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Abstract
This section is a practical guide to the selection, specification, and installation of
instruments for indicating, recording, and controlling pressure. Section 410
discusses general concepts of pressure measurementparticularly-as they bear on
selecting a pressure instrumentdescribes and discusses specific devices and
provides guidance in their application and specification. Section 420 gives general
and specific guidance for the installation of pressure instruments. Section 440 lists
reference material for further reading.
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Contents
Page
410
400-2
411
General Information
412
Pressure Elements
413
Pressure Gages
414
415
416
Pressure Transmitters
417
Pressure Switches
418
Draft Gages
419
Diaphragm Seals
420
421
422
430
431
Standard Drawings
440
References
400-16
400-19
400-1
July 2000
Range
Field indicators, recorders, and transmitters should have ranges approximately
double the expected operating pressure. The field pressure controller range should
cover the minimum and maximum operating pressures.
Units of Calibration
Pressure instruments should read in the following units:
Above atmospheric: Pounds per square inch gage (psig), inches of water
(inches H2O), or inches of mercury (inches Hg)
Below atmospheric: Pounds per square inch absolute (psia), ounces per square
inch, inches H2O vacuum, or inches of mercury vacuum (inches Hg vac). Absolute pressure instruments should be ordered with compensation for barometric
pressure changes
Overrange Protection
Pressure instruments should withstand the maximum operating pressures encountered. Under unusual conditions, such as thermal expansion, the instrument may
exceed its range. Most instruments can withstand overpressures up to 1.4 times their
maximum range. Instruments exposed to a vacuum should be selected to withstand
full vacuum. Certain pressure elements can withstand high overrange. Diaphragm
elements with capsules backed up by a metal housing have a high overrange
capacity, and many modern electronic pressure transmitters can withstand extreme
overpressure. Pressure limiting valves, or gage savers, block the inlet pressure at a
preset limit, but are rarely used.
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400-2
Chevron Corporation
Fig. 400-1
Fig. 400-2
Connection Size
The process connection for all pressure instruments should be -inch male or
female National Pipe Thread (NPT). Receiver gages should have a -inch NPT
process connection.
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July 2000
requires a specific type of sensing element. In this case it is important to know the
differences between various instruments.
Manometers
A manometer is a U-shaped tube filled with a liquid, usually mercury or water. A
differential pressure will cause the column on the high-pressure side to fall and the
column on the low-pressure side to rise. The value of the differential pressure equals
the difference in hydrostatic head between the two columns of liquid. Manometers
are used to indicate low pressures, such as furnace drafts, and to calibrate low-pressure instruments.
Bourdon Tubes
A Bourdon tube (Figure 400-3) is a curved metal tube closed at one end and fixed to
a pressure source at the other. Application of pressure at the fixed end results in
movement at the free end as the tube cross section deforms. Bourdon tubes come in
a C shape, spiral, or helix, depending on the pressure to be measured. The Bourdon
tube is the most commonly used element for pressure gages.
Bellows
A bellows pressure element expands when pressure is applied to the inside, actuating an indicator, transmitter or controller. Bellows elements are generally used in
pressure ranges from 0 to 10 inches H2O and from 0 to 10 psig, and for vacuum
ranges from 10 to 20 inches H2O. In pneumatic instruments, bellows usually operate
at approximately 3 to 15 psig.
Diaphragms
The diaphragm sensor is a thin flexible metal disk. Pressure applied to one side of
the disk causes a deflection that actuates the indicator, transmitter, or controller.
Diaphragm elements are used to measure very low pressures, and vacuums
from inch to 5 inches H2O. They are commonly used to measure furnace draft
pressures.
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400-4
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Fig. 400-3
(a) C SHAPE
(b) SPIRAL
(c) HELICAL
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400-5
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Fig. 400-4
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400-6
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Fig. 400-5
Fig. 400-6
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400-7
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The sensing side of each direct-operated pressure regulator and field pressure
controller
Across filters
Furnace fuel oil, fuel gas, and atomizing steam branch headers
Each furnace, using a single draft gage manifolded to the convection section
inlet, bridgewall, and below the stack damper
Rating
For most process applications, pressure gages with an accuracy grade 2A in accordance with ANSI B40.1, GaugesPressure Indicating, Dial Type, Elastic Element,
are acceptable. Grade 2A means the pressure gage is accurate to 0.5% of span.
Gage Construction
Pressure gages should have 4-inch dials, -inch gage connections, and stainless
steel movements (gages with 6-inch dials are also acceptable in most locations). The
case can be cast iron or cast aluminum with a blowout plug or plastic (fiberglassreinforced polypropylene or phenolic) material with a blowout back. The gage
connection should have wrench flats. The lens should be shatterproof glass. White
dials with black figures and letters are standard. Other colors and graphic designs
are available. Adjustment of the zero should be possible without removing the
pointer from its shaft.
All pressure gages should display the tube, tip, and socket material on the front dial.
The information should be imprinted by the manufacturer and should clearly
describe the materials.
Range
Pressure gage range should be selected so that the gage operates in the middle third
of the scale. Overrange and underrange travel stops should be provided.
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400-8
Chevron Corporation
When the maximum scale reading is 1000 psig or higher, metal case gages should
have solid fronts separating the dial from the movement (this is standard with plastic
cases). Also, the Bourdon tube should be bored instead of drawn, and the connection between the Bourdon tube and the socket and tip should be threaded and backwelded.
Liquid-filled Gages
The cases of liquid-filled gages are filled with a viscous lubricating fluid. Such
gages maintain their accuracy much longer than conventional gages. They should be
used in pulsating or vibrating services, such as the discharges of reciprocating
pumps and compressors, and should be considered for other severe services. The fill
liquid should be glycerine for ambient temperatures above 0F and silicone oil for
ambient temperatures below 0F, or if the process fluid and glycerine are incompatible. Mineral oil (sometimes specified under the brand name Kaydol) is acceptable for services above 0F. Liquid-filled gages should be filled until only a trace of
a bubble is left in the face, to allow for thermal expansion and to show that the gage
case is filled. The maximum temperature for liquid-filled gages is 150F.
Receiver Gages
Receiver gages should have 4-inch diameter dials, bronze Bourdon tubes and
stems, and -inch NPT process connections. Local instrument air pressure gages on
control valves, pneumatic transmitters, and controllers should have 1-inch or
2-inch diameter dials. Receiver gages and instrument air pressure gages should be
rated Grade B in accordance with ANSI B40.1. Grade B pressure gages are accurate to 2%.
Each instrument air supply regulator outlet (if the regulator does not have a
pressure gage)
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Inlets and outlets (both shell and tube side) of all heat exchangers and reboilers
400-9
July 2000
It is not necessary to change the pressure setpoint from a central control house
It is not necessary to record the pressure from a central control house
It is not necessary to change the controller tuning from a central control house
The controlled pressure is not part of a cascade loop
Field pressure controllers may be either indicating controllers or recording controllers. Blind controllers are rarely used.
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Control Mode
The control mode is normally selected from the following options:
On/off control. For alarms, protective devices, and startup and shutdown of
equipment
Proportional only control. For simple pressure control where small variations
from the setpoint are unimportant. The proportional band should be adjustable
at least from 0% to 200%
Proportional plus reset control. This is the usual control mode for field pressure controllers. The proportional band should be adjustable at least between
0% and 200%. For applications where the controller occasionally operates
above or below setpoint or in intermittent service, it should be specified to
include anti-reset windup
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400-11
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same two wires that carry the output signal. Smart transmitters that operate on a
24-volt DC power supply are preferred. Some advantages of smart transmitters
include lower cost of ownership, improved diagnostic capabilities, ease of calibration and commissioning. The electronics enclosures for newer transmitters minimize the effects of radio frequency interference (RFI). In addition, much of the RFI
in the signal wiring can be eliminated by metal conduit.
Electronic pressure transmitters must be specified to meet the appropriate electrical
classification. Intrinsically safe transmitters must be specified as such and so labeled
by the manufacturer. Transmitters should be supplied with linear output meters and
with accessories for mounting on a 2-inch pipe.
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switch contacts are used in many producing applications. They are usually electrical but can be pneumatic.
Explosionproof (NEMA 7)
Weather-resistant (NEMA 3 & 4)
General purpose (NEMA 1)
Electrical pressure switches should have snap-acting, dual, single pole double throw
(SPDT) or double pole double throw (DPDT) contacts. The contacts should be rated
to supply the operated device with a minimum of 10 amperes at 115 volts AC and
5 amperes at 28 volts DC. For potentially corrosive environments and for intrinsically safe systems, hermetically sealed switch contacts should be specified. The
engineer should study the switch specifications to verify that its ratings are compatible with the application. Switch contacts should be open in the alarmed condition.
Terminal blocks or terminal strips should be provided. Dead front or shrouded
terminal blocks are acceptable.
The electrical conduit connection should have a minimum diameter of inch. If the
switch contacts are handling milliamp signals, the contacts may be specified with a
gold or other conformal coating to minimize oxidation. This usually adds only about
20 dollars to the cost of the switch.
The pressure element may be a Bourdon tube, a bellows diaphragm, or a spring
disk. Spring disks are preferred if the application permits a relatively large dead
band (about 7% to 8% of the differential pressure range). Otherwise, specify
Bourdon tubes for set pressures above 100 psig and bellows diaphragms for set
pressures less than 100 psig. The pressure switch setpoint should be in the middle
third of the range. Proof pressure should be higher than the maximum process pressure.
Electrical pressure switches are available with either a fixed or an adjustable dead
band between the setpoint and the reactivation point (see Figure 400-7). Closedifferential switches are generally factory set at 0.5% to 1% of the span. On double
adjustment switches, both the set and reactivation points can be adjusted. The
minimum differential varies from 2% to 8% of the span. The type of switch depends
on the application.
Electrical pressure switches should have internally adjustable setpoints with calibrated scales. Dual control electrical pressure switches are available with two independent switches in the same housing.
Selection of the adjustable range for a specific installation should consider both the
setpoint actuation accuracy and the life factor. For greatest accuracy, the setpoint
should fall in the upper half of the range. For the most favorable component life, it
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400-13
July 2000
Fig. 400-7
should be in the lower half. The usual compromise is to specify a setpoint in the
middle third of the range.
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Chevron Corporation
are available. In vibrating service, diaphragm seals should be remotely mounted and
have armored stainless steel capillary tubing. Diaphragm seals have the following
applications:
Steam
Dirty process streams containing solids that can plug the pressure element
Diaphragm seals can be used at temperatures ranging from -40F to 1500F. They
can have either a -inch or 1-inch NPT screwed or flanged process connection,
depending on the piping classification. The bottom housing and the diaphragm
material should be 316SS or better and should be compatible with the process fluid.
Filling fluid identification or maximum temperature limit should be stamped on the
body or nameplate. The diaphragm should be welded or attached to the body so that
fluid will not escape when the diaphragm is disassembled.
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Stepladder or
Rolling Platform(1)
Permanent
Ladder
Pressure Transmitter
Yes
Yes
No
Yes
No
No
Yes
No
No
Yes
No
No
Yes
Yes
Yes
Instrument Type
(1) Provided the instrument is less than 10 feet above grade and the site is safe for a ladder or platform.
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For process leads, pretraced, preinsulated tubing bundles, heated either by steam or
electricity, are preferred. In liquid service where plugging is likely (i.e., heavy fuel
oil) pressure taps should be located in the top half of the pipe.
Siphons
Siphons, or pigtails, should be provided for vapor services above 150F and for
steam service to prevent the condensing vapor from overheating the instrument. In
liquid service, if the pressure gage is mounted above the pressure tap, a siphon
should be provided when the process fluid temperature exceeds 300F. See
Standard Drawings GB-J1143, GB-J1146, and GB-J1147. See also API RP 551,
Section 4.3.4.
Tubing
AP RP 551 recommends -inch or 3/8-inch O.D. tubing to connect remote-mounted
pressure instruments to process connection block valves. For manufacturing applications, -inch O.D. stainless steel tubing should be used. For production applications, many facilities have standardized on 3/8-inch O.D. stainless steel tubing.
Restriction Fittings
Restriction fittings are installed at the root valve to minimize the release of process
fluid should the instrument or instrument tubing fail. They are subject to plugging
and are generally used only in toxic (H 2S), corrosive (NH3), hazardous (LPG) and
clean refinery stock services. Remotely mounted pressure instruments should
include a restriction fitting screwed into the outboard end of the root valve. The
fitting should be a special blind tubing fitting with a small-diameter drilled hole.
(See Standard Drawing GB-J1223). Pressure instruments mounted directly on the
root valve should include a restriction adapter screwed into the outboard end of the
root valve. The adapter should be made of steel barstock with NPT threads at both
ends.
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Pressure Switches
Facilities for testing alarms and shutdowns should include but not be limited to:
Field High Pressure Switch. A pressure gage on the switch process lead and a
valved connection should be provided to permit testing with a portable pressure source. See Standard Drawings GB-J1146 and GB-J1147
Field Low Pressure Switch. A pressure gage on the switch process lead and an
atmospheric bleed connection should be provided to bleed off pressure and
permit testing against the pressure gage reading. In LPG, high H2S, and other
hazardous services, the bleed should be piped to the relief system or another
safe place. See Standard Drawings GB-J1146 and GB-J1147
Draft Gages
See Standard Drawing GB-J1148 for typical installation.
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GB-J1143
GB-J1144
GB-J1146
400-18
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GB-J1147
GB-J1148
GB-J1223
440 References
The Company employs the following industry codes, standards, and recommended
practices for the design, specification, and installation of pressure instrumentation:
Chevron Corporation
1.
2.
ISA S20, Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves, Instrument Society of America,
1981.
3.
Pressure Instrumentation, Production Facility Bookware Series, Paragon Engineering Services, Inc., 1987.
4.
5.
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