Advanced

measuring devices

Introduction:
Measuring devices used in industry are going to in advance
technology. Due to advancement there is reliability accuracy for our process
whish is very necessary .They are fast and versatile and flexible.
In advance technology we often consider three advance technologies.

1- Ultrasonic
2- Laser
3- Microwave

1- Devices Based on Ultrasonic:

I. Flow meters:
Introduction:
An ultrasonic flow meter is based upon the variable time
delays of received sound waves which arise when a flowing liquids rate of flow is
varied. Two fundamental measurements Techniques, depending upon liquid
cleanliness, are generally used. In the first technique two opposing transducers
are inserted in a pipe so that one transducer is downstream from the other. These
transducers are then used to measure the difference between the velocity at which
the sound travels with the direction of flow and the velocity at which it travels
against the direction of flow. The differential velocity is measured either by direct
time delays using sound wave burst o )frequency shifts derived from beat together,
continuous signals. The frequency measurement technique is usually preferred
because of its simplicity and independence of the liquid static velocity. A relatively
clean liquid is required to preserve the uniqueness of the measurement path. In the
second technique, the flowing liquid must contain scatters in the form of particles
or bubbles which will reflect the sound waves.
These scatters should be traveling at the velocity of the liquid. A Doppler method
is applied by transmitting sound waves along the flow path and measuring the
frequency shift in the returned signal from the scatters in the process fluid. This
frequency shift is proportional to liquid velocity.

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Types:
Ultrasonic flow meters usually work with at least three
different types:

a) Transmission flow meters

b) Reflection (Doppler) flow meters
c) Open-channel flow meters

a) Transmission flow meters:

Transmission flow meters can be distinguished into:

In-line flow meters (intrusive, wetted)

Clamp-on flow meters (non-intrusive)

i) Transit-Time Flow meters (general):

The most commonly used ultrasonic flow meter is the transit-time flow
meter which is used for liquids and gases.
Transit-time flow meters work by measuring the time of flight difference between
an ultrasonic pulse sent in the flow direction and an ultrasound pulse sent
opposite the flow direction. This time difference is a measure for the average
velocity of the fluid along the path of the ultrasound beam. By using the absolute
transit time and the distance between the ultrasound transducers, the current
speed of sound is easily found. The measuring effect can be adversely affected by
many things including gas and solid content.
By using at least 3 transducers, an "ultrasonic anemometer" measures wind speed
and direction in open air, with no moving parts.

Portable Transit Time Flow Meter

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ii) Transit-Time Clamp-On Flow meters (non-

intrusive):
For clamp-on flowmetry, the ultrasonic transducers are mounted
(clamped) on the outside of the pipe wall. For accurate flow computation, the transducer
distance, the pipe dimensions and the pipe material has to be known. The sound speed of
the flowing medium is needed for initial transducer positioning but is updated during the
flow measurement.

b) Doppler Flow meters:

Doppler flow meters are used for slurries, liquids with bubbles, gases with
sound reflecting particles, or single phase turbulent clean liquids. Measurement of the
Doppler shift resulting in reflecting an ultrasonic beam off either small particles in the
fluid, air bubbles in the fluid, or the flowing fluid's turbulence is another recent, accurate
innovation made possible by electronics.

Doppler Flow Meter

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c) Open-channel Flow meters:
Open channel flow measurement is based on upstream levels in front
of flumes or weirs although in-channel devices using cross-correlation and
Doppler are also used. Ultrasonic open channel flow meters are widely used to
measure flows in streams, rivers and where hydraulic head is an issue. Many
examples of open channel flow meter exist in the world today with varying degrees
of accuracy.

Open Channel Flow Monitor

Applications:
Ultrasonic level sensors are used for non-contact level ensing of
highly viscous liquids, as well as bulk solids. They are also widely used in water
treatment applications for pump control and open channel flow measurement. The
sensors emit high frequency (20 kHz to 200 kHz) acoustic waves that are reflected
back to and detected by the emitting transducer.

Defects and solutions:

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Ultrasonic level sensors are also affected by the changing speed of
sound due to moisture, temperature, and pressures. Correction factors can be
applied to the level measurement to improve the accuracy of measurement.
Turbulence, foam, steam, chemical mists (vapors), and changes in the
concentration of the process material also affect the ultrasonic sensors response.
Turbulence and foam prevent the sound wave from being properly reflected to the
sensor; steam and chemical mists and vapors distort or absorb the sound wave;
and variations in concentration cause changes in the amount of energy in the
sound wave that is reflected back to the sensor. Stilling wells and wave guides are
used to prevent errors caused by these factors.
Proper mounting of the transducer is required to ensure best response to reflected
sound. In addition, the hopper, bin, or tank should be relatively free of obstacles
such as weldments, brackets, or ladders to minimize false returns and the resulting
erroneous response, although most modern systems have sufficiently "intelligent"
echo processing to make engineering changes largely unnecessary except where
an intrusion blocks the "line of sight" of the transducer to the target. Since the
ultrasonic transducer is used both for transmitting and receiving the acoustic
energy, it is subject to a period of mechanical vibration known as ringing. This
vibration must attenuate (stop) before the echoed signal can be processed. The net
result is a distance from the face of the transducer that is blind and cannot detect
an object. It is known as the blanking zone, typically 150mm - 1m, depending
on the range of the transducer.

II. Level meter:

Sonic Methods A fixed-point level detector based on sonic
propagation characteristics is available for detection of a liquid-vapor interface.
This device uses a piezoelectric transmitter and receiver,
separated by a short gap. When the gap is filled with liquid, ultrasonic
energy is transmitted across the gap, and the receiver actuates a relay.
With a vapor filling the gap, the transmission of ultrasonic energy is
Insufficient to actuate the receiver.
The requirement for electronic signal processing circuitry can be used to make the
ultrasonic sensor an intelligent device. Ultrasonic sensors can be designed to
provide point level control, continuous monitoring or both. Due to the presence of
a microprocessor and relatively low power consumption, there is also capability
for serial communication from to other computing devices making this a good
technique for adjusting calibration and filtering of the sensor signal, remote
wireless monitoring or plant network communications. The ultrasonic sensor
enjoys wide popularity due to the powerful mix of low price and high functionality.

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Level Indicating Transmitter:

Transmitter displays, controls and transmits level. Mount the non-
contacting ultrasonic sensor at the top of your tank and the compact, watertight
electronics/display enclosure at a convenient location nearby. The standard
ultrasonic Sensor measures liquid levels up to 32 ft. (10 m), and includes
automatic temperature compensation. Choose the optional all-Teflon sensor for
chemical compatibility, or one rated to 50 ft (15.6 m) range. All ultrasonic sensors
are available with optional intrinsic safety for installation in hazardous rated
locations. This can also be ordered with gauge-type pressure sensors for special
applications.

Level Indicating Transmitter

III. Residual Stress Measurement :

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The Ultrasonic Computerized Complex (UCC) for residual stress

analysis was developed recently based on an improved ultra-sonic methodology.
The UCC includes a measurement unit with supporting software and a laptop with
an advanced database and an Expert System (ES) for analysis of the influence of
residual stresses on the service life of welded components. The developed device
with gages for ultrasonic residual stress measurement is presented in Figure 2.
The UCC allows determining uni- and biaxial applied and residual stresses for a
wide range of materials and structures. In addition, the developed ES can be used
for calculation of the effect of measured residual stresses on the fatigue life of
welded elements, depending on the mechanical properties of the materials, type of
welded element, parameters of cyclic loading and other factors.

2- Based on Laser:

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Introduction:
A laser is an oscillator that operates at optical
frequencies. These frequencies of operation lie with in a spectral region that
extends from a very far infrared to the Vacuum Ultraviolet (VUV) or soft x-ray
region. At the lowest frequencies at which they operate, laser overlap with the
frequency coverage of meters, to which they are closely related, and millimeter
wave source using solid state or vacuum tube electronics, such as TRAPATT,
IMPATT and Gunn diodes, klystrons, gyroklystrons and traveling wave tube
oscillators, whose principles of operation are quite different. In common with
electronic circuit oscillators, constructed using an amplifier with an appropriate
amount of positive feedback. The acronym LASER, which stands for LIGHT
AMPLIFICATION by STIMULATED EMISSION PROCESSES of
RADIATION, is in reality, there for, a slight misnomer.
Laser sensors can be ideal for collision avoidance, level measurement for liquids
and solids, conveyor belt profiling, proximity detection, positioning and equipment
monitoring, or even altimetry applications. The variation in material
characteristics or the difference in environment conditions can be a contributing
factor of why a particular sensor wont work properly. Certain sensors struggle to
recognize a moving target in dusty conditions whereas others have difficulties
obtaining a valid level measurement to liquids.
Considering all these factors, it would be nearly impossible to design an all-
encompassing laser sensor that could work in a wide variety of scenarios. This is
why our line of lasers is all considered to be quite an engineering feat.

Below are just a fraction of applications our lasers can be used for.

I. Level Measurement:
Tall narrow bins
Complex infrastructure inside bins (ladders, agitator blades, etc.)
Non-intrusive measurements (through sight glass)
Plastic pellets, slurries
Outdoor river/stream monitoring
Waste water treatment
Lock level
Stockpile height
Molten metal level
Ore pass and loading pocket level

II. Positioning and Detection:

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Overhead crane
Crane avoidance
Tripper car
Distance between vehicles (mounted in vehicle)
Steel slab detection and positioning
Pipe/tree length cutting system
Camera focusing
Surveillance detection and camera focusing
Vehicle profiling
Fixed point traffic monitor (speed, profiling, length, DBC)
Truck loading system
Parking garage system (open spots, illegal parking)
Bridge height clearance
Ship docking
Targeting systems
In-flight refueling

Altimetry:
General altimeter
UAV altimeter
Flight inspection systems
Geophysical pod referencing

Some sensors used in industry:

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ULS APD-G (Universal Laser Sensor):
It has 4 measurement modes along with user selectable output
power and frequency makes this our most versatile Industrial Sensor. Long
range capability and high accuracy make this sensor a world-class leader.

Industrial Wide Beam Sensor:

Ideal for applications limited to 4 to 20 mA output
requirements such as collision avoidance and proximity detection.

Impulse XL Industrial Sensor:

Ideal for applications requiring ultra-long ranging. A 4x zoom scope allows

the user to pinpoint the target at these ultra-long ranges. An LCD readout gives real time
distance measurement to the user. Serial connectivity also allows the user to interface to a

PC, controller, or data recorder.

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3- Based on Microwave

Introduction:
Microwaves have frequencies > 1 GHz approx. Stray reactance are more
important as frequency increases. Transmission line techniques must be
applied to short conductors like circuit board traces. Device capacitance and
transit time are important. Cable losses increase: waveguides often used
instead. Microwave sensors are ideal for use in moist, vaporous, and dusty
environments as well as in applications in which temperatures vary.
Microwaves (also frequently described as RADAR), will penetrate temperature
and vapor layers that may cause problems for other techniques, such as
ultrasonic. Microwaves are electromagnetic energy and therefore do not
require air molecules to transmit the energy making them useful in vacuums.
Microwaves, as electromagnetic energy, are reflected by objects with high
dielectric properties, like metal and conductive water. Alternately, they are
absorbed in various degrees by low dielectric or insulating mediums such as
plastics, glass, paper, many powders and food stuffs and other solids.

Microwave sensors are executed in a wide variety of techniques. Two basic signal
processing techniques are applied, each offering its own advantages: Time-
Domain Reflectometry (TDR) which is a measurement of time of flight divided by
the speed of light, similar to ultrasonic level sensors, and Doppler systems
employing FMCW techniques. Just as with ultrasonic level sensors, microwave
sensors are executed at various frequencies, from 1 GHz to 30 GHz. Generally, the
higher the frequency, the more accurate, and the more costly. Microwave is also
executed as a non-contact technique, monitoring a microwave signal that is
transmitted through the medium (including vacuum), or can be executed as a
radar on a wire technique. In the latter case, performance improves in powders
and low dielectric media that are not good reflectors of electromagnetic energy
transmitted through a void (as in non-contact microwave sensors). But the same
mechanical constraints exist that cause problems for the capacitance (RF)
techniques mentioned previously.

Microwave-based sensors are not affected by fouling of the microwave-

transparent glass or plastic window through which the beam is passed nor by high

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temperature, pressure, or vibration. These sensors do not require physical contact
with the process material, so the transmitter and receiver can be mounted a safe
distance from the process, yet still respond to the presence or absence of an object.
Microwave transmitters offer the key advantages of ultrasonic: the presence of a
microprocessor to process the signal provides numerous monitoring, control,
communications, setup and diagnostic capabilities. Additionally, they solve some
of the application limitations of ultrasonic: operation in high pressure and
vacuum, high temperatures, dust, temperature and vapor layers. One major
disadvantage of microwave or radar techniques for level monitoring is the
relatively high price of such sensors.

I. Viscosity measurement device:

The present invention relates to an industrial
microwave device for the continuous, real time measurement of viscosity of a
viscous medium. The invention can be used for measuring the viscosity of all polar
liquid media and in particular all polymers containing dipolar elements. More
specifically, the invention makes it possible to continuously chek the evaluation of
the viscosity of the resins used for the production of high performance composite
materials during the polymerization and/or cross linking thereof. These composite
materials are used for producing parts in the automobile, aeronautical and space
fields. In particular, the invention applies to phenolic, polyurethane, polyester and
epoxy resins, as well as to polymers containing dipolar elements, e.g.>C=0,

groups.
Microwave devices for the continuous measurement of the viscosity of a viscous
medium. The device includes a microwave source connected via a microwave
guide to a sensor essentially incorporating at least one semi regid, coaxial
microwave guide (2) for immersion in the medium. the cable has an other sheath
(4) and a core (6),which conduct electricity and are arranged coaxially the space
defined between the outer sheath and the core is filled by a dielectric (8). The core
has a bare end (12) for a placing in contact with the viscous medium. The sensor
is intended to produce in the medium incident microwaves of a given power level,

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and to detect the power of the microwave reflected by the medium . a second
microwave guide (10) is provided for coupling the detector to the sensor.

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II. Multiphase flow measuring device:

The present invention relates to a method and
apparatus for making measurements in multiphase flow using microwave
techniques. In particular, the invention provides a method and apparatus for
measuring volume fractions of phases in multiphase flows such as are typically
encountered in producing hydrocarbon wells.
A method for measuring multiphase flows in a conduit using series of microwave
antennae arranged around the circumference of the conduit so as to transit
microwave energy into, or detect propagated microwave energy in the conduit, the
method including the steps of: transmitting microwave energy from each antenna
in turn while detecting microwave energy at the non-transmitting antenna and
integrating the conduit. Apparatus for performing method includes means for
exciting each antenna in turn to transit microwave energy into the pipe and means
for detecting microwave energy at the non-transmitting antennae, and means for
integrating the results from all transmitters to characterize the flow in the conduit.

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References:

1- Liptk, Bla G.: Process Measurement and Analysis,Volume 1

2- http://www.greyline.com

3-DOE FUNDAMENTALS HANDBOOK

INSTRUMENTATION AND CONTROL
U.S. Department of Energy

4- Chemical engineers Handbook by Perry 8th edition

5- Handbook of laser technology and applications, Volume 1

By Colin E. Webb, Julian D. C. Jones

6- : http://www.lasertech.com/Industrial-Laser-Sensors.aspx

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