Industrial

Instrumentation
Dr. Ing. Naveed Ramzan
Instruments are our eyes
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





Course Outline
Human natural observation capabilities are
generally not designed for process conditions.

Instruments must have desired
capabilities to match process
conditions.

Process Control has the role of a
decision makers (Like brain)
Sensors
Sensors feel the condition and originate the signal
followed by modification and amplification for effective
display /transmission or control objectives.
Importance of effective
measurement in process
industry

Failure to measure effectively the level of liquid
in bottom of the tower lead to

--- Fire

--- Explosion
Instrument
Typical components of instrument

A Sensor:
(measures a physical quantity and converts it into a
signal)

A Modifier
(Change the type of signal)

A Display unit
(transmitting arrangement )

Perhaps the best advice for engineering students is
that instruments are always incorrect!!!!.
Functional Elements of an Instrument
Process/
Measured medium
Primary
Sensing
Element
Variable
Conversion
Element
Variable
Manipulation
Element
Data
Transmission
Element
Data
Presentation
Element






Observer
PEC UET Lahore Dr. Shahid Naveed 24. Juni 2014 / Dr. Ing Naveed Ramzan 7

Functional Elements of an Instrument (Contd)
Typical Example:
Primary
Sensing
Element
Variable
Conversion
Element
Data
Transmission
Element
Variable
Manipulation
Element
Data
Presentation
Element
Temperature
Measured
Quantity
Pressure
Variable
Conversion
Element
Pressure
Motion
Motion
Fluid
Temperature Tube
Tubing
Spiral Bourdon
Tube
Linkage Gear
Scale & Pointer
Functional Elements of an Instrument (Contd)






Observer
Process/
Measured medium

Static characteristics

Dynamic characteristics
Performance Characteristics of Instruments
Static characteristics

Static characteristics of an instrument includes;

Accuracy
Precision
Repeatability
Range
Resolution
Others ( Sensitivity , Dead zone etc.)

Performance Characteristics of Instruments (Contd)
Static characteristics of an instrument includes;


1. Accuracy
Static Characteristics
Accuracy is the degree of
conformity of the measured
value with the accepted
standard or ideal value, which
we can take as the true
physical variable.
Accuracy is usually expressed in engineering units or as a percentage
of the sensor range, for example:

Thermocouple temperature sensor with accuracy of 1.5 K.

Orifice flow meters with accuracy of 3% of maximum flow range
Static characteristics of an instrument includes;


2. Precision
Static Characteristics
Precision is the degree of exactness
for which an instrument is designed
or intended to perform.

It is composed of two
characteristics;
1. Conformity
2. Number of significant figures
Static characteristics of an instrument includes;

3. Repeatability

The closeness of agreement among a number of
consecutive measurements of the same variable
(value) under the same operating conditions,
approaching in the same direction.
Static Characteristics
PEC UET Lahore Dr. Shahid Naveed 24. Juni 2014 / Dr. Ing Naveed Ramzan 14

The term approaching
in the same direction
means that the variable
is increasing
(decreasing) to the
value for all replications
of the experiment.
Static characteristics of an instrument includes;

4. Reproducibility

The closeness of agreement among a number of
consecutive measurements of the same variable
(value) under the same operating conditions over a
period of time, approaching from both directions.
Static Characteristics
The period of time is long, so that changes occurring
over longer times of plant operation are included.

Reproducibility includes hysteresis, dead band, drift
and repeatability.
Gradual change in instruments
measurements.
OR
Measure of difference in repeatability.

Under laboratory conditions drift of an
element can be determined by one of
two ways;
1. Point drift
2. Calibration drift
Drift
By maintaining exact operating and load
conditions , monitoring of output variations
for a fixed input signals as a function of time
is called point drift.

Used for stable process conditions
Point Drift
By maintaining input
signals, operating
conditions, a load
approximately
constant comparison
of calibration curves
at the beginning and
at specified intervals
of time is called
Calibration drift.
Used for varying
process conditions

Calibration Drift
Dead zone is the largest range of values of a
measured variable to which the instrument
does not respond.

This is sometimes called dead spot and
hysteresis.
Dead Zone
Backlash
Backlash or mechanical hysteresis is defined as
that lost motion or free play which is inherent in
mechanical elements such as gears, linkages or
other mechanical transmission devices that are
not rigidly connected.
Range represents the minimum and maximum
values which can be determined by an instrument
or equipment.
Difference between upper and lower range is
known as Span.
Span can be the same for two different range
instruments.
Static characteristics of an instrument includes;

5. Range/Span

Static Characteristics
If a chemical reactor typically operates at 300 C, the engineer might select a
range of 250-350 C.

Since the reactor will be started up from ambient temperature occasionally,
an additional sensor should be provided with a range of -50 to 400 C.
Static characteristics of an instrument includes;

5. Linearity
Static Characteristics
This is the closeness to a straight line of
the relationship between the true
process variable and the measurement.
Lack of linearity does not necessarily
degrade sensor performance. If the
nonlinearity can be modeled and an
appropriate correction applied to the
measurement before it is used for
monitoring and control, the effect of the
non-linearity can be eliminated.
Linearity is usually reported as non-linearity, which is the
maximum of the deviation between the calibration curve and a
straight line positioned so that the maximum deviation is
minimized
Static characteristics of an instrument includes;

6. Reliability
Static Characteristics
Reliability is the probability that a device will adequately perform (as
specified) for a period of time under specified operating conditions.
Some sensors are required for safety or product quality, and
therefore, they should be very reliable.
If sensor reliability is very important, the engineer can
provide duplicate sensors, so that a single failure does
not require a process shutdown
Calibration
Assigning standard
values to an
equipment is
calibration.

PEC UET Lahore Dr. Shahid Naveed 24. Juni 2014 / Dr. Ing Naveed Ramzan 23

Numerical differences between true value of
a quantity and its value as obtained by
measurement.

Static errors are generally of three types;

1. Mistake or gross error (human mistakes)
2. Systematic errors (instrumental or
environmental errors)
3. Random or accidental errors (unknown)
Static Error
Dynamic characteristics
Performance Characteristics
Dynamic Characteristics of an instrument includes;


1. Speed of response
2. Fidelity
3. Lag
4. Drift
Other Issues


1. Maintenance
2. Consistency with process environment
3. Safety
4. Cost
Other Issues
Consistency with process environment

Direct contact

Sensors such as orifice plates and level floats have direct contact with process fluids.

Sheath protection

Sensors such as thermocouples and pressure diaphragms have a sheath between the process
fluid and the sensor element

Sample extraction

When the process environment is very hostile or the sensor is delicate and performs a
complex physiochemical transformation on the process material, a sample can be extracted.

Other Issues
Location of Measurement Displays



Local display


Local panel display


Centralized control room


Remote monitoring
The Smart Sensor Revolution
Digital conversion and transmission


Diagnostics


Signal conditioning


Configuration
Principle measurements desired in industry
(a) Temperature
(b) Pressure
(c) Level
(d) Flow
(e) Others ( Composition, pH etc.)





Principle measurements desired in Industry
PEC UET Lahore Dr. Shahid Naveed 24. Juni 2014 / Dr. Ing Naveed Ramzan 30

Home Work
PEC UET Lahore Dr. Shahid Naveed 24. Juni 2014 / Dr. Ing Naveed Ramzan 31


You have two challenges



What variables should be
measured?


What sensor should be
specified for each
measurement?
































Reactor with feed-effluent heat exchange
Discussion & Questions?
24. Juni 2014 / Dr. Ing Naveed Ramzan 32