Instrumentation is defined as the art and science of measurement and control of

process variables within a production or manufacturing area. [1] The process

variables used in industries are Level, Pressure, Temperature, Humidity, Flow, pH,
Force, Speed etc.

Instrumentation is the use of measuring instruments to monitor and control a process. It is the
art and science of measurement and control of process variables within a production, laboratory,
or manufacturing area.
An instrument is a device that measures a physical quantity such as flow, temperature, level,
distance, angle, or pressure. Instruments may be as simple as direct reading thermometers or may
be complex multi-variable process analyzers. Instruments are often part of a control system in
refineries, factories, and vehicles. The control of processes is one of the main branches of applied
instrumentation. Instrumentation can also refer to handheld devices that measure some desired
variable.

Measurement
Instrumentation is used to measure many parameters (physical values). These parameters
include:

Pressure, either
differential or
static

Flow

Temperature

Levels of
liquids, etc.

Density

Viscosity

Voltage

Other
mechanical
properties of
materials

Inductance

Capacitance

Resistivity

Properties of
ionising
radiation

Frequency

Current

Chemical
composition

Chemical
properties

Properties of
light

Vibration

Weight

Industrial instrumentation
1. 1. Shot Term Training Programme on Industrial Instrumentation11/26/12 1
2. 2. SyllabusBasic concept of measurement, Transducers and theirclassification,
Measurement of non-electrical quantitieslike Angular and Linear

Displacement, Strain,Vibration, Pressure, Liquid flow, Temperature, Forceand

Torque. Instrumentation amplifiers, Dataacquisition and conversion, Digital
signal transmissionand processing, Microprocessor based
instrumentation.Input and output devices and Displays. 11/26/12 2
3. 3. INTRODUCTIONAn instrumentation system is an assembly ofvarious
instruments and componentsinterconnected to measure analyse andcontrol
the electrical, thermal hydraulic andother non-electrical physical
quantities.11/26/12 3
4. 4. Elements of Measurement System The whole operation can be described
interms of three functional elements. Eachfunctional element is made up of a
distinctcomponent or group of components, whichperforms required and
definite steps inmeasurement. These may be taken as basicelements, whose
scope is determined by theirfunctioning rather than their
construction.11/26/12 4
5. 5. Variable Primary sensing elementElements of Measurement System
Signal Terminating stage Data-presentation elementconversion element
Transmitting element11/26/12 5Conditioning
6. 6. Primary sensing element The quantity under measurement makes itsfirst
contact with primary sensing element ofa measurement system. Immediately
after thisa transducer converts measured into ananalogous electrical signal.
This is true inmost of the cases but in many cases themeasured quantity is
directly converted intoan electrical quantity by a transducer.11/26/12 6
7. 7. Variable conversion element The output of the primary sensing element
maybe any kind of electrical signal. It may be a voltage, afrequency or some
other electrical parameter. Often thisoutput does not suit to the system. For
the instrument toperform the desired function, it may be necessary toconvert
this output to some other suitable form whileretaining the original signal. The
function of variablemanipulation element is to manipulate the signal .
11/26/12 7
8. 8. Data-presentation element The information about the quantity
undermeasurement has to be conveyed to thepersonnel handling the
instrument or thesystem for monitoring control, or analysispurposes. The
information conveyed must bein a form intelligible to the personnel.11/26/12
8
9. 9. Data-presentation element cont.. These devices may be analogue or
Recorders like magnetic Ammetersdigital indicating instruments like
Analogue and Printers Storage type CRT High speed cameratapes, digital
computers.11/26/12 9
10.10. Terminating stage The final stage in a measurement system isknown as
terminating stage. When a control device is used for the finalmeasurement

stage it is necessary to applysome feedback to the input signal toaccomplish

the control objectives. 11/26/12 10
11.11. Signal Conditioning Many a times one has to perform certain operationson
the signal before it is transmitted further. Theseprocesses may be linear like
amplification, alternation,integration, differentiation addition and
subtraction.Some non-linear processes like modulation, detection,sampling
filtering, chopping and clipping etc. areperformed on the signal to bring to the
desired form.This is called signal conditioning.In fact the element that follows
the primary sensingelement in any instrument or instrumentation
systemshould be called signal-conditioning element. 11/26/12 11
12.12. Transmitting elementWhen the elements of an instrument arephysically
separated, it becomes necessary totransmit data from one to another.The
element that performs this function iscalled a transmitting element.11/26/12
12
13.13. Typical Instrumentation SystemConsists of following operation.Monitoring
processes: - An instrumentationsystem has an essential function of
monitoringthe process. It simply indicates the value orcondition of parameter
under the study in theprocess.11/26/12 13
14.14. Process ControlIn order to control the process variables liketemperature,
pressure, humidity etc. these quantitiesmust be measured at the desired
location in theprocessing plant. They are compared with the referenceor
desired signal and the error signal is amplified tooperate the actuator in
controlling the process. Thecorrective action goes on till the controlled output
issame as the desired output, in that case the error signalwill be zero and the
actuator will not operate. 11/26/12 14
15.15. TRANSDUCERS A device, which converts one form of energyinto another
form of energy, is called transducer.For the field of electrical
instrumentationtransducer is defined as a device, which convertsa physical
quantity (or a physical condition) intoan electrical signal Transducer is often
referredas pick-up. 11/26/12 15
16.16. Secondary Transducers11/26/12 16 Primary TransducersType of
Transducers
17.17. Primary transducersPrimary transducers are detectors, which sensea
physical phenomenon. The example of primary transducer is athermocouple,
which senses the radiant energyand directly converts it into an
analogouselectrical output, which is a voltage.11/26/12 17
18.18. Secondary transducers Secondary transducers convert the
analogousoutput into on electrical signal.11/26/12 18
19.19. Classification of transducersThe transducers can be active, that is
selfgenerating type or passive, that is externallypowered.Passive transducers

derive the power requiredfor energy conversion from an external

powersource. Potentiometers are the examples ofpassive
transducers.11/26/12 19
20.20. Active transducers(i) Thermoelectric,(ii) Piezoelectric,(iii) Photovoltaic(iv)
Magnatostrictive,(v) Electro kinetic(vi) Electrodynamic,(vii) Electromagnetic,
(viii) Pyroelectric,(ix) Galvanic11/26/12 20
21.21. Passive transducers(i) Resistive (viii) Hall effect(ii) Inductive (ix)
Synchro(iii) Capacitive (x) Gyro(iv) Photoconductive (xi) Radio active(v)
Magneto resistive absorption(vi) Thermo resistive (xii) Ionic conduction(vii)
Elastoresistive11/26/12 21
22.22. Basic requirements of Transducers 1. Ruggedness 2. Linearity 3.
Repeatability 4. Convenient instrumentation 5. High stability & reliability 6.
Good dynamic response 7. Excellent mechanical characteristics 8. Built-in
integrated device with noise and other defects minimized11/26/12 22
23.23. Pressure Transducers Electrical TransducersTypes of Detectors
Inductive Oscillation transducersPiezzo-electric Transducers
Transducer11/26/12 23
24.24. Advantages of Electrical transducerover mechanical transducers1.
Minimized friction2. Minimized mass-inertia effect3. Easy Electrical
amplification4. Very small power electrical/electronic system controlled5. The
electrical output can be easily used, transmitted and processed for the
purpose of measurement.6. Miniaturization due to integrated circuits and use
of microprocessors.7. Easy Data transmission etc.11/26/12 24
25.25. MEASUREMENT OF DISPLACEMENT11/26/12 25
26.26. VariableMajor electrical transducers fordisplacement measurement
Variable inductance-LVDT/resistance- Potentiometric/strain gauge Synchros
and Variable capacitance variable reluctance resolvers11/26/12 26
27.27. Advantages of Synchros and resolversi. Infinite resolutionii. No wear of
rotation, except at slip ringsiii. System operating at much higher speediv.
Relatively insensitive characteristics tostray cable capacitancesv. High
reliability and accuracyvi. Useful operating angle of 360 degree andcapable
of continuous rotations. 11/26/12 27
28.28. MEASUREMENT OF STRAIN11/26/12 28
29.29. Electrical strain gauges11/26/12 29Optical gauges Mechanical gauges
Types of strain gauges
30.30. Wire gauges i. Flat grid type ii.Types of electrical strain gauges
Unbonded StrainWrap around type iii. Single wire gauge iv. Woven type

Thin film Semiconductor strain gauges Foil gauges gauges

gauges11/26/12 30
31.31. MEASUREMENT OF PRESSURE11/26/12 31
32.32. Classification of transducers 1. Gravitational i.e. Manometer 2. Elastic
Bellows11/26/12 32Bourdon tube Capsule Diaphragms type
33.33. Transduction methods: 1. Potentiometric Device 2. Strain Gauge
transducer 3. Variable reluctance Sensor 4. LVDT type transducer 5. Variable
capacitance Device 6. Thin Film Pressure transducer 7. Force Balance
transducer 8. Piezoelectric Pressure Transducer11/26/12 33
34.34. MEASUREMENT OF FLOW11/26/12 34
35.35. Classification of Flow meters 1. Head type flow meter based on
differential pressure measurement i.e.Orifice plate, Ventury tube, Flow nozzle
and Pitot tube 2. Electromagnetic flow meter 3. Rotameter (Variable area
meter) 4. Mechanical flow meter 5. Anemometer 6. Ultrasonic flow meter 7.
Vortex flow meter11/26/12 35
36.36. MEASUREMENT OF TEMPERATURE11/26/12 36
37.37. Types of Temperature sensors 1. Mechanical temperature sensors i. Liquid
in glass thermometer ii. Liquid filled systems iii. Vapour pressure
thermometer 2. Resistance type temperature sensors 3. Platinum resistance
thermometer 4. Thermocouples 5. Thermisters 6. Solid state sensors 7.
Quartz thermometer 8. Radiation thermometer 9. Optical pyrometer11/26/12
37
38.38. MEASUREMENT OF FORCE AND TORQUE11/26/12 38
39.39. Types of transducers 1. Force Measuring sensor Load cell: i. Column type
device ii. Proving rings iii. Cantilever beam iv. Shear type load cell v.
Pressducer 2. Digital force transducer 3. Force balance device 4. Hydraulic
load cell 5. Electronic weighing system11/26/12 39
40.40. Torque measuring transducers 1. Absorption type 2. Transmission type 3.
Stress type 4. Deflection type11/26/12 40
41.41. INSTRUMENTATION AMPLIFIER11/26/12 41
42.42. Important features i. Selectable gain with high gain accuracy and gain
linearity ii. Differential input capability with high common mode rejection,
even with sources having unbalance high out put impedances iii. High
stability of gain with low temperature coefficient iv. Low DC offset and drift
errors referred to input v. Low out put impedance11/26/12 42