INDUSTRIAL

INSTRUMENTATION
MS. ANEM SAEED
 Pressure Sensor
“IN ANY GIVEN PLANT, THE NUMBER OF PRESSURE GAUGES
USED IS PROBABLY LARGER THAN ALL OTHER INSTRUMENTS
PUT TOGETHER”
Objectives
Study of pressure measuring instruments of latest technologies
Types/classification and working principles of pressure measuring
instruments
Selection criteria of pressure measuring devices to suit an
application
Pressure Measurement
1. Pressure = Force / Area
2. It is in perpendicular direction to the surface it contacts
3. Pressure can be used inferentially to measure other variables
such as Flow and Level
4. Fluids exerts pressure on the containing vessel equally and in all
directions
Pressure Measurement
1. The SI unit of Pressure measurement is Pascal (Pa) which is
equivalent to (N/m2) or (kPa).
2. In English systems, the pressure is usually expressed in (psi) and in
(psig) where “g” is the indication of gauge pressure.
Pressure Measurement
Pressure Measurement
Pressure is commonly quoted as being Absolute or Gauge
Pressure Measurement
Pressure Measurement Methods
1. Elastic pressure transducers

2. Manometer method

3. Pressure measurement by measuring vacuum

4. Electric pressure transducers

5. Pressure measurement by balancing forces produced on a known area

by a measured force
Elastic Element Pressure Gauges
1. Elastic elements employed in these type of pressure gauges show
elastic deformation.
2. The magnitude of deformation is the measure of the force which is
indication of the pressure that caused the force.
3. Dynamic feature of elastic elements is that they are not only used for
pressure measurement but also for flow measurement and level
detection.
4. Different shapes of elastic elements have been devised to cover
different types of pressure ranges.
Elastic Element Pressure Gauges
1. From low to high pressure range, the elastic element
pressure gauges can be described in the following order:

 Bellow type pressure gauge

 Diaphragm type pressure gauge
 Bourdon type pressure gauge
Bellow Pressure Gauges
Sensitive to very low pressure
Specify low pressures with proper
indicating mechanism
Strong enough to deliver accurate
reading
 Bellow Pressure Gauges
A typical bellow is a metallic unit made up of small
circular parts
The main attribute if this element is that it only
expand axially when pressure is applied
Bellows elastic element can be made from brass,
bronze, stainless steel, beryllium – copper or any other
metal alloy depending on the type of service requires.
The main factors to be considered in this regard are:
strength or pressure to be faced, fatigues and
corrosion resistance or corrosion protection.
Bellow Pressure Gauges
Bellow is connected by linkages to either
direct pressure indication trough pointer
or electrical signals as in transducer.
Usually bellows assembly comprises a
spring which doesn’t let bellow expand
completely and avoid permanent damage.
They are present as a single element and
also as dual bellow assembly.
Diaphragm Pressure Gauge
Diaphragm are popular because they required less space
and the motion they produce is sufficient for operating
electronic transducers
Diaphragm Pressure Gauge
Diaphragm element is basically a membrane capable of
elastic deformation.
It is a thin film of elastic material having a circular shaped
flat or corrugated structure.
Diaphragm Pressure Gauge
The membrane can be of various types of materials depending on
the pressure range.
For low pressure operations rubber, leather and plastic sort of
material are employed.
For moderate pressure material like silicon is utilized.
For high pressure stainless steel and other iron alloys are employed.
The diaphragm pressure gauges has rest of the arrangement same
as in case of bellows.
Diaphragm Pressure Gauge
Capsules are formed when two diaphragms are joined together
back to back by soldering or welding.
Metals like brass, bronze, beryllium and copper are used to make
capsules.
Diaphragm Pressure Gauge
In simple diaphragm pressure gauges one side is subjected to
atmospheric or reference pressure and the other side to the
external pressure that is to be measured.
Diaphragm Pressure Gauge
When pressure is applied to only one side of the diaphragm it
gives the gauge pressure.
For measuring absolute both sides of the diaphragm are subjected
to different pressure.
Diaphragm Pressure Gauge
They are used to measure gauge pressures over very
low ranges.
Two types of diaphragm pressure gauges are:
1. Metallic diaphragms gauge (brass or bronze)
2. Slack diaphragms gauge (Rubber)
Bourdon Tube Pressure Gauge
For high pressure measurement, Bourdon type pressure gauges are
more advantageous because of high mechanical strength with a
reduced area for pressure to work against.
Bourdon tubes are circular shaped tubes with oval cross section
and mainly found in following three shapes:
C-shapes
Helical
Spiral
Bourdon Tube Pressure Gauge
The shape and material of construction used depends on the
pressure range for which it is required.
Most commonly used materials are bronze, beryllium, copper or
stainless steel.
High tensile strength material is essential for high pressure
operation.
Bourdon Tube Pressure Gauge
Bourdon tubes are generally are of three types;
1. C-type
2. Helical type
3. Spiral type
Bourdon Tube Pressure Gauge
Bourdon Tube Pressure Gauge
Bourdon tubes have one end fixed and one free end.
When pressure is applied within the tube the surface area
of tube tends to change.
The distension caused in the tube ultimately straightens
the tube slightly and gradually until the pressure is balanced
by the elasticity of the element.
Bourdon Tube Pressure Gauge
The end that is fastened to a fixed position remains static,
the free end thus moves when the pressure develops inside
the tube and the movement of the free end can be
transmitted through a pointer to indicate reading on a scale.
It can be connected to any other electrical transducers or
recording device through mechanical linkage.
Electric Pressure Transducers
Electrical pressure transducers can be considered a modified form
of elastic pressure gauges as the employ elastic element.
Pressure sensing element such as a bellow , a diaphragm or a
bourdon tube.
Along with the pressure sensing element, there are primary
(resistance or voltage) and secondary conversion elements to
convert pressure signals into readable signals.
Electric Pressure Transducers
Electrical pressure transducers use electrical circuit to convert the
motion produced by the mechanical pressure elements into changes
in electrical values. These values can then be measured to indicate
pressure.
There are mainly three types of electrical pressure transducers –
inductive, resistive, and capacitive.
Electric Pressure Transducers
So generally they are the devices that convert mechanical output
into electrical signals.

Pressure Detection Block

Diagram
Types of Electric Pressure
Transducers
Some of the most commonly used electrical pressure sensors are:

Strain gauge pressure transducers

Capacitive pressure transducers
Potentiometer pressure transducers
Resonant Wire pressure transducers
Piezoelectric pressure transducers
Strain Gauge Pressure Transducers
A strain gauge is a resistance pressure transducer whose electrical
resistance changes when it is stretched or compressed.
The resistance of metal conductor under constant temperature
varies directly with length and inversely with cross section area.
R = K = L/A
Strain Gauge Pressure Transducers
When a wire of such metal is stretched or is under strain it tends to
increase in length and decrease in diameter which consequently
cause change in resistance of the metal.
The change in resistance is measure of the force applied.
The device that exploit these phenomena is known as strain gauge
and is primarily used to measure the pressure of system and know as
pressure transducers.
Strain Gauge Pressure Transducers
A pressure transducer contains an elastic element (diaphragm)
which is deformed by the pressure which can cause a strain gauge to
stretch or compress. This deformation of the strain gauge causes the
variation in length and cross sectional area due to which its
resistance changes.

Strain Gauge
Strain Gauge Pressure Transducers
A Strain gauge is a sensor whose resistance varies with applied force; It
converts force, pressure, tension, weight, etc., into a change in electrical
resistance which can then be measured.
Depending upon the wire arrangement and dimensions the strain gauges
can be divides into bonded and unbounded types.
When the pressure is applied the elastic element flexes and along with it the
electrical wire.
The resistance in the wire changes and in order to measure this strain it
must be connected to an electrical circuit that can measure minute changes
in resistance with change in strain.
Strain Gauge Pressure Transducers
Staring gauge transducers usually employ 4 strain gauge elements
electrically connected to form a Wheatstone bridge circuit.
Strain Gauge Pressure Transducers
Strain gauge pressure transducers can be used in different
configurations for measuring gauge, absolute, differential and
vacuum pressure.
Strain gauge pressure transducers are used for narrow pressure
span and for differential pressure measurments
Available for pressure ranges as low as 3 inches of water to as high
as 200,000 psig
Inaccuracy ranges from 0.1 % of span to 0.25 % of full scale
Capacitive Pressure Transducer
Capacitive type pressure sensors exploit capacitive properties of a materials.
Capacitance is a measure of amount of electrical energy stored for a given
potential.
The most basics form of capacitor is about two plates separated by some
insulator in between.
The capacitance equation for two plates is:
 Capacitive Pressure Transducer
The capacitance equation for two plates is:

C=ε0 εr A/d
Where,
C = the capacitance of a capacitor in farad
A = area of each plate in m2
d = distance between two plates in m
εr= dielectric constant
ε0 = 8.854*10^-12 farad/m2
Capacitive Pressure Transducer
Thus, capacitance can be varied by changing distance between the plates, area
of the plate or value of the dielectric medium between the plates. Any change in
these factors cause change in capacitance.

In capacitive transducers, pressure is utilized to vary any of the above

mentioned factors which will cause change in capacitance and that is a
measureable by any suitable electric bridge circuit and is proportional to the
pressure.
 Capacitive Pressure Transducer
When the two input pressures are equal the
diaphragm is positioned centrally and the
capacitance are equal.
A difference in the two input pressure causes
displacement of the sensing diaphragm and is
sensed as a difference between the two
capacitances
Capacitive Pressure Transducer
Most common design in capacitive pressure transducers has a diaphragm plate.
The capacitance is varied by using a fixed plate and other diaphragm plate.
The diaphragm plate is primary sensing element.
Made of metal or metal coated quartz. Stainless steel or nickel steel alloys are
preferred choice of materials for diaphragm.
The diaphragm is subjected to process pressure and the f=deflection of
diaphragm is indication of the change in process pressure.
Capacitive Pressure Transducer
Wide range ability from high vacuum in the micron range to 10,000
psig
Differential pressure as low as 0.01 inch can be readable
Accurate within 0.1 % of reading or 0.01 % of full scale
 More Corrosion resistant
 Potentiometer Pressure Transducer
The device consists of a
potentiometer whose wiper
alarm is mechanically linked to
bourdon tube or bellow. The
movement of wiper alarm
across the potentiometer
converts the mechanically
detected sensor deflection
into a resistance measurement
using a Wheatstone bridge
circuit.
Potentiometer Pressure Transducer
-- Extremely small and installed in very tight quarters such inside the
housing of 4.5 in dial pressure gauge
-- Provide strong output so no need of additional amplifier
-- Range 5 to 10,000 psig
-- Accurate within 0.5 % and 1 % of full scale
Resonant Wire Pressure Transducer
A wire is griped by a static
member at one end and by the
sensing diaphragm at the other.
An oscillatory circuit causes the
wire to oscillate at its resonant
frequency. A change in process
pressure changes the wire tension
which in turn changes the
resonant frequency of the wire. A
digital counter circuit detects the
shift.
Resonant Wire Pressure Transducer
-- Used for low differential pressure applications
-- Generates inherently digital signal
-- Sensitive to shock and variation

-- Range :
From Absolute pressure 10 mm Hg
Up to Differential pressure 750 in Water
or Gauge pressure 6000 psig

-- Accuracy 0.1 % of Calibrated Spam

Piezoelectric Pressure Transducer

When a pressure , force or

acceleration is applied to
a quartz crystal , a charge
is developed across the
crystal that is proportional
to the force applied
Piezoelectric Pressure Transducer
-- Signals generated by crystals decays rapidly
-- measure rapidly changing pressure resulting from
blasts, explosions or pulsation pressures

-- Range : 5,000 to 10,000 psir

-- Rugged construction, small size and high speed

Where and How have EPTs failed?
EPTs require a constant supply of electricity for them to function.
They do not come with built-in power supply.
High performance comes at a cost. Installation of auxiliary display
modules and electrical circuitry increases capital cost.
Physical properties, like temperature, which can effect electrical
constants may effect the consistency of EPTs.
Where and How have EPTs failed?
For this reason, temperature compensation is always required with
EPTs.
Some electrical phenomena, like piezoelectric energy, have limited
applicability. This limits their use in industry.
Electricity exposes personnel to potential hazards.