Introduction to Basic Instrument

Calibration
 INSTRUMENTATION

DEFINITION:
Instrumentation has to do with the development
of measurement Systems for a wide range of
application in the scientific and technical world
In the process industry, it is the application of
instrument to an industrial process for the purpose
of measuring or controlling its activities.

2
What are instruments?
Instruments are devices that have the capability
of doing any one of the following on a process.
 Sense the presence of a process variable
 Measure the amount of process variable
 Record the amount of process variable
 Indicate the measured variable for operators
to see
 Transmit the measured variable for control
purpose 3
What is Calibration?
Calibration processes usually have to do with
testing/restoring the original integrity of
equipment in order to take it back to its
manufactured accuracy.
The checking of instrument measurements against
a standard known and acceptable value is know as
calibration.
It is important to know that reference instruments
used in calibration are those whose calibration is
traceable to instruments held in national standard
4
laboratories.
Traceability! What does it mean?
'Traceability' means that the measurement results
can be related to a stated reference by an unbroken
chain of accredited comparisons. The stated
reference usually refers to national or international
standards
Traceability gives the user confidence that his/her
measurements agree with the National Standards
within the stated uncertainty. It also ensures that
the measurements will be equivalent to those
made using different instruments from different
suppliers. 5
The Pyramid of the Traceability of Measurements
6
Definition of Some Important Terms
Accuracy: This is a measure of how close a
measurement is to the true value.
Precision: Precision is defined as the ability of a
measuring instrument to reproduce exactly the
same result over and over again under the same
conditions.
Primary Sensing Element: This is the part of a
measurement device that responds to the stimulus
initiated by the variable being measured.
7
Secondary Element: This is the part of an
instrument that convert the response of the
primary element into a form that can be read by
an observer.
Atmospheric Pressure: It is the pressure
exerted by the surrounding air on the surface of
an object.
Absolute Pressure: This is the pressure at any
point beneath the surface of a liquid including
the atmospheric pressure.
8
Absolute pressure is measured in reference to
total vacuum, and as such can only have positive
values.
Gauge Pressure: Pressure measured in
reference to atmospheric pressure is called gauge
pressure. The value can be either positive or
negative.
Gauge pressure is the pressure at any point
beneath the surface of a liquid excluding the
atmospheric pressure.
9
Mathematically,
Absolute press. = Gauge press. + Atmosp. Press
Sometimes the type of measurement (reference
condition) is indicated next to the unit
designation:
 For gauge pressure by adding letter g to the
unit symbol, e.g. barg, kPag, psig or possibly
bar(g) etc
 For absolute pressure by adding letter a to the
unit symbol, e.g. bara, kPaa, psia or possibly
bar(a) etc. 10
Relevance of Instrumentation
 It gives an idea of how much of a process
variable is present at any point in time.
 Without instrumentation, the monitoring and
control of a process will not be possible.
What is a process?
A process is any operation or sequence of
operations involving a change of energy, state,
composition, dimension or other properties that
may be define with respect to a datum. 11
Common Types of Processes
 Liquid
 Gas
 Bulk solids (Granular solids)
Common Process Variables
 Pressure
 Temperature
 Level
 Flow 12
Fundamental/Base Quantities
There are seven fundamental quantities otherwise
known as base quantities from which every other
S.I units are derived. Their units are referred to as
fundamental or base units.
BASE QUANTITY BASE UNITS
Length Meters (m)
Mass Kilogram (kg)
Temperature Kelvin (K)
Time Second (s)
Electric Current Ampere (A)
Luminous Intensity Candela (cd)
Amount of Substance Mole (mol) 13
Derived Quantities
Apart from the seven fundamental quantities, all
other SI units are called derived units and their
corresponding quantities, derived quantities
BASE QUANTITIES DERIVED UNITS
Frequency Hertz (Hz)
Force Newton (N)
Energy Joule (J)
Electric Charge Coulomb (C)
Electric Power Watt (W)
Potential Difference Volt (V)
Area Square meter (m2)
Velocity Metre per second (m/s)
14
Mass Density Kilogram per cubic metre (kg/m3)
Volume Cubic metre (m3)
SI Unit Prefixes

15
Pressure
Pressure is defined as force per unit area.
The pressure of a process has to do with how
much force the process exact on a unit area.
Units of Pressure Measurement
The primary unit of pressure in the International
System of Units (SI) is pascal (Pa). However,
commonly used units of pressure in the industries
are;
 Pound-force per square inch (psi or lbf/in²) –
used mainly in the USA, 16

1 psi = 6,894.8 Pa
 Kilogram-force per square centimetre
(kgf/cm², in Poland abbreviated as kG/cm²),
1 kgf/cm² = 98,066.5 Pa
 Millimetre of mercury (mmHg),
1 mm Hg = 133.3 Pa
 Torr (Tr) – equal to 1/760th of standard
atmosphere and thus practically equal to 1
mm Hg
17
 Standard atmosphere (atm) – so-called
standard pressure,
1 atm = 101,325.0 Pa
 Bar (bar) – defined as 100 kilopascals,
1 bar = 100,000.0 Pa.
 Technical atmosphere (at) – defined as one
kilogram-force per square centimetre, thus
1 at = 98,066.5 Pa
18
Temperature
Temperature is a measure of the degree of
hotness or coldness of a body.
Unit of Temperature Measurement
The following are common units for temperature
measurement.
o
 Degree Celsius ( C)
o
 Degree Fahrenheit ( F)
 Kelvin (K)
19
Level
Level (usually associated with liquid and
granular solids) refers to the deepness of a
process with reference to the base of it’s
container or a set datum point.
Unit of Level Measurement
Level is simply a distance and hence can be
expressed in any of the units of measurement of
distance.
 Metric Unit – meters (m)
20
 Imperial Unit – feet & inches (ft & in)
Flow
Flow has to do with the steady movement of
matter from one point to another in a process. By
means of flow along pipelines, oil and gas
produced at one location is transported to another
for further processing.
Flow measurement systems and consequently the
unit of flow measurement is dependent on the type
of flow.
Types of Flow
 Laminar flow 21

Turbulent flow
Laminar Flow:
This type of flow is that which is associated with
highly viscous fluids and are characterised by a
Reynolds number of ˂2000.
Turbulent Flow:
This is the kind of flow that prevails in most
industrial processes. It is characterised by a high
Reynolds number.
Flow Measurement
Flow can be measured as either mass flow or
volumetric flow. 22
Volumetric Flow Rate
This is the volume of fluid flowing per unit time
and it is the product of the velocity of the fluid
and the cross-sectional area of the pipe.
Mass Flow Rate
Mass flow rate is the mass of fluid flowing per
unit time and is related to the volumetric flow
rate by the formula;

23
Units of Flow Measurement
The units used to express the rate of flow of a
substance can be of several types depending on
how the specific process needs the information.
TYPE OF UNIT OF FLOW MEASUREMENT
PROCESS
Solids This is normally expressed in weight rate e.g.
Tonnes/hour, Kg/minutes
Liquids Expressed both in weight rate and in volume
rate e.g. Tonnes/hour, Kg/minute, litres/hour,
litres/minutes, m3/hour etc.
Gases Express in volume rate at NTP or STP like Std
m3/hour, Nm3/hour, sccm, etc.
24
Steam Expressed in weight rate like Tonnes/hour,
Kg/minutes etc.
Basic Calibration Equipment/Tools

1. Multimeter

2. Insulation Resistance
Tester
25
4. Hart Communicator

5. Decade box

6. Signal generator
26
7. Dead weight
tester

8. Comparison
pump

9. Loop calibrator
27
10. Digital Pressure
calibrator

11. Hydraulic Hand

pump

12. Extension box

28
13. Temperature
bath

14. Test flange

29
15. Tool Box

16. Test bench

30
 Identification of Electrical /Pneumatic
Instruments
What does the term Pneumatic mean?
When you hear the word Pneumatic, it simply
means a system that uses compressed air to
transmit and control energy.
Pneumatics is the study of air and gases and the
relationship between volume, pressure and
temperature of the air

31
What is Electricity?
Electricity is a phenomenon associated with the
presence and flow of electric charge.
Reasons Why Compressed Air is used to
Operate Instruments
 It is a clean source of power
 Pressure transmission is undiminished in all
direction
 Low cost
 Environmentally friendly 32
Features of Instruments that uses Pneumatic
signals
 They uses nozzle/flapper principle
 They are operated by air ( verified on name
plate)
 No sign of electrical connection rather you
find a pot
 Pneumatic instruments exhaust the inlet air to
the atmosphere after use.
33
Some Standard Signals
 4 – 20 mA
 3 – 15 psi

Standard Analogue Signal

4 – 20 mA is used in electrical and
electro/pneumatic instrumentation to transfer
process measurement information.

34
Standard Pneumatic Signal
On the other hand 3 – 15 psi is used in
pneumatic instrumentation to transfer process
measurement information.

Electro-Pneumatic Instruments. What are

they?
They are instrument that are partly electrical and
partly pneumatic. An example of an electro-
pneumatic instrument is a current to pressure
transducer (I/P transducer). 35
 Basic Process Instruments
Gauges
These are devices that can measure and indicate
field variables
Types of Gauges
 Pressure gauges
 Temperature gauges
 Level gauges

36
Pictorial View of a Pressure Gauge

37
Pressure Gauge Description
The following constructional features are used
for pressure gauge description.
 Pressure range
 Facial size
 Process connection
 Constructional material
 Type of damping
38
Primary Element for Pressure Measurement
 Bourdon tube (“C”, Spiral and Helical
Shapes)
 Bellows
 Diaphragm
Types of Pressure Gauges
 Test gauge
 Process gauge
 Instrument gauge
39
Applications of Pressure Gauge
 Vessels and tanks
 Pipelines
 panels
 Process control manifolds
 Calibration operations

40
Temperature Gauge
Having defined a gauge, what would you say a
temperature gauge is? It is simply a type of gauge
that can measure and indicate different values of
temperature

41
Types of Temperature Gauges
1. Liquid in glass gauge (laboratory thermometer)
2. Bi-metallic temperature gauge (industrial
gauges)
3. Bourdon tube temperature gauge
4. Thermocouple temperature gauge
Temperature Gauge Installation
Temperature gauges are installed to a process by
means of an accessory known as the thermowell.
42
Types of Thermowell
 NPT thermowell
 Flanged thermowell
NPT Thermowell
Applications of Temperature
gauge
 Vessels and tanks
 Pipelines
 Instrument skid
 Control system
Flanged Thermowell 43
Units of Temperature Measurement
There are several units for temperature
measurement. Which of them do you know?
o
The Celsius scale ( C)
 It is the most commonly used temperature
scale
o o
 0 C and 100 C are the two fixed points of the
Celsius scale.
 It is worth noting that the triple point of water
o
is at 0.01 C (273.16K) 44
 o
The Fahrenheit scale ( F)
 The two fixed points used with the Fahrenheit
o o
scale is 32 F and 212 F
 The Fahrenheit scale has a linear relationship
with the Rankine scale
The Kelvin scale (K)
 Also known as the absolute thermometric scale
 It has a linear relationship with the celsius scale
 It is simply expressed as Kelvin (K) and not
o
degree Kelvin ( K) 45
 o
The Rankine Scale ( R)
 The rankine scale is to Fahrenheit scale what
the Kelvin is to Celsius scale
o
 It is expressed as ( R)

Relationship Between Temperature Scales

o
1) Kelvin (K) and Rankine ( R) Conversion
o
T(K) = 5/9 T( R)
o
T( R) = 9/5 T(K)
46
 o
2) Celsius ( C) and Kelvin (K) Conversion
o
T(K) = t( C) + 273.15
o
t( C) = T(K) – 273.15
o o
3) Fahrenheit ( F) and Rankine ( R)Conversion
o o
T( R) = t( F) + 459.67
o o
t( F) = T( R) – 459.67
o
4) Fahrenheit ( F) and Kelvin (K)Conversion
o
T(K) = 5/9 [ t( F) + 459.67]
o
t( F) = 9/5 [T(k) – 255.4] 47
 o o
5) Celsius ( C) and Fahrenheit ( F)Conversion
o o
t( C) = 5/9 [t( F) - 32]
o o
t( F) = 9/5 [t( C) + 17.7]
Exercises:
Work out the following temperature conversion
o
1. 50K to Rankine scale. [Answer: 90 R]
o
2. 40 C to Kelvin temperature
[Answer: 313.15K]
o
3. 44 F to Rankine temperature
o
[Answer: 503.67 R]
48
 o
4. 62 F to Kelvin temperature
[Answer: 289.8K]
o o
5. 37 C to Fahrenheit [Answer: 98.6 F]
o o
6. 84 F to Celsius [Answer: 28.9 C]

49
Level Gauge
Level gauges are devices that are used to
measure the depth of liquid in tanks and vessels.

But Why do We have

to measure Level ?
 To avoid spill
 For control of the process
 To be able to quantify the amount of liquid 50

consumed
Types of Level Gauges
 Dipping tapes and sticks: They are either
tapes with a weight attached to the end or a
graduated stick.
 Glass level gauges: These are also called
sight glasses. They are vertically mounted
level gauges usually provided with a
transparent glass window through which the
level of liquid within a tank can be visually
observed. There are two types namely the
reflective and transparent glass level gauge.
51
 Magnetic level gauges:
The magnetic level gauge consists of a float
carrying a magnet (the shape of which is like a
pineapple slice). The float/magnet assembly is
contained in the tank containing the liquid whose
level is to be determined. The gauge also has a
chamber which houses a series of small polarised
magnetic blades which flips over to indicate the
level as the float/magnet assembly passes them.

52
Characteristics of Magnetic
Level Gauge
1. Resolution is dependent on
the height of the magnetic
blade
2. Not very accurate (accuracy
= ±2mm)
3. Graduation is usually in
meters, centimetres or
volume
4. Can handle high pressure 53
o
100 - 200 bar and 400 C
Indirect Method for Level Measurement
This method is based on the formula for hydrostatic
pressure calculation.
The formula states; P = ρgh
2
Where: P = Pressure in Pascal (Pa) or N/m
3
ρ = the density of the liquid (kg/m )
h = the height of the liquid in meters (m)
2
g = acceleration due to gravity (m/s )
If pressure is known and the liquid has a uniform
density, then we can say that the level (h) is;
54
h = P ÷ (ρ x g)
Indirect Method of Level Measurement in an 55

Open Tank
Indirect Method of Level Measurement in a 56

Closed Tank
Example:
Calculate the level of liquid in the tanks with the
following parameters
1. The pressure indicated by the DPT connected to the
open tank is 200mbar (Hint: 1mbar = 100Pa)
3
the density of the liquid is = 1000 kg/m
2
Acceleration due to gravity = 10 m/s
[Answer: 2m]
2. The pressure indicated by the DPT connected to the
open tank is 52kPa
3
the density of the liquid is = 810 kg/m
2
Acceleration due to gravity = 10 m/s 57

[Answer: 6.4m]
Flow Gauges (Flow Meters)
Flow gauges are devices that can sense, measure
and indicate liquid flow rates.
“Orange Research flow gauges indicate liquid flow
rates from low flows of a few gallons per hour to
high flows up to 200 gallons per minute.”

58
Applications of Flow Gauges
 Hydraulic tanks
 Pressure vessels
 Coolant tanks
 Hydraulic line
 Oil reservoirs
SWITCHES
These are devices that can perform On/Off
operations in response to the magnitude of process
variables on their sensing line. 59
Types of Switches
 Pressure switch
 Temperature switch
 Level switch
 Flow switch
Pressure Switches
Pressure switches are instrument devices that
make or break electric/pneumatic circuits when a
certain pressure set point has been reached at their
inputs. 60
Types of Pressure Switches (Based on the type of
signal switched)
 Electrical pressure switch
61
 Pneumatic pressure switch
Types of Pressure Switches (Based on sensed
pressure)
 Absolute pressure switch
 Gauge pressure switch
 Differential pressure switch
Construction
The primary sensing element of a pressure switch
is often a piston seat arrangement where the sensed
pressure act directly against a spring force.
The secondary elements may be a nozzle/flapper
arrangement or a mechanism to operate an 62

electrical switch or a three way valve.

Applications of Pressure Switch
For monitoring of pressure on a pipeline and
sending signals for control basis.
Temperature Switches
They are instruments used in performing ON/OFF
operation in response to temperatures.
Types of Temperature Switches (According to
construction)
 Capillary type
 Probe type 63
Examples of Temperature Switches

64
Applications of Temperature Switches
For monitoring/Control of process temperatures,
such as temperatures of burners, heaters, etc.
Level Switches
These are instruments devices used to activate
ON/OFF operations in electrical/pneumatic loops
of process control systems in response to changes
in liquid level.
Level switches are usually calibrated to operated
at a defined set point. This set point is usually
decided and fixed during calibration. 65
 Electrical level switch installed on an
Electrical level switch horizontal tank
66
Constructional Features of Level Switches

67
Types of Level Switches
Pneumatic Level Switch: these work with the
nozzle/flapper principles.
Electrical level switches which work on the
principles of positive linear position transfer to dry
contacts of NC/NO.
Areas of Application of Level Switches.
 Tanks
 Vessels
68
Flow Switches
Flow switches are devices that operates to either
open or close electrical or pneumatic contacts when
it senses a flow in a process line.

69
Limit Switches (Proximity switches)
Limit switches are a type of sensor that detect
presence and absence.

Falcon valve actuator limit switch 70

There are mechanical limit switches that have
some sort of arm, lever, knob, plunger, etc., which
is physically or mechanically activated by making
contact with another object.

71

Mechanical limit switch

There are other variations of limit switches in
which the switch is not mechanically activated by
means of arm, lever etc. but are activated when
certain targets come into the region that can be
detected by the sensors (Proximity Switches).

72
Proximity Limit Switch
 Valve actuator proximity limit switches

It should be noted that the input of a Limit Switch

is always a rotational or linear force while the
output is a resistance through electrical contact.
73
Limit switches find application in equipment that
require rotational, linear or direction travel, such
as cranes, shutdown valves and other equipments
that have travel limit as a function of safety and a
switching device.

74

Valve actuator mounted limit switch

Pressure Regulators
Pressure regulators are devices used to obtain a
regulated output pressure at their output no matter
how much the inlet pressure is as long as it is
higher than the desired output and it is within the
range of pressure it is designed to handle

75

Instrument Air Pressure Regulator

Types of Pressure Regulator
1. Instrument air pressure regulator:- For
instrument air.
2. Process pressure reducing regulator:-
Designed to handle larger volume than the
instrument air regulator. It can handle
pressure typical of a process line.

76

Process pressure reducing regulator

 RECORDERS
A Recorder is an Instrument device that is used in
recording process variable values.
They leave permanent traces on a calibrated paper
known as “Chart paper”. Information about the
time at which the variable was recorded can also
be read from the chart paper.
They are useful because they allow us to keep
recorded values for further use or interpretation.

77
78
Pressure Recorders
This is a type of recorder that is designed to record
pressure values.
Temperature Recorder
A Temperature Recorder performs the function of
recording values of temperature in processes to
which they are installed.
Flow Recorder
In this case what is being measured and recorded is
the value of flow in a process control system.
79
Construction of a Recorder
1. Recorder casing
2. Chart drive (manual or electronic)
3. Pen mount or carrier (1,2 or 3 pen)
4. Pen arm (static, differential and temperature)
5. Static pressure element
6. Temperature element
7. Flow element
8. Chart plate
80

9. Chart paper
81
82
Recorders usually come with various numbers of
pen and thus can be regarded as;
 1 pen Recorder
 2 pen Recorder
 3 pen Recorder
Applications of Recorders
They are commonly use on;
 metering skid
 Hydro-testing exercise
 Instrument skid 83
3 WAY VALVES
Three way valves are instrument device employed
for ESD and OSD activation
ESD – Emergency Shutdown
OSD – Operational shutdown.

84

Pneumatic Pilot Operated 3 way valve Manually Operated 3 way valve

CONSTRUCTION
 They have three (3) ports
 The port can be of ¼ FNPT, 3/8 FNPT, ½
FNPT etc.
PILOT OPERATED 3 – WAY VALVE
This type of 3-way valve has a 4th port which is
also called the sensing or signal port.
The medium for the signal can be either Air or
Hydraulic.
Pilot pressure is usually very small (0-30 psi)
compared to the pressure of air at the inlet and 85
outlet ports of three way valves.
Solenoid Valves
These are electrically operated 3 – way valves. The
control signal here is voltage.
Common solenoid voltages are; 12VDC, 24 VDC,
48VDC, 120 VDC etc.

86
CONTROLLERS
A controller is a comparative device that receives
an input signal from a measured process variable,
compares this value with that of a predetermined
control point value and determine the appropriate
amount of output signal required by the final
control element to provide corrective action within
a control loop.
Types of Controller
Pressure Controller
Temperature controller 87

Level controller
Pressure Controllers
Pressure controller is a controller designed to
control process pressure. It has sensing pressure
input which detects the sensing pressure and utility
pressure output which is used for control operation.

88
Temperature Controllers
This type of controller is used in process control to
regulates process temperature about a desired value.

89
Applications of Temperature Controllers
They are commonly used in plastic extension,
injection, compounding screening industries.
They are also required in package sealing, paint
application, glass and heat treating factories.
Level Controllers
This is a device used in process control system to
control liquid levels in tanks or vessels.
The input is a set liquid level, while the output is a
utility pressure of a desirable value. 90
Applications of level Controllers
They are used to monitor and control level of water,
chemicals, lubricants, bulk solids, plastic etc.
in supply tanks, settling tanks and vessels.

91
Transmitters

92
When we talk about Transmitters we are talking
about Signal Transfer or Conversion.
The principle of Transmitters is based on sensing
the parameter (sensor), gathering information in a
physical value and converting the information
gathered to electrical or pneumatic values.
Below are standard signals commonly
encountered in process control systems.
 Pneumatic signal 3-15 psi
 Electric signal 4-20mA
 Voltage signal 1-5V 93
Therefore the basic function of a transmitter is to
transmit information via retrieving pneumatic or
electrical values from the sensor output and
convert them into a standardized signal usable by
acquisition equipments.
Acquisition Equipment are recorders, controllers,
process Automation system, HMI (Human
Machine Interface) etc.
Construction
Transmitters are made up of;
•Teat Body
•Transducer Element 94

•Converter
Types of Transmitters
1. Pressure Transmitter
2. Temperature Transmitters
3. Level Transmitters
4. Flow Transmitters
Pressure Transmitter
Pressure transmitters senses and transmit
electronic or pneumatic signals proportional to the
sensed pressure with reference to the operating
range of the device. 95
Rosemount 3051 Smart Pressure Transmitter

96
Temperature Transmitters
Temperature transmitters senses temperature and
produces standard output signal (3 – 15 psi or 4 –
20 mA) that is proportional to sensed temperature
with reference to the operating range of the device

97
Temperature Transmitter Installation drawing

98
Level transmitters
These are transmitters that measure level and send
4 – 20 mA or 3 – 15 psi standard signals as an
output.
Different type of level transmitters exist that are
based on different type of sensing and
measurement techniques/technologies. One of
such techniques has been discussed earlier under
indirect method for level measurement. This
measurement technique, measures level by
sensing the hydrostatic pressure in the tank.
99
The principle of operation is based on the
differential value of pressure measured and thus a
differential pressure transmitter (DPT) is used.
The high pressure port of the DPT is connected to
the tank at the minimum level while the low
pressure side senses the pressure at the top of the
tank above the liquid level. In some cases the low
side is connected to the atmosphere.
Any difference between the pressure sensed by the
two sides is due to the head pressure alone and can
be used to measure liquid level in the tank.
100
Level transmitters based on other
sensing/measurement technologies other than that
already mentioned include;
 Microwave level transmitter
 Radar level transmitter
 Guided radar or infra red level transmitter
 Capacitance level transmitter
 Tuning fork level transmitter
 Ultrasonic level transmitter etc.

101
Radar level transmitter Guided radar level
transmitter 102
Capacitance level Ultrasonic level
transmitter 103
transmitter
The value of output sent by transmitters
irrespective of their type is usually by two factors,
viz; the value of the measured variable and the
operating range of the transmitter. Without a
knowledge of the operating range of a transmitter,
the output signal of that transmitter will be
meaningless.

104
Flow Transmitters
Flow transmitters are those transmitters that are
able to send 4 – 20 mA analog outputs in response
to quantity of flow (volume or mass) measured by
a flow meter. They are usually an integral part of
some flow meters. Examples of such flow meters
includes;
 Vortex flow meters
 Swirl flow meters
 Electromagnetic flow meters
 Turbine flow meters 105
 Ultrasonic flow meters
 Coriolis flow meters

ABB CoriolisMaster MC2

ABB ProcessMaster Based on Based on coriolis flow
metering principle 106
Electromagnetic principle
To convert flow measurement from a flow
transmitter to normal or mass units in many cases
an additional temperature measurement is all that is
required and in some case pressure measurement
when there is process pressure variation to
compensate for the pressure effect.
Multivariable Transmitter Alternative
Multivariable transmitters measures all tree
parameters (Differential pressure, Absolute
pressure and Temperature) required by a flow
computer for the calculation of mass flow rate.
107
Rosemount 4088 Multivariable Transmitter
108
Additional measurement of temperature and pressure to convert
volumetric flow to mass flow.
109
DP Transmitter as Flow Transmitters
Orifice plate is the primary sensing element when
using a DP transmitter for flow measurement. Its
function is to create a differential pressure by
reducing the stream/flow size sharply thereby
creating a sudden pressure drop.

110

ABB 266MST Differential Pressure Transmitter

Installation of Flow Transmitters Primary
Element HP
Orifice Plate
LP

111
 VALVES
These are instrument devices that function as a
final control element for solids, liquids and gas
flow control.
There are various types of valves that differ in
construction and at times application. They
include;
According to Construction
• Ball Valves
• Globe Valves
• Gate Valves 112

• Butterfly Valves etc.

According to Function
• Pressure Relief/Safety valves
• Shutdown valves
• Blow down valves
•Control valves (Pressure, Flow, Level & Temp.)
• Check valves
There also exist, smaller valves that are robust and
very portable and are used for instrument
pneumatic and hydraulic signals control. They are
called instrument valves. Instrument valves are
mostly made of stainless steel and galvanized steel
materials. 113
Final Control Element
The instrument device or element that changes the
flow value directly or indirectly via a manipulated
controlled variable is called the final control
element e.g. valves, pumps etc.
Actuators
These are instrument device use to control the
opening or closing of valves. They can either be
pneumatically or electrically operated.
There are two types of pneumatic actuators.
Diaphragm or piston operated actuator. They can
also be classified as Air to Open (667) or Air to 114
close (657) actuator.
 115
Various types of pneumatic diaphragm actuator
Types of Actuators Based on Operation
 Spring loaded actuators
 Double acting actuators
Positioner
This is an instrument device that receives a
control signal (either pneumatic or electric) and
outputs a regulated proportional air pressure to a
pneumatic actuator. The output from a controller
is used to adjust the opening/closing position of a
valve or other final control element.
116
 Electro-Pneumatic Positioner

Pneumatic Positioner Pneumatic actuator with 117

Positioner
Globe Valve
Globe valve is the most widely used control valve
in process control system. They have the advantage
of providing tight shut off and can withstand high
differential pressure. Maintenance also is very easy

118

Single-seated and double-seated globe valves

Globe Valve

Internal Structure of a 119

Globe Valve
Butterfly Valve
These set of valves are economically, straight-
through flow design with low pressure drop and
little likelihood of clogging. They are specially
used for blurry processes.
Their disadvantage is that they do not shut off as
tightly as globe valve. They have very low
differential pressure.
The flow element of a butterfly valve is a disk.

120
Butterfly Valve

121

Structure of a Butterfly Valve

Ball Valve
The Ball Valve has a greater seating area because
its flow control element is a big sphere. They allow
higher differential pressure and have better seating
characteristics than butterfly valves.

122
Gate Valve
They have a straight-through flow and can be shut
off as tightly as globe valves.
They also have good sealing characteristics.
They have lower pressure drop than the globe
Valve but not as low as butterfly valves

123
Blow down/ Shutdown Valve
These are Ball Valves that are operated with either
pneumatic or electric actuators. Most of the control
panels are constructed to meet their design
philosophy. Blow down valve is a direct opposite
of a shutdown valve in operation. While a
shutdown valve is normally closed, a blow down
valve is normally open.

124
Actuated Valve (Shutdown/Blow down)

125

Spring loaded Shutdown valve Actuator

Control Valve
A control valve is usually made up of a valve ( globe
or butterfly) fitted with an actuator that is control by
a controller in response to the process variable
(pressure, flow, temperature, level, etc.)it controls.
A control valve actuator can be Pneumatic or
Electrically stimulated.

126

Globe control valve

Internal Structure of a Control
Valve

127
Pressure Relief /Safety Valve
PRV/PSV are safety valves that set limit on rising
pressures within liquid and gas lines. In normal
operation, the valve is closed and no pressure
passes from the inlet to the outlet of the valve.
But when pressure exceeds the set limit, the valve
opens to relieve pressure and thus protect the
facility on which it is installed from being
damaged due to over-pressure.
In practice, both PSV and PRV may be used
without distinction. However, there are technical
128
differences between them.
 Differences Between PRV and PSV

PRESSURE SAFETY VALVE PRESSURE RELIEF

VALVE
This relief device is installed onA PRV is a relief device on a
a compressible fluid or gas line. liquid filled vessel.
The opening of PSV is sudden The opening of a PRV is
and when it occurs, the valve gradual and it increases with
gets almost immediately to the pressure until it is fully open.
fully open position.
A PSV opens as soon as the set A PRV opens proportionally
point is reached with increasing inlet pressure

129
There are two types of PSV/PRV, namely;
 Direct Acting (Conventional) PSV – in this
type of PSV, pressure is held closed by the
direct force of a mechanical spring until the
cracking pressure is reached. The cracking
pressure can be set by changing the tension in
the spring using an adjusting nut.

130

Conventional PSV
 Pilot Operated PSV – this type of PSV
makes it possible to handle higher pressure
and flow. It is relatively smaller than a direct
acting PSV rated for the same pressure. A
pilot operated PSV is opened with the help of
a pilot valve.

131

Pilot operated PSV

Cut section of a Pressure Safety Valve

Pilot operated safety vlave

132

Conventional safety valve

Further Calibration Tools and Equipment
1.Foxboro Tool Kit Bag
2.Clamp Meter
3.DC Power Supply
4.Safety Barrier
5.Lap Top
6.Standard Test Gauge

133
 STEPS PROCEDURE FOR
PNUEMATIC INSTRUMENT
CALIBRATION

134
PRESSURE,TEMPRATURE AND FLOW
RECORDER CALIBRATION

Calibration test equipment are:

1. Pressure source
2. Test manifold
3. Test gauge
4. Tubing and fittings
5. Foxboro calibration kit
6. Temperature bath 135
Calibration steps
1. Firmly secure the recorder by placing it on a 2”
fabricated stand.
2. Hook-up tubing from the pressure source to the
recorder and a test gauge.
3. Check the zero alignment of the recorder via the
calibration chart.
4. Adjust and correct it if necessary.
5. Apply 25%, 50%, 75% and 100% of the total range of
the recorder element.
6. Check if there are variations if yes then make
adjustment to correct errors
Note: Your adjustment depends on the errors found.
There are basically three errors; 1. Zero, Linearity and 136
Angular
 PNEUMATIC PRESSURE SWITCH
CALIBRATION PROCEDURE (AMOT SWITCH)
Calibration Test Equipment are:
1. Air compressor
2. Pressure Source(Hydraulic hand pump/druck
Calibrator)
3. Air Regulator
4. Test Gauge
5. Manifold
S w it c h G au g e

Air
C o m pa ra t o r
C o m p a ra t o r

137
Calibration Steps
1. Hook-up the sensing pressure port of the pressure
Switch to the test manifold
2. Connect the Air source to the 3-way valve of the
switch via tubing and fittings
3. Know the set point of the switch
4. Apply pressure slowly to ascertain the set point of the
switch sensing
5. Make pressure adjustment if there are deviation
6. Confirm the switch response at the set point
7. At the point of response note the change of state.
Then record the set point and reset value of the
switch. 138
PRESSURE GAUGE CALIBRATION PROCEDURE

Calibration Test Equipment are;

•Dead weight tester
•Foxboro calibration kit
•Pointer extractor
•Hand tools

139
Calibration Step
1. Confirm Zero reading and adjust if necessary
2. Mount gauge on dead-weight tester and apply pressure
3. Apply calibration pressure equal to 25%, 50%, 75%
and 100% of the full range of the pressure gauge.
4. Check if there are deviation as compared to the applied
weight on the dead-weight tester against the pressure
gauge.
5. Correct variation if there are; repeat steps 1 to 3 and
record the calibration result for both the rising and
falling pressures.

140
CALIBRATION OF TEMPERTURE SWITCH
Calibration test equipment are:
•Fluke multi-meter
•Temperature Bath
•Hand tools
Calibration Step
1. Confirm the set point of the temperature Switch
2. Set up the temperature bath and turn it on
3. Insert the probe or capillary of the switch in the
temperature bath.
141
4. Stimulate the bath to the temperature of the switch (set
point)
5. Confirm that the switch trigger at set point
6. Adjust switch set point nut or knob if need be. Record
the set and reset of the switch
7. Repeat steps 4-5 and confirm that the switch is
operating as desired

142
CALIBRATION OF PRESSURE CONTROLLER
Calibration Test Equipment are;
• Portable air compressor
• Air Regulator
• Druck Calibrator/Hydraulic Hand Pump
• Pressure gauge
• Test manifold
• Tubing/fittings
• Hand tools
143
Calibration step
1. Connect the instrument line from the compressor to the
controller air supply inlet (1-2 bar)
2. Connect the process signal line from pump to the
controller with a test gauge
3. Connect a gauge manifold to the output of the
controller to monitor the output signal.
4. Confirm the set point of the pressure controller

144
5. Confirm the action of the controller
6. Apply the process pressure slowly to attain the set
point of the controller
7. Confirm if the controller gives an output signal at the
set point
8. Perform set point adjustment if necessary by turning
the set point adjustment and the proportional band
knobs
9. Repeat step 5 and 6 then record calibration values

145
CALIBRATION OF TEMPERATURE
CONTROLLER
Calibration test equipment are;
• Temperature bath
• Portable air Compressor
• Thermometer
• Hand tools
Calibration Steps
1. Insert the controller capillary into the temperature bath
2. Confirm the set point of the controller
146
3. Stimulate the temperature bath by setting it to the
required temperature
4. Confirm where there is an output signal from the
controller at the temperature set point value
5. Make necessary adjustment to the controller output if
there is a variation between the set point and the
controller output
6. Ensure the controller gives an output signal when the
process value reaches the temperature set point value.

147
TRANSMITTER CALIBRATION PROCEDURE
Calibration test equipment are;
• Power pack AC – DC
230 – 24
• Resistance box
• Hart Communicator (375)
• Pressure Source (Hydraulic Pump, Druck Calibrator)

148
Calibration step (workshop)
1. Mount the pressure transmitter on a 2” Fabricated
stand pipe.
2. Connect the power source 230AC to an AC-DC
converted 24VDC
3. Loop the power source with a Resistor of 250 ohms.
4. Power the Transmitter via the Loop
5. Ensure the Transmitter is powered
6. Check the protocol used by the Transmitter and Turn
On the Hart Communicator to same protocol;
7. Ensure there is a communication between the
149
Transmitter and Hart Communicator
8. Carry out a Loop check on the Transmitter by inputting
the correct output of 4, 8, 12 ,16 and20 mA and confirm
if the Transmitter response to those output values
9. Confirm the pressure range of the transmitter
10.Calibrated the Transmitter by applying 0%, 25%, 50%,
75% and 100% of the pressure range of the Transmitter
11.Confirm the Transmitter gives an equal analogue output
of 4,8,12,16 and 20mA at each pressure test point.
12. Make adjustment where necessary via the hart
communicator on the transmitter
13. Repeat step 8-11 and confirm everything is correct.
14. Record all observation and correction and re-
commission/certifythe transmitter ok. 150
CONTROL VALVE CALIBRATION PROCEDURE
Calibration Test Equipment
• Hand Tools
• Loop Calibrator
• Air compressor

151
Calibration Step
1. Confirm the action of the valve (fail open or fail close)
2. Confirm the spring rating of the diaphragm
3. For electro-pneumatic control valve connect the air source
to the valve with a regulator.
4. Connect the loop calibrator to the I/P converter with the
right polarity
5. Stroke the valve by applying 4,8,12,16 and 20mA and
check if the movement corresponds with the valve
indicator scale.
6. Make adjustment on the valve via the positioner and valve
stem accordingly
7. Repeat step 5-6 and confirm if the valve movement is
152
same with the current input.
8. Record your data and certify the valve ok
PRESSURE SAFETY VALVE CALIBRATION
PROCEDURE
Calibration Test Equipment
•Various Flange sizes
•Test gauge
•Test bench
•Mechanical tool box
•Air compressor
PSV Test Gauge

Vent
Pressure
Source
153
Calibration steps
1. Inspect the internal and external part of the PSV
against corrosion and metallic deposit
2. Clean the inlet/outlet of the PSV with Air.
3. Record all data of the PSV
4. Mount the PSV on the test bench
5. Confirm the set point of the PSV
6. Apply pressure slowly up to the set point of the PSV
7. Confirm the PSV relieves properly at the set point
8. Confirm the PSV reseat after relieving within 97% -
95% of its set-point.
9. Repeat step 6-8 and confirm that the PSV maintain a
constant relieving and reseating sequence
10.Depressurize and dismantle the PSV from the test 154
bench
11.Tag the PSV and certify the PSV.
Thank You