APPLIED

INSTRUMENTATION
(3361701)

S.V.Gandhi
 Unit 1

Fundamentals of Analytical
Instruments

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 Factors Affecting For Selection Of
Pressure Instruments

 The selection of pressure devices is not nearly as difficult as

selecting flow or level devices.
 pressure measurement, the emphasis is less on fluid
characteristics and more on consideration of accuracy, ranges
or measurement and material selection.
 For comparison and evaluation, pressure elements are divided
into the following categories: manometers, bourdon
elements, diaphragms and bellows.

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 Accuracy
For a very critical process very accurate instrument like bourdon
tube, manometer should be used which are having a ± 0.1 %
accuracy
 Range
For low range; McLeod gauge, Pirani gauge.

 Material Selection

 Type of Mounting
 Cost
Bourdon Tubes – Low cost. Diaphragm and Bellows – Moderate
Cost.
Strain Gauge – Moderate to High Cost due to electrical readout.
 Type of Sensing
 Type of Function
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Describe Factors Affecting For
Selection Of Flow Instrument:-

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 Line size
 Range:
Rotameters used for low range
 Fluid characteristics:-
Fluid, gas, slurry etc. – Orifice – Difficult to use for slurry services.
Venturi Tubes can be used for viscous fluids.
 Corrosive effect:-
For the protection against corrosive effect, we have to use
electromagnetic flow meter.
 Type of mounting:
The instrument should be select according to the specific
requirement of mounting.
Magnetic Flow Meters, Turbine Flow Meters – Inline Mounting
Required.

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 Type of function:-
The instrument is selected for indicating, recoding or transmitting
purpose.

 Phase of flow:
The instrument is selected according to the phase for flow whether
it steady or pulsating. Rotameters are not good in Pulsating
Services.
 Type of sensing:
Direct or indirect sensing instrument.
 Type of signal:
The instrument is selected according to the availability of plant
signal.
Magnetic Meters – Electric Signal

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Describe Factors Affecting For
Selection of Level Instrument

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• 1. Range:
• Sight glass Indicator Type Instruments: Up to 900 mm
• 2. Continuous or Point Sensing:
• • Level sensors can operate either continuously or by point sensing.
Point sensing involves taking measurements at certain instances.
• 3. Direct or Indirect:
• • Liquid level sensors measure position and level either by direct or
indirect methods. Direct measurement includes methods that
directly sense position and level.
• 4. Contact or Non-contact:
• • Liquid level sensors measure using either contact or non-contact
methods.
• 5. Internal or External:
• • Liquid level sensors can be mounted either internally or
externally.
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• Materials:
Liquid level sensors can be made from a variety of different
materials depending on the type of device and the media
being addressed.
• Fluid characteristics:
(a) temperature; (b) pressure; (c) specific gravity; (d) whether
the fluid is clean or dirty, contains vapour or solids, etc.

• Corrosive effects:

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Factors Affecting The Selection of
Temperature Instruments

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 Range
Thermocouples are used from -273 deg. C to 2760 deg. C.
Depending on the materials used for the Thermocouple Wires.
RTDs are used for range from – 200 deg. C to 800 deg. C.
Bimetalic thermometers used for range -10 deg. C to 110 deg. C
Thermisters are used for cryogenic temperatures from -273 deg. C
to -180 deg. C
Radiation Pyrometers are used for higher temperature above 2700
deg. C. to 4500 deg. C.
Optical Pyrometers are used for intermediate temperatures from
800 deg. C to 3300 deg. C
Infrared Pyrometers – Range up to 4500 deg. C.
 Accuracy:
Filled System Thermometers: ± 0.5 %
Thermocouples: ±0.1%
RTDs: ±0.05%
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 Response Time:
Filled System Thermometers are having low response time or time
lag in measurement up to 5 seconds.
Thermocouples and RTDs are sensitive to variations and RTDs are
having fast Response to temperature change.
 Type of Signal:
Filled Systems thermometers show expansion properties of liquid
or gas, so detection is due to pressure change.
Thermocouples do not need any supply, but produce emf based on
temperature.
RTDs shows change in Resistance.
Radiation Pyrometers Uses either Thermocouples or RTDs to
receive radiation to sense temperature by non-contact method.
Solid Expansion Thermometers like Bimetalic Strip show Material
Deformation for temperature change.

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Factors Affecting The Selection of
Control Valve

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 Pressure Drop Requirement:
For Linear Valve Preferred ΔP = 50 %
For Equal Percentage ΔP = 35%.
For Adequate Control in many applications ΔP = 15%
 Capacity Requirement:

 Valve Rangeability:
It is the Ratio of Flow Rate in Percentage to valve stem travel
percentage. Based on the application higher Rangeability valves are
selected. For example Full Ball Valve has excellent Rangeability of
100:1, where as Diaphragm and Pinch off Valves are having
Rangeability of 5:1.

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 Choosing the Flow Characteristics:

 Choosing the Body Design:

Double Seated Globe Valves: Due to their balanced design they are
widely used.
Single Seated Globe Valves: Due to unbalanced design, used in
small sizes – 2 inches or below.
Ball valves: Used mainly due to their pressure recovery up to 70%.
Sliding Gate: Self Cleaning is their main advantage, so used in slurry
services

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 Instrumentations Related Document
Process flow sheets
Material balances generally are shown. Additional information often
given includes:
• Operating conditions at various stages of the process (flows,
pressures, temperatures, viscosities, etc.)
• Equipment size and configuration and, in some cases, utility
requirements.
• Instrumentation on process flow sheets may or may not be
essentially complete.
• In some instances, practically all of the instrumentation is included;
in others, only the major control systems are shown.
• In most processes the primary control variables have been
determined and verified through laboratory and/or pilot plant
operations if the process is new.
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 Mechanical flow sheets
flow sheets or P&I (Process and Instrument) diagrams provide
much detailed, mechanical information not shown on
process flow sheets, while omitting much of the process
information shown on the process flow sheets.
They repeat all the major equipment and piping lines as
well as show:
1. All other equipment items with design temperatures and
pressures
2. All interconnecting piping with size, material and
specifications indicated
3. Utility requirements including pipe sizes, materials and
fabrication methods.
4. All major instrument devices

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 Instrument index sheets:-
The instrument index sheets provide a summary of all instruments
required for the job.
• Listing each number identified item of each loop (see Figure 3).
• The list should be made near the start of a job and used to check
progress in specification writing, purchasing, expediting, delivery
and installation.
• As items are added, the list increases; deletions should be lined out
(not erased), Thus serving as a record of changes.
• Even though information is not complete, the list should be issued
early in the job so that project engineers and others concerned with
the job may use it to gauge the job requirements.
• Instrument index sheets may serve strictly as an index of items
required and provide minimum information.

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 Loop wiring diagram:-

Electronic loop wiring diagrams are electrical schematic drawings which

are prepared for individual (or typical) electronic loops.
The simplest loop is one that contains only a transmitter and a receiver.
Other loops may contain many items-transmitter, recorder, controller,
alarm units, Control valve, Transducer, Integrator and perhaps other items.

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 Panel drawing and specification:-

Panel specifications and instrument specifications for all panel

instruments must be prepared early in the job a decision should be
made concerning the extent of engineering to be done by the panel
fabricator. This decision is based on four primary factors.
1. Cost
2. Time
3. Available manpower
4. Capability

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 The factors are so interrelated that they need not be
listed in a definite order of importance.
• Fabrication cost is always important, but other factors such as
installation schedule, start-up time, etc., can minimize initial
fabrication cost. Timing and cost, then, must be considered
together.
• If the timing or schedule is critical, panel fabrication may be
started before engineering is complete with a gain of several
weeks in panel delivery.
• The added cost of such an action may be small compared to
the advantage of earlier on-stream commitments or other
factors.
• Capability and availability of manpower are also closely
related. In most cases the buyer knows the panel fabricator
well enough to judge his engineering capabilities. The buyer
also knows his own department's
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workload and capabilities.
 Checklist of good installation
practices
1.Make sure all instrument items are accessible. (This should be
determined during the engineering phase, but slips do occur. so this
should be checked thoroughly.)
2. Do not locate instruments in main traffic lanes.
3. Turn pressure gauges and dial thermometers toward traffic lanes for
easy observation by Operators.
4. Cover glass fronts on instrument items during construction where
heavy traffic or work might cause breakage.
5. Make sure glass and identification plates are covered before
painting is done in the vicinity of instruments.
6. Make sure instrument calibration is done prior to installation unless
in-place calibration is required.
7. Be certain that door space is sufficient for entry of control panels
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before completion of the control building and control room.
8. Check instrument air headers and sub headers for moisture and cleanliness
before turning on instrument air to the instruments.
9. Disconnect instruments prior to hydrostatic testing of equipment and
piping unless the test pressure falls within the range of the device.
10. Do not install orifice plates until lines have been flushed.
11. Do not install positive displacement meters, rotameters or other in-line
del-ices that may be damaged until lines have been flushed.
12. Do not run pneumatic tubing lines too close to hot surfaces.
13. Do not locate capillary lines where they can be stepped on or otherwise
damaged. (Use protective covering if necessary.)
14. Keeps a progress record using the form shown in figure so that job
progress is carefully charted.
15. Keep a record of job labour cost and project the total labour cost by
comparing progress and estimated total job labour cost.
16. Where service is required on special equipment, make sure it is installed
in plenty of time for check-out by the vendor-alert him early enough so
that he can properly schedule the work for which he is responsible.
17. Know the warranties that apply to instrument items or groups of
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Typical Checks Out Procedure For:

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Flow transmitter:-
The following typical check-out procedure is for a pneumatic dp (differential
pressure) cell.
• Determine that both orifice holes have been drilled in the orifice flange by
pushing a wire rod through each hole.
• Check orifice plate size with micrometer. This should be done for all plates
when they are received.
• Make sure each plate is stamped on the upstream side with tag number and
size.
• Determine that the orifice plate is installed with the proper side facing
upstream.
• Is there adequate room for maintenance of the dp cell?
• Can the cover be removed without disturbing the piping?
• Blow down the air supply lines and filter; turn on air supply; set air supply
regulator at 20 psig.
• Check the instrument for the following items and conditions:
1. 3-15 psi receiver gauge calibrated to read 0-10 square root.
2. Check range of transmitter against required range on the specification
sheet.
3. Check identification tag on transmitter.
4. Determine that piping configuration is consistent with the requirements for
its service.
:
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 Calibrate dp cell if it is not already calibrated. Proceed as follows
1. Disconnect meter body from all process piping.
2. Both meter body chambers should be dry; remove drain plugs if necessary
to drain liquid; replace drain plugs.
3. Connect a calibrating signal to the high pressure side of the meter body.
4. Use a manometer or other acceptable readout device calibrated in inches
of water (the low pressure side of the meter should be vented to
atmosphere).
5. When no pressure is applied to the high side the transmitted signal should
be 3 psig on the output manometer or gauge.
6. If it is not 3 psig. Reset the zero adjusting screw units the output reads 3
psig.
7. Increase calibrating signal to full range (as shown by the specification
sheet). Transmitter output should 278 Applied Instrumentation read 15
psig. If not, adjust "span" adjustment screw until 15 psig output is
obtained.
8. Recheck zero after "span" adjustment. Repeat until both are correct.
9. Check transmitter output for 25, 50 and 75% of range.
10. Output should be (a) 25% -6 psig; (b) 50% - 9 psig; (c) 75% -12 psig.
11. These values should be recorded on a calibration form.
12. This form is typical of those used by contractors and/or users to show that
all instrument systems have been calibrated, checked and are ready for
service. They are dated and signed by the calibrator and an inspector who
may be a contractor or user representative.
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 Temperature transmitter:-
The following procedure is for a "filled system" temperature
transmitter. Check the following against the requirements of the
specification sheet:

1. Check instrument tag number and range of instrument. The range

should be stamped on the element or inside the instrument case.
2. Is the output gauge installed? The scale should reflect the range of
the transmitter.
3. Check the element bulb length and the capillary length.
• Blow down air supply lines and filter.
• Turn on air supply to the instrument.
• Set the regulator output to 20 psig.
• Make sure the capillary is adequately protected. It should be run in a
channel or other protective support to prevent its being stepped on
or accidentally hit by passersby.
• Excess lengths of capillary tubing should be neatly coiled.

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 Calibrate or check calibration as follows:
1. Immerse the sensing bulb in a known temperature ' bath.
Use a mercury manometer or other accurate readout
device on the transmitter output.
2. At an "upper" temperature level (80% or above) Check
"span" of instrument. Check spans adjustment if necessary.
3. If the instrument is indicating or recording, check these
devices at the same time.
4. After each change of span adjustment, recheck "zero" at a
low temperature reading.
5. When a "zero" change of adjustment is required, recheck
the upper temperature point to make certain the span has
not changed.
6. Increase input signals to 25, 50 and 75% of span, recording
values.
7. Decrease signals in the reverse of (6) above.
8. Set any switches for alarms or shutdown if used
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Thank You

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