Industrial Instrumentation: Dr. - Ing. Naveed Ramzan

Industrial
Instrumentation
Dr. –Ing. Naveed Ramzan
PEC – UET Lahore Dr. Shahid Naveed 9. Dezember 2021 / Dr. –Ing Naveed Ramzan 1
Pressure Sensors
“In any given plant, the number of
pressure gauges used is probably
larger than all other instruments
put together”
Practical Considerations in Pressure Measurements
In industrial applications, good repeatability often is more

important then absolute accuracy.
If process pressures vary over a wide range, transducers with good
linearity and low hysteresis are the preferred choice.
Ambient and process temperature variations also cause errors in

pressure measurements, particularly in detecting low pressures and
small differential pressures. In such applications, temperature
compensators must be used
Selection Criteria
Pressure transducers usually generate output signals in the millivolt range (spans of
100 mV to 250 mV). When used in transmitters, these are often amplified to the
voltage level (1 to 5 V) and converted to current loops, usually 4-20 mA dc. The
transducer housing should be selected to meet both the electrical area classification
and the corrosion requirements of the particular installation.
If the installation is in an area where explosive vapors may be present, the
transducer or transmitter and its power supply must be suitable for these
environments. This is usually achieved either by placing them inside purged or
explosion proof housings, or by using intrinsically safe designs.
The single most important decision in selecting a pressure transducer is the
range
When high process temperatures are present, one can consider the use of various
methods of isolating the pressure instrument from the process. These include loop
seals, siphons, chemical seals with capillary tubing for remote mounting, and purging.
Maintenance
Without exception, pressure sensors require scheduled, periodic
maintenance and/or recalibration.
Calibration
Pressure transducers can be recalibrated
1. on-line or
2. in a calibration laboratory.
Laboratory recalibration typically is preferred, but often is not possible or

necessary.
In the laboratory, there usually are two types of calibration devices:
1.deadweight testers that provide primary, base-line standards, and

2.laboratory or field standard calibration devices
Self Assessment Test
Question No. 1
The difference between gauge and absolute pressure is
A.a Vacuum
B.0.433 psia
C.atmospheric pressure
D.zero
Question No. 2
Pressure is defined as
A.Force per unit area
B. F. A
C.A/F
D.None of the above
Question No. 3
Metals used in the bourdon tubes should not undergo
A. Fatigue
B. hysteresis
C. creep
D.All of the above
Question No. 4
A capsule diaphragm is made by welding two diaphragms
A. to a solid base
B. together at the center
C. together around the edges
D.To two other diaphragms
Question No. 5
Dead weight tester is used for
A. testing dead weights
B. measuring process pressures accurately
C. producing high pressure
D. calibrating pressure instruments
Question No. 6
One torr is defined as
A.One mm Hg
B. One inch Hg
C. One atmosphere
D. One kilopascal
Question No. 7
Which gauge measures pressure by sensing changes in the thermal

conductivity of the gas
A.Pirani gauge
B.Slack diaphragm gauge
C.Mcleod gauge
D. None of them
Question No. 8
A thermocouple gauge is one type of
A.Ionization gauge
B.Thermal conductivity gauge
C.Mcleod gauge
D. None of these
Question No. 9
Diaphragms used in pressure applications are
A.light
B.Small in size
C.slack
D. bimetallic
Question No. 10
A Mcleod gauge can measure pressure as low as
A.0.05 torr
B.0.005 torr
C.0.0005 torr
D. 0.00005 torr
Question No. 10
What type of manometer is best for measuring low pressures
A.Well
B.Inclined
C.U-Tube
D. Multiple tube
Question No. 11
A capacitance pressure transducer indicates changes in pressure by

changing the
A.Voltage output of an ac circuit
B. frequency
C. capacitance
D. alternating current
Home Work
Make similar 10 MCQs from

Temperature and Pressure Sensors.
Solve Them and attached the sheet
with the test on coming Tuesday to
get 5 marks. Additional 5 marks for
the student who prepare the best
MCQs .
A Quick View! What we have covered?
Total Lectures held 8

 Fundamentals of Electrical Technology and
digital logic employed in the measurement
 Review of Scientific principles employed in instruments
 Parts of Instrument
 Performance Characteristics of Instruments
 Selection and Calibration of Instruments
 Instruments Identification and Line Symbols
 Principle measurements desired in industry
(a) Temperature
(b) Pressure, Load
(c) Level
(d) Flow
(e) Others ( Weight, Composition, pH etc.)
(f) Transducers
 Installation and Installation Costs
 Case Studies
Quiz Held = 1 : Next Test due on = 3-10-2009 (B)
6-10-2009 (A)
Assignment
due on
10-10-2009
Level Sensors
Level Measurement
Level is another common process variable that is

measured in many industries. The method used will
vary widely depending on the nature of the industry,
the process, and the application.
Inventory:
-- a constant supply or storage of material
Control:
-- continuous, batch, blending, and mixing control
-- stabilize flow to the next process
Alarming:
-- hi/lo limits, safety shut down
Data Logging:
-- material quantities for inventory and billing
purposes and where regulatory requirements are
necessary
What is measured?
The measured medium can be liquid, gas or solid

and stored in vessels (open/closed tanks),
silos, bins and hoppers.
Units of level can be expressed in:

 feet (meters)
 gallons (liters)
 pounds (kilograms)
 cubic volume (ft3, m3)
Methods ---- Direct or Indirect (inferential)
 Hydrostatic Head
 Float
 Load Cells
 Magnetic Level
Gauge
 Capacitance
Transmitters
 Magnetostrictive
 Ultrasonic
 Microwave
 Laser
 Radar
 Guided Wave Radar
 Dip Stick
 Vibration
Direct Methods
Direct methods sense the surface or

interface of the liquid and is not
affected by changes in material density
(Specific Gravity)
Examples:
 Dip Stick
 Resistance Tapes
 Sight Glass
 Floats
 Ultrasonic
Indirect Methods (Inferential)
Indirect methods “infer” liquid level by measuring

some other physical parameter such as pressure,
weight, or temperature.
Changing materials means a corrective factor must
be used or recalibrating the instrument.
Examples:
 Hydrostatic head methods
 Load Cells
 Capacitance
 Conductivity
Selection Criteria
When determining the type of level sensor that

should be used for a given application, there are
a series of questions that must be answered:
 Open tank or closed tank?

 Can the level sensor be inserted into the tank or
should it be completely external? Contact or non-
contact?
 Continuous measurement or point measurement?
 Direct or Indirect measurement?
 What type of material is being measured? Liquid
or Solid? Clean or Slurry?
Selection Criteria
For all liquids you will need:
 The system operating temperature with max. and

min. excursions?
two wide range – expensive the sensor
 The system operating pressure?
 Check that system ‘T’ and ‘P’ do not conflict with

the materials of construction?
Selection Criteria
For Solids:
 Bulk density
Be careful with very large silos as compaction
at the bottom can greatly change assume bulk
densities
 Flow characteristics?
 Expected particle size distribution?
 Is solid abrasive and/or corrosive and what is the

moisture/solvent content?
For Liquids
Dip Stick
 Simple and cheap

 Can be used with any wet
material and not affected
by density.
 Can not be used with
pressurized tanks
 Visual indication only
(electronic versions are
available)
RodGauge - similar to a dipstick found in a car, it has weighted

line markings to indicate depth or volume
For Liquids
Sight Glass
Another simple
direct method of
measuring liquids.
Can be used in
pressurized tanks
(as long as the
glass or plastic
tube can handle
the pressure)
Good for applications where non-contact measurement is needed (like beverages)
For Liquids
Floats
Float rides the surface level to provide the measurement. Many
different styles are available. Usually used for pump control,
high/low level alarms and emergency shut-off
Liquid density does not affect measurement

For Liquids
Conductivity Level Measurement
Point Level Measurement Continuous Level Measurement
Advantages and disadvantages
Low Cost
Conductive, non-coating liquids only
Insulating coatings can cause problems
For Liquids
Resistance Tape
The pressure of the fluid in the tank causes the
tape to short-circuit, thus changing the total
resistance of the measuring tape. An electronic
circuit measures the resistance; it's directly
related to the liquid level in the tank.
For Liquids
Bubblers Instrument input

does not matter
Bubblers allow the P
indicator to be Regulated purge

located anywhere. system
(air or nitrogen)
The air pressure in

the tube varies
with the head
pressure of the
height of the
Bottom of tube
liquid. determines reference
point
Can’t be used in closed tanks or where purging a liquid is not allowed (soap). Very
popular in the paper industry because the air purge keeps the tube from plugging .
For Liquids

does not matter
Advantages: P
-- Easy installation Regulated purge

system
(air or nitrogen)
-- Continuous reading
providing analogue or
digital signal
-- No moving parts
-- Good accuracy and Bottom of tube

repeatability determines reference
point
For Liquids

does not matter
Limitations: P
-- Not suitable for Regulated purge

system
pressurized tanks
(air or nitrogen)
-- Sediments may block tube

or probe
-- Tanks must be freely Bottom of tube

vented determines reference
point
Hydrostatic Head Level Sensors
 These methods infer level by measuring

the hydrostatic head produced by the
liquid column.
 A pressure sensing element is installed

at the bottom of the tank and pressure
is converted to level.
 Different liquid densities or closed tank

applications must be accounted for.
Hydrostatic Head Level Sensors
General Theory for Head Measurement
The Pressure exerted by

Liquid Density (D)
the Height of the liquid
Height (H)
is:
P = H x Density*
Pressure PSI
If the Density of the liquid

is known then
H= Pressure
Density*
*Note: For liquids other than water, use the density of water 0.0361 lb/in3 as a reference and
multiply by the SG of the liquid.
Example
A dip stick measurement of the level of these 2 tanks
indicates 30 feet of liquid in both tanks. Calculate the
pressure that each gauge will read if tank 1 contains
water (S.G. = 1) and tank 2 contains oil (S.G. = 0.85)
Water Oil
Density (D) Density (D)
Height
Height
(H)
(H)
Tank 2
Tank 1 PSI
PSI
P = ? psi P = ? psi
Example
A dip stick measurement of the level of these 2 tanks indicates 30 feet of liquid in both tanks.
Calculate the pressure that each gauge will read if tank 1 contains water (S.G. = 1) and tank 2
contains oil (S.G. = 0.85)
Water Oil
Height
Height
(H)
(H)
Tank 2
Tank 1 PSI
PSI
P = H x Density P = ? psi
= 30 ft x 0.0361 lbs/in3
= (30 x 12) x 0.0361
= 13 psi
Example
A dip stick measurement of the level of these 2 tanks indicates 30 feet of liquid in both tanks.
Calculate the pressure that each gauge will read if tank 1 contains water (S.G. = 1) and tank 2
contains oil (S.G. = 0.85)
Water Oil
Height
Height
(H)
(H)
Tank 2
Tank 1 PSI
PSI
P = H x Density x SG P = H x Density x SG
= 30 ft x 0.0361 lbs/in3 x 1 = 30 ft x 0.0361 lbs/in3 x 0.85
= (30 x 12) x 0.0361 = (30 x 12) x 0.0361 x 0.85
= 13 psi = 11 psi
Hydrostatic Head Level Sensors (Cont‘d)
Practical Considerations when using head

type instruments
The reference point of the tank vs
instrument input must be considered.
Liquid Density Liquid Density

(D) (D)
Height (H) Height (H)
Pressure
PSI
Pressure PSI
This may not be practical in some applications where the tank elevation
is below grade or where a remote visual reading is required.
Tank Elevations
Vertical rises and drops contribute to the overall

height and therefore head pressure. Horizontal
runs have no effect.
Water
Density (D)
Height
(H)
P
Closed Tank Applications

P (atmospheric)
Open tanks are vented to

atmosphere so the pressure at
the bottom of the tank is only
due to the head pressure of the
liquid.
P Head =hxD
Closed tanks are not vented to

P
atmosphere so the pressure at
the bottom of the tank is due to
vapour
the head pressure of the liquid +

the vapour pressure above the
surface.
P Head = (h x D) + P vapour
Magnetic Level Sensor
Used where the sight

glass level gauge can
not be used.
Magneto-resistive types
can provide an electrical
output.
Liquid/liquid interface (such as water and oil) can be measured by

changing the buoyancy of the magnetic float
Displacers
 Not the same as a float.

 The displacer is immersed in the tank and the
buoyant force of the liquid produces a torque
which is proportional the amount of liquid level.
The output force

can be
converted to
provide a
proportional
pneumatic or
electrical
continuous
output of tank
level.
Displacers
Displacer – side mounted unit

The displacer float size and
diameter is selected
according to the size of
tank and the height of the
level to be measured.
The output force can be
converted to provide a
proportional pneumatic or
electrical continuous
output of level.
Advantages and
disadvantages:
 Very little movement of
displacer float
 Affected by different liquid
densities
 Limited to smaller tanks sizes
UltraSonic Level Measurement
 Non-Contact direct level

sensor
 Level is a function of the
time it takes an ultrasonic
pulse to hit the surface and
return
Limitations include:
• Surface foam absorbs signal, agitation create reflections
• High Pressure & High Temperatures affect the signal speed
• Vapour and condensate create false echo’s
Radar Level Sensors (Microwave)
Similar to ultrasonic but at a much higher frequency (6.3 GHz)

Various designs
-- Frequency Modulated
Continuous Wave
-- Pulsed Wave
-- Guided Wave
These sensors have better performance in applications where vapour, dust or uneven
surfaces exist.
Load Cells
Tank level is determined by the

weight of the quantity of
material
Load Cells (strain gauge
transducers) placed at the
bottom of the tank measure
the weight and then convert it
to an electrical signal.
Capacitance Level Detection (RF Level Probes)
RF Capacitance level sensors are similar in operation to

conductivity sensors and are typically used when non-
conductive liquids are measured.
The only variable is the dielectric of the tank material that varies in proportion to the level.
Conductive liquids like mineral water will short out the probe to the tank wall.
Good for solids
Can be used for non-liquids
RF capacitance
probes are used
in a wide range of
applications and
are subjected to
certain limitations
such as:
 Electrode Coating
 Low sensitivity
 Temperature
 Different
materials
 Shielding & noise
Summary
• Level is measured by locating the

boundary between two media, called
the interface
• Level can be measured directly or
indirectly
• Noninvasive devices are preferred
when the material is corrosive,
hazardous, sterile, or at a high
temperature or pressure
Creative Assignment! HAZOP?????
Batch application using point level measurement

 Detect if the level
is at a
predetermined
point
 Generally used to
detect either a low-
level condition or
high-level condition
 The output of a
point level sensor
is on-off, or 1 or 0
state digital signal
A batch process does NOT use a continuous level measurement device.

Discussion & Questions?
Dr. Shahid Naveed 9. Dezember 2021 / Dr. –Ing Naveed Ramzan

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Industrial

Dr. –Ing. Naveed Ramzan

In industrial applications, good repeatability often is more

Ambient and process temperature variations also cause errors in

The single most important decision in selecting a pressure transducer is the

Pressure transducers can be recalibrated

Laboratory recalibration typically is preferred, but often is not possible or

In the laboratory, there usually are two types of calibration devices:

1.deadweight testers that provide primary, base-line standards, and

The difference between gauge and absolute pressure is

A.Force per unit area

D.None of the above

Metals used in the bourdon tubes should not undergo

D.All of the above

A capsule diaphragm is made by welding two diaphragms

B. together at the center

C. together around the edges

D.To two other diaphragms

Dead weight tester is used for

A. testing dead weights

B. measuring process pressures accurately

C. producing high pressure

D. calibrating pressure instruments

One torr is defined as

Which gauge measures pressure by sensing changes in the thermal

B.Slack diaphragm gauge

A thermocouple gauge is one type of

B.Thermal conductivity gauge

Diaphragms used in pressure applications are

A Mcleod gauge can measure pressure as low as

What type of manometer is best for measuring low pressures

A capacitance pressure transducer indicates changes in pressure by

A.Voltage output of an ac circuit

Make similar 10 MCQs from

Total Lectures held 8

Level is another common process variable that is

The measured medium can be liquid, gas or solid

Units of level can be expressed in:

Direct methods sense the surface or

Indirect methods “infer” liquid level by measuring

When determining the type of level sensor that

 Open tank or closed tank?

For all liquids you will need:

 The system operating temperature with max. and

 The system operating pressure?

 Check that system ‘T’ and ‘P’ do not conflict with

 Expected particle size distribution?

 Is solid abrasive and/or corrosive and what is the

 Simple and cheap

RodGauge - similar to a dipstick found in a car, it has weighted

Good for applications where non-contact measurement is needed (like beverages)

Liquid density does not affect measurement

Conductivity Level Measurement

Point Level Measurement Continuous Level Measurement

Advantages and disadvantages

Bubblers Instrument input

Bubblers allow the P

indicator to be Regulated purge

The air pressure in

Bubblers Instrument input

-- Easy installation Regulated purge

-- Good accuracy and Bottom of tube