Report on Instrumentation

CONTENT

1. INSTRUMENTATION.....page 3
2. AIR OPERATED CONTROL VALVES.......page 3
3. FLUID FLOW MEASUREMENTS.......page 5
4. TEMPERARURE MEASUREMENT.......page 7
5. PRESSURE MEASUREMENT ......page 9
6. LIQUID MEASUREMENT...page 10
7. REFERENCES......page 11
FIGURES
Figure 1.1Pressure Control Air Valve ...page 4
Figure 1.2 Orifice Plate In Flange Connection . .....page 5
Figure 1.3 Rotameter .page 6
Figure 1.4 Bimetallic Dial Temperature Indicator ..page 8
Figure1.5 Thermocouple ..page 9
Figure1.6 Bourdon Tube ..page 9
Figure1.7 Liquid Measurement ..page 10

1. Instrumentation
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Instruments are devices used to perform 2 main functions in a chemical process.

These functions are those that can be used to control the process at the best
operating conditions and secondly they provide a record of what has happened in
the chemical process.
There are 4 main process operating conditions that are considered as important
variables used in chemical processes these include;
1.) Flow Rate
2.) Temperature
3.) Pressure (Vacuum)
4.) Liquid Level
Instrumentation system can be used to monitor the process variable present in a
chemical process. The process variable need to be monitored due to the fact that,
any small variation from the prescribed operating conditions may cause poor quality
product, loss of material, loss of productions and fouling of equipment. Therefore
the instruments present in an instrument system can be used for monitoring
process variable and it can be used to control these variables as well.
Instruments used on a chemical process, must be able to provide records of
operations. This is done to keep checks on operating efficiency, yields produced as
well as on production. Therefore it is necessary to calculate daily, how much
material flows into and out of each process.
In addition to the above mentioned functions. Instruments also provide a local
indication of the process variable which the process controller is able to check on as
well as to compare it with the reading on the panel in the control room.
2. Air-Operated Controls Valves
When applying the proper procedures, it is easy to see that if a valve could be made
to operate automatically and in accordance with the changes in a certain variable,
this variable can then be controlled automatically as well. Such a valve is called an
Air operated diaphragm control valve.
The difference between an ordinary gate valve and an air operated diaphragm
control valve is as follows;
In an ordinary gate valve, the gate is caused to move up and down by turning the
hand wheel. However in an air operated diaphragm control valve, the stem of a
motor valve is connected to a rubber disc or diaphragm which is then moved up or
down by the resultant force imparted by air pressure and a balance spring.

2.1 Actions Of Air Operated Control Valves;

There are 2 common types of air operated control valves also known as pneumatic
actuator control valves these include; air to open diaphragm control valves and air
to close diaphragm control valves.
In summary Control valves operated through pneumatic actuators can either be
i.)
ii.)

Air To Open
Air To Close

These valves are designed in such a way that if the air supply fails, the control valve
will either be fully opened or fully closed. However these actions are determined by
the safety requirement of the process for example if the valve is used to control
steam or fuel flow; the valve should be shut off completely in case of air failure and
therefore the valve should be fully closed. On the other hand, if the valve is
handling cooling water to a reactor, the flow of air should be maximum in case of
emergency and therefore the valve should be fully opened.
Figure 1.1 - Pressure Control Air Valve

3. Fluid Flow Measurement

When working with fluids which travel at a variety of speeds, it is important to keep
track of the speed of the fluid used. Therefore on a typical GTL Plant fluid flow
measurement devices are used to control and monitor the flow rate of these liquids.
The two most common flow measuring devices used in a GTL Plant is the orifice
Plate and the Differential Pressure Meter.
These devices operate based on the principle that a fluid (Gas/Liquids) flowing
through a constriction in a line will show a pressure drop and that this pressure drop
is proportional to the rate of flow.
3.1 Orifice Meter
The orifice meter consists of a circular plate with a circular hole in the center of the
plate. This device is then placed between two flanges in a line this is done to ensure
that a differential pressure inside a pipe is created.
The selection of the size of the orifice depends upon the rate of flow expected to
pass through it. Which means that the smaller the hole, the greater the pressure
drop across the plate for a given rate of flow and vice versa. It is therefore
important that the size of the orifice is chosen correctly so that the pressure drop
which is at a maximum expected flow rate will not exceed the range of the flow
meter or measuring device.
Figure 1.2 Orifice Plate In Flange Connection

3.2 D/P Cell

Another type of differential measuring device most commonly used, is the
differential pressure cell also known as a D//P Cell.
The D/P Cell operates on the force balance principle. Besides being used as a
different measuring device, a D/P Cell is also used as a level indicator and can

operate level alarms. In this case the differential pressure caused by the weight of a
column of liquid is transmitted to the indicator or it is transmitted to an alarm.

3.3 Rotameter
Another type of flow measuring device is the rotameter. It consists of a tapered
glass tube with metal or plastic bob inside it.
The Rotameter function by allowing the bob found inside the Rotameter to rise up
inside the glass tube whenever a fluid flows inside it. The higher the bob rises in the
glass tube indicates the speed at which the liquid is flowing through the pipe. Please
note that the rotameter is structured in such a way that the flowrate inside the pipe
can be read on a scale which is etched onto the glass.
Figure 1.3- Rotameter

4. Temperature Measurement
The measurement of a substance temperature can be measured by either a
Thermometer, R.T.D. OR by use of Thermocouples. Example of uses for these
devices includes, checking metal surface temperature and brickwork temperature.
Bimetallic Dial Temperature Indicator is an industrial thermometer typically used in
a GTL Plant. This thermometer is made up of a long, narrow tube containing a
bimetallic element which is connected to a pointer which has a dial marked off into
degrees. It is made up of two narrow strips of different metals bonded together. As
the temperature changes, one of strips expand more than the other and the
elements are bent. The amount that the element is deflected is dependent on the
temperature and so can be calibrated to measure the temperature change. This coil
can then be placed inside a tube and the degree of the coiling of the metal can then
be attached to a pointer with a dial which will then allow the temperature changes
to be read off the pointer.
Figure 1.4- Bimetallic Dial Temperature Indicator

4.1

R.T.D. (Resistance Thermo Device)

Resistance Thermo Device Is a device that is similar to the bimetallic temperature

dial. This device works by having 3 wires wrapped together. It functions on the
principle that temperature change effect the electrical resistance of the wires and
the change can then be measured and converted to units of degrees.
4.2

Thermocouple

Thermocouple device have 2 wires of different metals twisted together at their ends
and this end is then welded closed, this point is referred to as the junction point.
The principle of thermocouple is based on the fact that when two unlike metals are
joined, they generate a very small voltage. This voltage generated in the wires is
proportional to the temperature of the junction. To use this device the welded
junction is placed at the point where the temperature is being measured.
The voltage generated by the thermocouple is measured by means of an instrument
called a Potentiometer, where it is calibrated in millivolts and is directly linked to the
measurement at the junction example of thermocouple is the Alumel and Nickel
Thermocouple.
Figure 1.5- Thermocouple

Please Note that a thermowell is a device used to get the sensing element i.e. the
thermometer, R.T.D and Thermocouple. As close to the process point as possible.

5. Pressure Measurement
The most convenient and widely used pressure measuring device for industrial
application is the Bourdon Tube Pressure Gauge.
The Bourdon Tube is a thin-walled metal tube of oval shape. This tube is then bent
into an arc of a circle having; 1 end of the tube closed and connected to a pointer
and the other end opened and connected to a vessel/ line on which the pressure is
being measured.
A pressure is then applied to the inside of the tube, after which the flat sides of the
tube then stretches and tend to straighten out the tube. This then causes the
moving of the closed end of the tube to move the linkage it is connected to. This is
done in order to magnify the movement of the tube and the pressure applied to the
device can then be read off a marked dial.
Figure 1.6- Bourdon Tube

6. Liquid Measurement
The most common device used in liquid measurement is the gauge glass. Gauge
Glasses/ Sight Glasses are made up of a transparent tube through which the
operator of a tank or boiler can observe the level of liquid contained within a tank.
Simple Gauge glasses/Sight glasses are made up a plastic or glass tube connected
to the bottom of the tank at one end and the top of the tank at the other end. The
level liquid found within a sight glass is then used to measure the liquid found inside
the tank.
Figure 1.7- Liquid Measurement

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7. References
Instrumentation By Mr. Ade. S.L (www.slideshow.net)
Instrumentation By Devidas Bage,Patrik Dalvi,Gopesh Chilveri, Aniket
Dupade (www.slideshow.net)
Chemical Plant 3 Module B, UNISA, Study Guide, CHP321B BY E.M. Roos
and Revised by M.A. Smith
Notes from Ben Marais Basics and Fundamentals Lecture Session on
Instrumentation, PetroSA.

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