Pressure Transmitter Training

Fundamentals of Pressure Measurement

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
Topics To Be Covered
Pressure Measurement
• Absolute, Gauge, & Differential Pressure
Pressure Transmitters
• Basic Functions
Transmitter Terminology
• Span & Range Limits
Flow Rate Applications
• Primary Devices & Square Root Relationship
Level Applications
• Open & Closed Tanks; Dry & Wet Legs
Intelligent Transmitters
• Characterization, Calibration, & Reranging
Construction
• Body Styles, Flanges, & Seals

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
What is Pressure?
• Pressure is Force applied over a known Area (force per unit area)
Force
• Pressure = ---------
Area
• Some typical units of pressure measurement:
• Pa, kPa, & MPa
• psi (lb/in2 or lbf/in2)
• kg/cm2 (kgf/cm2)
• bar
• The letter “a” is added to indicate “absolute” pressure; for example:
• kPaa, psia, & bara
• When the letter “a” is not added, the measurement is assumed to be
“gauge” and not “absolute”, unless otherwise stated.

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
 Absolute & Gauge Pressure Measurement
Absolute Gauge
Pressure Pressure

Barometric Pressure
(Variable)
Vacuum Region

Zero Absolute Pressure

(0 psia, 0 kPaa, 0 bara)

• Barometric or Atmospheric Pressure varies with location and weather.

• Gauge Pressure is referenced to current barometric pressure; can be positive or negative.
• Vacuum measurement in the industries is normally a gauge pressure measurement,
referenced to barometric pressure.
• Absolute Pressure has a fixed reference of zero absolute & there are no negative values.
• Absolute Pressure is independent of barometric pressure.

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
Pressure Transmitters – Basic Functions
Getting the measurement to the control room!

The manual way…

The automatic way…

Analog Communiations:
4 to 20 mA dc loop
Transmitter regulates current, proportional to pressure
Digital Communications:
Fixed loop current with…
HART, FOXCOM, FOUNDATION FIELDBUS, PROFIBUS, etc.
digital signal

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
Span and Range Terminology
Range Values: The end points of a measurement range

• Lower Range Value (LRV): The starting point of the range; corresponds to the 4 mA output
for a 4 to 20 mA transmitter.

• Upper Range Value (URV): The ending point of the range; corresponds to the 20 mA output
for a 4 to 20 mA transmitter.

Span: The absolute value difference between URV and LRV (URV – LRV); examples:

• Range: 0 to 100; LRV = 0 & URV = 100; Span = 100

• Range: -10 to 90; LRV = -10 & URV = 90; Span = 100

• Range: 75 to -25; LRV = 75 & URV = -25; Span = 100

Transmitter/Sensor Span Limits: Span must be within transmitter Span Limits.

Transmitter Range Limits: Each range value (LRV & URV) must be within transmitter range
limits.

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
Span and Range
Examples
Example 1: Range: 0 to 100 inH2O
• LRV = 0, URV = 100, & Span = 100
• IDP10 Span Code B: Span Limits 3.5 & 200, Range Limits +/- 200
• Span of 100 is within limits of 3.5 & 200
• Both LRV and URV are within limits of +/- 200

Example 2: Range: 2050 to 2100 mbar

• LRV = 2050, URV = 2100, & Span = 50
• IDP10 Span Code B: Span Limits 8.7 & 500, Range Limits +/- 500
• IDP10 Span Code C: Span Limits 70 & 2100, Range Limits +/- 2100
• Neither B nor C meets both span and range limit requirements, but…

• IDP25 Span Code C: Span Limits 6.25 & 2500, Range Limits +/- 2500
– Meets both span and range limit requirements

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
d/p Cell™ Terminology

Span and Range Values and Limits:

• Same as shown on previous slides, including the examples that we examined
earlier:
– Range: 0 to 100; LRV = 0 & URV = 100; Span = 100
– Range: -10 to 90; LRV = -10 & URV = 90; Span = 100
– Range: 75 to -25; LRV = 75 & URV = -25; Span = 100

But the following is unique for d/p Cell™ transmitters:

• Measurement is the difference between the pressure on the “High” side, marked “H” and
the pressure on the “Low” side, marked “L”.

• A negative range value indicates that the pressure on the “Low” side is higher than the
pressure on the “High” side

• d/p Cell™ range examples…

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
d/p Cell™ Range Examples

Example 1 (DP for gauge pressure):

• DP LRV: Low Side = 0 and High Side = 0 DP = 0
• DP URV: Low Side = 0 and High Side = 100 inH2O DP = 100 inH2O
• Range: 0 to 100 inH2O; Span: 100 inH2O

Example 2 (DP for flow):

• DP LRV: Low Side = 600 psi & High Side = 600 psi DP = 0
• DP URV: Low Side = 596.4 psi & High Side = 600 psi DP = 100 inH2O
• Range: 0 to 100 inH2O; Span: 100 inH2O (3.6 psi)

Example 3 (DP for level):

• DP LRV: Low Side = 6000 & High Side = 1000 mmH2O DP = -5000 mmH2O
• DP URV: Low Side = 6000 & High Side = 5500 mmH2O DP = -500 mmH2O
• Range: -5000 to -500 mmH2O; Span: 4500 mmH2O

Note: DP Span is the “difference of the difference” in pressures

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
d/p Cell™ for Flow Rate Measurement
LRV = 0
URV = “DP across primary element (e.g. orifice
plate) at maximum flow rate”
URV from flow sizing sheet: d/p Cell™ Transmitter
• Bore calculated for design maximum DP
or…
• Maximum DP calculated for design bore size

Orifice Plate & Flange Union

Pipeline Flow

Schematic Illustration of d/p Cell™ Transmitter used for Flow Rate Measurement

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
DP Transmitters for Flow Rate
Advantages:

Wide Range of Materials

Large Pipe Diameters

High Pressure Rating

Variety of Primary Devices

Standards for Custody Transfer, e.g. Natural Gas

Low Cost

Quick Delivery

Limitations:

Not suitable for viscous fluids and sediment (unless using seals)

Square law affects accuracy and limits flow turndown

• Effects of turndown…

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
Flow Error in % of Reading – Effect of Square Root

Read Read Read Read Read Read Read Flow

Enter DP Enter DP Operating Sq. Rt. of Oper. DP Sq. Rt. of Oper. % of Max Flow Turndown Error in
Error Value URV DP Value Oper. DP W ith Error DP w/error Flow Ratio % of Reading
0.100 100 100.00 10.000 100.10 10.005 100 1.00 0.05
81.00 9.000 81.10 9.006 90 1.11 0.06
64.00 8.000 64.10 8.006 80 1.25 0.08
49.00 7.000 49.10 7.007 70 1.43 0.10
36.00 6.000 36.10 6.008 60 1.67 0.14
25.00 5.000 25.10 5.010 50 2.00 0.20
16.00 4.000 16.10 4.012 40 2.50 0.31
9.00 3.000 9.10 3.017 30 3.33 0.55
4.00 2.000 4.10 2.025 20 5.00 1.24
1.00 1.000 1.10 1.049 10 10.00 4.88
0.81 0.900 0.91 0.954 9 11.11 5.99
0.64 0.800 0.74 0.860 8 12.50 7.53
0.49 0.700 0.59 0.768 7 14.29 9.73
0.36 0.600 0.46 0.678 6 16.67 13.04
0.25 0.500 0.35 0.592 5 20.00 18.32
0.16 0.400 0.26 0.510 4 25.00 27.48
0.09 0.300 0.19 0.436 3 33.33 45.30
0.04 0.200 0.14 0.374 2 50.00 87.08
0.01 0.100 0.11 0.332 1 100.00 231.66

Guideline: Limit flow turndown ratio to approximately 3:1 to 5:1,

depending on the required accuracy

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
d/p Cell™ Level Measurement - Vented Tank

Example:

LRV = 0

URV = Maximum Level X SG

2.25 m X 0.8 = 1.8 mH2O 2.25 m maximum

level
SG = 0.8
Range: 0 to 1.8 mH2O

Zero Level

Schematic Illustration of d/p Cell™ Transmitter used for Open Tank Level

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
Closed Tank – Dry Leg

Example:

LRV = 0
Pressure
URV = Maximum Level X SG

2.25 m X 0.8 = 1.8 mH2O 2.25 m

maximum
SG = 0.8
Range: 0 to 1.8 mH2O level

Zero Level

Schematic Illustration of d/p Cell™ Transmitter used for Closed Tank Level with
Dry Leg

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
Closed Tank – Wet Leg

Example:
Wet Leg
LRV = (0) (0.8) - (3) (1.2) = -3.6 mH2O SG = 1.2
Pressure
URV = (2.25) (0.8) - (3) (1.2) = -1.8 mH2O

Range: -3.6 to -1.8 mH2O 2.25 m

maximum
SG = 0.8
level
3m

Zero Level

Schematic Illustration of d/p Cell™ Transmitter used for Closed Tank Level with Wet Leg

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
Closed Tank – Dual Seals
Example:

LRV = (0.2) (0.8) - (3.0) (1.76) = -5.12 mH2O at minimum level

URV = (2.25 + 0.2) (0.8) - (3.0) (1.76) = -3.67 mH2O at maximum level
Pressure
Range: -5.12 to -3.32 mH2O
Capillary
2.25 m Fluid
max. SG = 1.76
level
SG = 0.8
3m

Zero Level
0.2 m

Schematic Illustration of d/p Cell™ Transmitter used for Closed Tank Level with
Dual Remote Seals

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
 What is an Intelligent Transmitter?
Input Outputs
Previously: Analog
Measured Pressure Transmitters 4 to 20 mA Output
4 to 20 mA Only

LCD Indicator, Engr. Units

Now: Intelligent
Measured Pressure Transmitters Digital Value of Pressure,
Engr. Units
Digital Value of
Pressure
4 to 20 mA Signal

Intelligent Transmitters - Internal Digital Value of Pressure is key:

• It exists from Lower Range Limit (LRL) to Upper Range Limit (URL).
• It can be sent digitally to local indicator or to remote system, eliminating need for reranging.
• Selected pressure ranges can also be converted to an analog mA signal.

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
Behind the Scenes – Questions to be answered

What is Characterization?
• How are the coefficients determined?
• Where are the coefficients stored & why?

How does Calibration affect the transmitter?

• What is One Point & Two Point calibration?
• What is the effect on accuracy?

What is Reranging?
• How can reranging be done with or without pressure?
• How are LRV & URV used?
• Why is reranging not required with digital communications?

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
Characterization
• Precise pressure is applied in steps from LRL to URL and repeated at different temperatures.
• Coefficients are determined & stored in sensor.
• Curve fit algorithm is used to linearize & compensate for temperature.
• Transmitter can accurately measure any pressure from LRL to URL.
• Calibration is done later to optimize accuracy over a desired range.

Example:
+200 inH2O
Internal
Digital Error Band
Value of
Pressure
-200 inH2O
-200 inH2O +200 inH2O
(LRL) Input Pressure
(URL)

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
Calibration
• Two Point Calibration using precise applied pressures
• Trims Internal Digital Value of Pressure (offset & slope)
• Optimizes accuracy over selected range

Example: +200 inH2O

100
Internal
Digital Calibrate for
Value of 0 Optimized Accuracy
Pressure example: 0 to 100 inH2O

-200 inH2O
-200 inH2O 0 100 +200 inH2O
(LRL) Input Pressure (URL)

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
One Point Calibration & Zeroing
• Trims the Internal Digital Value of Pressure (offset only)
• Zeroing can be done with various pressures
• Just “tell” the transmitter what pressure is applied

Example: +200 inH2O

100
Internal
Digital “Zero” trims the offset
Value of 0 without changing the
span
Pressure

-200 inH2O
-200 inH2O 0 100 +200 inH2O
(LRL) Input Pressure (URL)

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
 CAL LRV & CAL @ 0
• CAL LRV requires LRV pressure applied
• CAL @ 0 requires zero pressure (or zero differential pressure)
• Easy zeroing for non-zero based ranges
• Can be done from on-board pushbuttons or configurators
• CAL @ 0 is the Zero Trim function when using a HART Communicator

Example: Calibrated Range: 40 to 100 inH2O

+200 inH2O
LRV = 40
CAL LRV requires 40 inH2O applied
Internal 100 CAL @ 0 or Zero Trim requires 0 inH2O
Digital 40 applied
Value of 0
For Example:
Pressure Zero With:
40 inH2O Applied (LRV)
or…
-200 inH2O
-200 inH2O 0 40 100 +200 inH2O 0 inH2O Applied (CAL@0)
(LRL) (URL)
Input Pressure

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
Reranging (Without Applying Pressure)
• Example: Calibration 0 - 200 inH2O
• Set LRV & URV values to new desired 4 & 20 mA output points
• Internal digital values & calibration are NOT affected

mA
Example:
20
Desired
4 & 20 mA Points
4
For Example:
New range desired is
20 to 100 inH2O

-200 inH2O 20 100 +200 inH2O

(LRL)
Internal Digital (URL)
Value of Pressure

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
Reranging (With Applied Pressure) - HART
• Pressures not known? Let transmitter determine them – it’s intelligent!
• Example: Dual Seal d/p Cell for Level – exact DP values not known
• With minimum level in tank, let transmitter determine the DP
• With maximum level in tank, let transmitter determine the DP
• Reranging accomplished! New LRV & URV set for 4 to 20 mA output
• Internal Digital Values & Calibration are NOT affected

mA
For Example:
Desired 20 • Transmitter ordered with range:
0 to 200 inH2O
4 & 20 mA Points
• Approximate range needed for
4 dual seal: -95 to -5 inH2O
• Actual range determined by
transmitter: -93.5 to -2.7 inH2O

-200 inH2O ? ? +200 inH2O

(LRL) Internal Digital Value
(URL)
of Pressure

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
mA Trim
• Does NOT involve pressure
• Does NOT affect pressure calibration or reranging
• Trims the digital-to-analog output stage

Actual 20 mA
4 & 20 mA
Output
Values 4 mA

4 mA 20
@ mA @
LRV URV
Desired 4 & 20 mA Points

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
Foxboro Intelligent Transmitter Family

• Gauge & Absolute Pressure (Direct Connect)

• Gauge & Absolute Pressure (Bracket Mtd.)
• Differential Pressure (d/p)
• Flanged Level (flush or extended diaphragm)
• Direct Connect & Remote Seals
• Sanitary Tri-Clamp

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
 New! Low Profile DP Structures

Traditional DP Low Profile Low Profile

(horizontal connections) LP1 LP2

• Low Profile Structures join the Traditional d/p Cell™ group

• Low Profile has In-Line Process Connections (facing downward):
• Similar to Competitive Coplanar™ Mounting
• Single-ended Process Covers
• Fits or Retrofits to Coplanar™ Installation Design Standards

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
LP1 Low Profile Structure

• Process Covers & Sensor similar to traditional DP except:

• Process Covers turned 90 degrees to face down
• Single-ended Process Covers
• Single side vent screw standard – tangential & offset

• Ideal for manifold-mount applications

• Limited bracket mounting – bracket would interfere with process
connectors

• Vertical or Horizontal Installation

• Vent screw can be omitted for vertical mounting above pipeline, self
draining into pipeline; option V1

• Same price as traditional structure

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
LP2 Low Profile Structure

• Process Covers are a new design

• Process Covers turned 90 degrees to face down
• Single-ended Process Covers
• Dual vent/drain screws on each side
• Complete, easy, venting and draining

• Bracket or Manifold Installation

• Fits Foxboro or Coplanar™ Brackets & Manifolds

• Vertical Installation
• Use in vertical position
• Ideal replacement for most Coplanar™ applications
• Won’t drain & vent well in horizontal position; use LP1 to
replace a horizontal Coplanar™ transmitter

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk
 I/A Series Intelligent Transmitters
Take Advantage of the many Features & Benefits
of the
I/A Series Pressure Transmitter Family…

Gustaf Fagerberg A/S | Kornmarksvej 8-10 | 2605 Brøndby | tlf. +45 43 29 02 00 | Fax +45 43 29 02 02 | fagerberg@fagerberg.dk