭Differential Transformer (LVDT) due to its‬

‭●‬ ‭High accuracy‬

‭●‬ ‭Reliability‬

‭●‬ ‭Suitability for harsh industrial environments.‬

‭Types of Level Measurement‬

‭●‬ ‭Simplest method of measuring liquid level.‬

‭●‬ ‭Uses a tape or servo motor which is connected to a float‬

‭●‬ ‭Increment of buoyancy‬

‭●‬ ‭Hydrostatic level transmitters, or pressure level transmitters‬

‭Bubbler Type Level System‬

‭●‬ ‭Bubblers are all hydrostatic measurement devices. This technology is used in vessels‬

‭(tanks) that operate under atmospheric pressure.‬

‭The pressure gauge without calibration and pressure transmitter are installed in the‬

‭measurement system, Identify the two output‬

‭1.‬ ‭4 to 20 mA‬

‭●‬ ‭Standard in Industry‬

‭●‬ ‭Compatibility‬

‭2.‬ ‭Actual Pressure in psi‬

‭●‬ ‭Direct Measurement‬

‭●‬ ‭Pressure Transmitter Conversion‬

‭UNIT - 4‬
‭Identify the Capacitive level measurement is preferable for conducting and non-conducting‬

‭liquid‬

‭Non-conducting material :‬

‭Bare probe arrangement is used as liquid resistance is sufficiently high to make it dielectric.‬

‭Since the electrode and tank are fixed in place, the distance (d) is constant, capacitance is directly‬

‭proportional to the level of the material acting as dielectric.‬

‭Conducting Material :‬

‭The probe plates are insulated using thin coating of glass or plastic to avoid short circuiting. The‬

‭conductive material acts as the ground plate of the capacitor.‬

‭Proximity measurements (Non-contact type measurements):‬

‭In Proximity level measurement the area of the capacitance plates is fixed, but distance between‬

‭plates varies. Proximity level measurement does not produce a linear output and is used when the‬

‭level varies by several inches.‬

‭Liquid level rises (Maximum Level)‬‭- higher capacitance - overlap area increases.‬

‭Liquid level decreases (Minimum Level)‬ ‭- lower capacitance - overlap area decreases.‬
‭Statement (S1): Capacitive level sensor is coming under the active sensor.‬

‭Justification (J1): If the liquid is conducting in nature the cross sectional area is changing‬

‭with respect to liquid level the capacitance is changing‬

‭Justification (J2): Capacitance is not a proper data to convey the information about the‬

‭process parameter. It has to convert into voltage with the help of external power supply. T‬

‭To justify the statement which is the right option?‬

‭Justification 1 & 2 2.‬

‭Statement (S1): Capacitive level sensor is coming under the passive sensor.‬

‭Justification (J1): If the liquid is conducting in nature the cross sectional area is changing‬

‭with respect to liquid level the capacitance is changing‬

‭Justification (J2): Capacitance is not a proper data to convey the information about the‬

‭process parameter. It has to convert into voltage with the help of an external power supply.‬

‭To justify the statement which is the right option?‬

‭Justification 2 only‬
‭SCENARIO - 1‬
‭1.‬ ‭Sling Hygrometer - Latent heat of vaporization to determine the relative humidity‬

‭2.‬ ‭Helix Hygrometer (Metal/Wood Laminate) - Change in the length of the wood‬

‭3.‬ ‭Hair hygrometer - The simplest and oldest type of hygrometer‬

 ‭4.‬ ‭Electrical using electrodes with interdigitated fingers covered with a hygroscopic material‬

‭- Resistive hygrometer or resistive humidity sensors‬

‭●‬ ‭Relative humidity (Φ) -‬ ‭The percentage of water vapor by weight present in a given‬

‭volume of air or gas compared to the weight of water vapor present in the same volume‬

‭of air or gas saturated with water vapor, at the same temperature and pressure‬

‭●‬ ‭Specific humidity, humidity ratio, or absolute humidity‬‭- The mass of water vapor in a‬

‭mixture in grains (where 7000 grains = 1 lb) divided by the mass of dry air or gas in the‬

‭mixture in pounds. The measurement units could also be in grams‬

‭●‬ ‭Dew point -‬‭The temperature at which condensation of the water vapor in air or a gas‬

‭will take place as it is cooled at constant pressure.‬

‭●‬ ‭Dry-bulb temperature‬‭- The temperature of a room or mixture of water vapor and air‬

‭(gas) as measured by a thermometer whose sensing element is dry.‬

‭●‬ ‭Wet-bulb temperature‬‭- The temperature of the air (gas) as sensed by a moist element.‬

‭SCENARIO - 2‬

‭Thermal conductivity humidity sensor‬

‭Assertion (A): Thermal Conductivity Humidity Sensors are also known as Absolute‬

‭Humidity (AH) Sensors as they measure the Absolute Humidity.‬

‭Reason (R): Thermal Conductivity Humidity Sensors measure the thermal conductivity of‬

‭both dry air as well as air with water vapor‬

‭Both Assertion (A) and Reason (R) are true and Reason (R) is the correct explanation of‬

‭Assertion (A).‬

‭Why is one resistor maintained in a chilled environment using liquid nitrogen in a thermal‬

‭conductivity humidity sensor ?‬

‭●‬ ‭Thermal conductivity sensors measure humidity by comparing heat transfer in dry vs.‬

‭moist air.‬

‭●‬ ‭One resistor is kept cool with liquid nitrogen to maintain a constant, dry reference point.‬

‭●‬ ‭This stable reference allows for accurate detection of changes in heat transfer caused by‬

‭humidity variations in the surrounding air.‬

‭●‬ ‭The temperature difference between the chilled resistor and the heated sensor element‬

‭reflects the moisture content.‬

‭Suggest a method to convert humidity into electrical parameters in the Hair Hygrometer ?‬

‭●‬ ‭Mechanical linkage:‬‭Hair movement can be mechanically linked to a variable resistor,‬

‭changing its resistance with humidity.‬

‭●‬ ‭Capacitive sensor:‬‭Hair expansion/contraction alters the distance between conducting‬

‭plates in a capacitor, affecting its capacitance.‬

‭●‬ ‭Piezoresistive effect:‬‭Hair movement can put pressure on a piezoresistive material,‬

‭changing its electrical resistance based on the applied force‬

‭SCENARIO - 3‬

‭Rotameter type viscometer‬

‭Two parallel plates separated by 0.75 in are filled with a liquid with a viscosity of 7.6 ×‬

‭10−4 lb.s/ft2 . What is the force acting on 1 ft2 of the plate, if the other plate is given a‬

‭velocity of 4.4 ft/s?‬

‭Ans : 0.0053 lb‬

‭Which of the following types of viscosity measurement given below is working with the‬

‭following arrangement?‬

‭“Inner cylinder is driven by an electric motor and the force on the outer cylinder is‬

‭measured by noting its movement against a torsion spring”, Justify the answer.‬

‭Drag-type viscometer (Rotating disc viscometer)‬‭- The device consists of two concentric‬

‭cylinders and the space between the two cylinders is filled with the liquid being measured. The‬

‭inner cylinder is driven by an electric motor and the force on the outer cylinder is measured by‬

‭noting its movement against a torsion spring‬‭;‬‭the viscosity of the liquid can then be determined.‬

‭Difference and similarities of rotameter type viscometer and Saybolt type viscometer‬

‭Similarities:‬

‭●‬ ‭Both are used to measure the kinematic viscosity of liquids.‬

‭●‬ ‭Both rely on the relationship between flow rate and resistance to flow.‬

‭Differences :‬
‭Purpose of thermometer in rotameter type viscometer‬

‭The thermometer in a rotameter-type viscometer serves two important purposes:‬

‭1.‬ ‭Temperature correction‬

‭2.‬ ‭Standardization Measurement‬

‭●‬ ‭Viscosity of most fluids is highly dependent on temperature.‬

‭●‬ ‭The thermometer allows you to measure the fluid temperature during the viscosity‬

‭measurement.‬

‭●‬ ‭The thermometer ensures the operating temperature is maintained at the desired level for‬

‭a standardized viscosity measurement.‬

‭Thermal Conductivity Humidity Sensor The Wheatstone bridge arrangement is used In the‬

‭four arms;two arms are maintained in the constant value “R1” and “R2” other Two arms‬

‭are thermistors. Justify how the unbalancing condition occurs based on the humidity.‬

‭●‬ ‭In a Thermal Conductivity Humidity Sensor with a Wheatstone bridge arrangement,‬

‭unbalancing occurs as humidity changes because the thermal conductivity of the air‬
 ‭between the thermistors varies with humidity levels, leading to a temperature difference‬

‭between the thermistors.‬

‭●‬ ‭This temperature difference alters the resistance of the thermistors, causing an imbalance‬

‭in the bridge circuit, which can be measured as an electrical output proportional to‬

‭humidity.‬