Instrumentation GDR

INSTRUMENTATION
(Presented by G D Rathi)
WHAT IS INSTRUMENTATION?
WHAT IT CONSISTS?
INSTRUMENTATION
IT IS WINDOW TO PROCESS OF PLANT.

PROCESS IS SEEN BY FOLLOWING
PARAMETERS.
o Flow
o Level
o Temperature
o Pressure
o Density
INSTRUMENTATION
o Viscosity
o Speed
Analyzer (Analyzing following parameters)
pH
Conductivity
O2
Sulphur
H2S and so on.
o Vibrations of Compressor, Pumps

(Equipments)
INSTRUMENTATION
MEASUREMENT OF ALL ABOVE PROCESS PARAMETERS
& CONTROLLING OF THESE PARAMETERS IS
INSTRUMENTATION.
INTERFACE OF INSTRUMENTATION IS WITH PROCESS,
ELECTRICAL, PIPING, MECHANICAL EQUIPMENTS.
AUTOMATION IS PART OF INSTRUMENTATION.
INSTRUMENTION PERSON SHOULD KNOW THE
PROCESS.
FIRE & GAS DETECTION SYSTEM
WHAT IT CONSISTS OF?

FOLLOWING ARE MAJOR COMPONENTS OF
INSTRUMENTATION CLOSED LOOP.

TRANSDUCER, SENSOR
TRANSMITTER
CONTROLLER
FINAL CONTROL ELEMENT

FUNCTION /LOCATION OF THESE COMPONENTS IN
PROCESS PLANTS.
TRANSDUCER, SENSOR
Which senses the process parameters, located on pipe or
vessel or at process equipment.
Can be combined with transmitter.
Process parameter sensed by sensor is converted in to
electrical signal like millivolt or resistance or current.
TRANSMITTER
Which converts the signal from sensor to standard
electrical or pneumatic signal.
Standard electrical signal = 4 to 20 ma.
Standard pneumatic signal = 3 to 15 psig. (0.2 to 1
Kg/cm2g)

FUNCTION /LOCATION OF THESE COMPONENTS IN
PROCESS PLANTS.
CONTROLLER :
It is arithmetical block controls through PID function which
is proportional, integral, derivative action. (PID Tuning)
It can be single loop controller or multi loop controller.
Now days these controllers resides at DCS / PLC
microprocessor based computer system.
DCS Distributed Control system
PLC Programmable Logic Controller
FINAL CONTROL ELEMENT :

Controller output goes to Final control Element.
It can be Control Valve, VFD, Damper, MOV, On/Off
Valve.
INSTRUMENTATTION
LOCAL INSTRUMENTS
o PRESSURE GAUGES
o TEMPERATURE GAUGES
o LEVEL GAUGES
o DP INDICATORS
o GLASS TUBE ROTAMETERS
INSTRUMENTATTION
General software used

o INtools for inst index, hook ups,
sizing of all types instruments
o InstCal for sizing control valves,
orifice plates, safety valves and so
on.
o PDS / PDMS for modeling.
Marshalling Rack Room
System Architecture:
DCS Operator Station
Snap Shot of Control Room
INSTRUMENTATTION
HAVE LOOK AT CONTROL LOOP
INSTRUMENTATTION
FEEDBACK CONTROL LOOP
INSTRUMENTATTION
FEEDFORWARD CONTROL LOOP
TYPES OF FLOW MEASUREMENTS

AND
THEIR APPLICATIONS
TYPES OF FLOWMETERS
PRINCIPLE OF OPERATION
FEATURES OF FLOWMETERS
ADVANTAGES AND DISADVANTAGES
SELECTION/ APPLICATION OF A FLOWMETER
TYPES OF FLOWMETERS
VOLUMETRIC FLOWMETERS
Differential Head type
o Orifice plates
o Venturi meters
o Annubar
Differential Area type (Rotameters)
Electromagnetic flowmeters
Ultrasonic flowmeters
Turbine flowmeters
Vortex flowmeters
Positive Displacement Meters
MASS FLOWMETERS
Coriolis Mass flowmeter
Thermal Mass flowmeters
DIFFERENTIAL HEAD TYPE FLOWMETERS (ORIFICE)

Difference in pressure exists between
the upstream & downstream sides of a
restriction in a confined fluid stream,
which related to the square of fluid
velocity.
Q P
where
Q = Volume flow rate
P = Differential pressure between
taps
DIFFERENTIAL HEAD TYPE FLOWMETERS (ORIFICE)
Types of Orifice plates

Concentric orifice plate:
Most commonly used
Segmental & Eccentric orifice
plate
Used for fluids containing
suspended solids.
Tappings for the Orifice plates

Integral orifice plate (< = 1)
Calibrated Meter run with
Corner Taps for 1.5
Flange taps ( 2 to 12)
D and D/2 taps ( <= 14)
FEATURES OF ORIFICE PLATES

Design Pressure: No limitation. Limited by DP transmitter
Design Temperature: No limitation. Limited by DP transmitter
Sizes: Maximum size is pipe size
Flow range: limited only by pipe size.
Fluids/ Applications: Cryogenic(- Low Temp) / clean gases & liquids/
Steam (saturated/superheated)
MOC: No limitation (Steel/ monel/nickel/ haste alloy)
Accuracy : Totality It is from 0.1% to 1% of actual flow.
Rangeability is 3:1 to 5:1.

Upstream length/ Downstream straight length is 20D / 5D (D is pipe diameter)
ADVANTAGES OF ORIFICE PLATES

Easily installed between flanges.
Fabrication simple and inexpensive.
No limitations on the materials of construction, line size and flow rate
Cost relatively independent of pipe diameter since cost of DPT is fixed.
No process interruption for exchange of DP transmitter.
DISADVANTAGES OF ORIFICE PLATES

`
High permanent pressure loss & hence high energy consumption to

overcome pressure loss.
Impractical for systems with low static pressure.

Measuring range to about 3:1 to 5:1. ``
VENTURI METERS
A venturi tube also measures flow rates by constricting fluids
and measuring a differential pressure drop.
In the upstream cone of the Venturi meter, velocity is increased,
pressure is decreased.
Pressure drop in the upstream cone is utilized to measure the
rate of flow through the instrument
FEATURES OF VENTURI METERS

Design Pressure: No limitation. Limited by DP transmitter/ pipe press.ratings.
Design Temperature: No limitation. Limited by DP transmitter/ pipe pressure

ratings
Sizes: 25 mm to 3000 mm
Fluids/ Applications: Clean Liquids/ clean gases
: Limited applications: Dirty /corrosive/viscous Liquids & Dirty
gases
MOC: No limitation (cast iron/ carbon steel/ SS/Monel, Titanium, Teflon, Hastelloy,
Naval Bronze / haste alloy)

Upstream length/ Downstream straight length is 20D / 5D ( D is pipe diameter)
ADVANTAGES OF VENTURI METERS

Lower head losses than orifice plates reducing the capital
expenditure on pumping eqpt. / save pump energy costs
No process interruption for exchange of DP transmitter.
Can be used for temperature extremes
Cryogenics or High Temperatures
DISADVANTAGES OF VENTURI METERS
Highly expensive
Larger and heavier to handle.
ANNUBAR FLOWMETER
The probe is installed in the media line as a
pressure sensor.
With the flow, the probe records both the static
and the dynamic pressure via the probe
openings .
In the minus chamber of the annubar, lying on
the opposite side, only the static pressure has
any effect
The differential pressure corresponds to the
dynamic pressure in the pipeline & the flow can
is calculated directly.
ANNUBAR FLOWMETER
ANNUBAR FLOWMETER
FEATURES OF ANNUBAR
Fluids : Clean Liquids, gases and steam
MOC: Brass / steel/ stainless steel/ Hastelloy

Upstream length/ Downstream straight length is

20D / 5D
ADVANTAGES OF ANNUBAR
Integral manifold
transmitters
head
allows
direct
mounting
of
Hot tapping: Insertion/ installation without system shutdown

Very low pressure drop
DISADVANTAGES OF ANNUBAR
Not suitable for viscous and slurry applications
Can be used for only for clean fluids
DP
VARIABLE AREA FLOWMETER
o A free moving
float is balanced
inside a vertical
tapered tube
o As the fluid flows
upward the float
remains
steady
when the dynamic
forces acting on it
are zero.
o The
flow
rate
indicated by the
position of the
float relative to a
calibrated scale.`
VARIABLE AREA FLOWMETER
FEATURES OF ROTAMETERS
Sizes: upto 75 mm
Fluids/ Applications : Clean liquids, gases and vapours
Flow range: upto 920 cub.m/hr for liquids & 2210 cub.m/hr for
gases
MOC: Borosilicate glass/ brass / steel/ stainless steel/ Hastelloy
Accuracy : It varies from 1% to 2% of actual flow.
Rangeability is 10:1
Upstream length/ Downstream straight length is 10D / 5D
ADVANTAGES OF ROTAMETERS
Simple, robust and linear output
Does not require external impulse or lead lines.

Pressure drop is minimal and fairly constant.
DISADVANTAGES OF ROTAMETERS
Vertical installation only.
Glass tubes limit pressure & temperature and subject to
breakage from hydraulic & thermal shock
Metal tube meters more expensive.

Foreign particles can accumulate around the float & block the
flow
MAGNETIC FLOWMETERS
Operate on Faradays Law
of magnetic induction.
When a conductive fluid
moves in a magnetic field,
a voltage is generated
between two electrodes at
right angles to the fluid
velocity
and
field
orientation.
The flow tube has a fixed
area & field intensity so
the developed voltage is
linearly proportional to the
volumetric flow rate.
MAGNETIC FLOWMETERS
FEATURES OF MAGNETIC FLOWMETERS

Design Pressure: 20 BARS to 172 BARS
Design Temperature: Upto 120 deg.C with teflon liners /

180 Deg.C with ceramic liners
Sizes: 2.5 mm to 3000 mm
Fluids : Liquids (clean/ corrosive/dirty/viscous/ slurry)
Velocity range: 0.1 to 10 m/s
MOC: Liners: ceramic/ teflon/rubber
: Electrodes: Platinum/ hastelloy/SS
Accuracy : It varies from 0.5% to 1% of actual flow.
Rangeability is 10:1
Upstream length/ Downstream straight length is 10 / 5
ADVANTAGES OF MAGNETIC FLOWMETER

Flow rate unaffected by fluid
configuration.
density, consistency, viscosity, turbulence, or piping
Highly accurate due to absence of moving parts/ external sensing lines

Corrosion-resistant using Teflon liner and platinum electrodes
Wide flow measuring ranges & no pressure drop.
No Moving Parts. No Wear & Tear on components.
DISADVANTAGES OF MAGNETIC FLOWMETER
Costly, relative to other flowmeter types.
Temperature of the fluids being metered limited by the liner material rating.
Cannot be used for gas flow measurements
VORTEX FLOWMETERS
Vortex meters make use of a natural phenomenon

that occurs when a liquid flows around a bluff object.
Eddies or vortices are shed alternately downstream of
the object. The frequency of the vortex shedding is
directly proportional to the velocity of the liquid flowing
through the meter
VORTEX FLOWMETERS
An obstruction is placed across the
pipe bore at right angle to fluid flow.
As fluid flows, vortices are shed
from alternating sides of the body &
this shedding frequency is directly
proportional to fluid velocity.
Detection of the vortices by means
of pressure changes in the vortex
stream.
Rate of creation of vortices directly
proportional to the flow rate.
VORTEX FLOWMETERS
VORTEX FLOWMETERS
FEATURES OF VORTEX FLOWMETERS

Design Pressure: 138 bars
Design Temperature: -200 Deg. C to 400 Deg.C
Fluids : Gases (clean/ dirty) and clean liquids
Velocity range: 0.3 to 10 m/s (liquids) and 6 to 80 m/s (gases)
MOC: mostly in stainless steel, some in plastic

Accuracy : It varies from 0.5% to 1% of actual flow for liquids and
1% to 1.5% for gases
Rangeability is 20: 1
ADVANTAGES OF VORTEX FLOWMETERS:

Minimal maintenance, no moving parts.
Calibration using fluid flow not required & unaffected by viscosity, density,
pressure, and temperature within operating specification.
Digital or analog output.
DISADVANTAGES OF VORTEX FLOWMETERS
At low flows, pulses are not generated and the flowmeter can read low or even
zero.
Reynolds number should be greater than 10000
Vibration can cause errors in accuracy.
Correct installation is critical as a protruding gasket or weld beads can cause

vortices to form, leading to inaccuracy.
Long, clear lengths of upstream pipework must be provided, as for orifice plate
flowmeters.
ULTRASONIC FLOWMETERS
A pair (or pairs) of transducers, each having its own transmitter and
receiver, are placed on the pipe wall, one (set) on the upstream and
the other (set) on the downstream.
The time for acoustic waves to travel from the upstream transducer
to the downstream transducer td is shorter than the time it requires for
the same waves to travel from the downstream to the upstream tu.
The larger the difference, the higher the flow velocity.
FEATURES OF ULTRASONIC FLOWMETERS

Design Pressure: 207 bars (insertion type)/ unlimited (clamp on type)
Design Temperature: -180 Deg. C to 260 Deg.C
Fluids : clean gases, clean/corrosive liquids (with little/no solids/ bubbles)
MOC: mostly in stainless steel/ alloyic
Accuracy is
+0.5% of flowrate for insertion type
+1% to +3% of flowrate for clamp on type
Range ability is 10 : 1 to 300 : 1
Bidirectional flow measurement
For insertion type, hot tapping in pressurised pipelines possible
ADVANTAGES OF ULTRASONIC FLOWMETERS

No obstruction/ moving parts in the flow path
No pressure drop
Low maintenance cost
Multi-path models have higher accuracy for wider ranges of Reynolds
number
Can be used in corrosive fluid flow
Portable models available for field analysis and diagnosis

DISADVANTAGES OF ULTRASONIC FLOWMETERS
Only clean liquids and gases can be measured
Higher initial set up cost

Limited Acceptance in water & chemical industries.
TURBINE FLOWMETERS
Consists of a multi-bladed rotor
mounted at right angles to the flow &
suspended in the fluid stream on a
free-running bearing.
The diameter of the rotor is slightly
less than the inside diameter of the flow
metering chamber.
Speed of rotation of rotor
proportional to the volumetric flow
rate.
FEATURES OF TURBINE FLOWMETERS

Design Pressure: 1500 PSIG
Design Temperature: 150 Deg. C
Sizes: 5 mm to 600 mm (Full bore type)/ > 75 mm for insertion type

Fluids : Clean liquids/ gases and vapours
MOC: mostly in stainless steel/ hastelloy
Accuracy is
+0.25% to + 0.5% of flowrate for full bore type
+1% to +3% of flowrate for insertion type
Range ability is 10 : 1
Upstream length/ Downstream straight length is 15/ 5
For insertion type, hot tapping in pressurized pipelines possible
ADVANTAGES OF TURBINE FLOWMETERS

Very accurate. Commonly used to prove other meters.
Digital output provides for direct totalizing, batching, or digital blending without
reducing accuracy.
There is less tendency to read high in pulsating flow than in head or variable-area
type meters.
DISADVANTAGES OF TURBINE FLOWMETERS
Not usable in dirty streams or with corrosive materials.
Subject to fouling by foreign materials -fibers, tars etc.
Bearings subject to wear or damage. Shift in calibration if bearings replaced
Can be damaged by overspeeding (over 150 percent) or by hydraulic shock.

Pressure loss at rated flow varies & can be high.
TURBINE FLOWMETERS
POSITIVE DISPLACEMENT METERS

This meter repeatedly entraps the
fluid into a known quantity and than
passes it out.
The quantity of the fluid that has
passed is based on the number of
entrapments.
The volume flow rate can be
calculated from the revolution rate of
the mechanical device.
FEATURES OF PD FLOWMETERS
Design Pressure: 1500 PSIG (liquids)
: 100 psig (gases)
Design Temperature : 293 Deg. C (liquids)
: -34 to 60 Deg. C (gases)
Fluids : Clean Liquids/ gases
Flow range: 0 - 20000 GPM (liquids)
: 0 - 3000 cub.m/hr (gases)
MOC: mostly in aluminum,stainless steel, plastics, hastelloy
Accuracy is + 0.5% to + 1% of flowrate

ADVANTAGES OF PD FLOWMETERS
Good accuracy and high range ability
Can be used in viscous liquid flow
Low to medium initial set up cost

Require no power supply and available in wide variety of read out
devices
DISADVANTAGES OF PD FLOWMETERS
Maintenance required at frequent intervals because of the `moving
parts.
High pressure drop due to obstruction
Not suitable for low flow rate
Not suitable for fluids with suspended solids
Gas (bubbles) in liquid could significantly decrease the accuracy
THERMAL MASS FLOWMETER

Operates by monitoring the cooling effect of a gas
stream as it passes over a heated transducer.
Gas flows passes
transducers.
over
two
PT100
RTD
The temperature transducer monitors the actual

gas process temperature, whilst the self-heated
transducer is maintained at a constant differential
temperature by varying the current through it.
The greater the mass flow passing over the
heated transducer, the greater current required to
keep a constant differential temperature.
The measured heater current is therefore a

measure of the gas mass flowrate.
FEATURES OF THERMAL MASS FLOWMETERS

Design Pressure: 1200 PSIG
Design Temperature: 176 Deg. C
Fluids : Clean gases
Flow range: 0 2500 SCFM
MOC: mostly in stainless steel/ glass, teflon, monel
Accuracy is +1% to + 2% of flowrate
Range ability is 10 : 1 to 100:1
Upstream length/ Downstream straight length is 5/ 3
ADVANTAGES OF THERMAL MASS FLOWMETER

No temperature or pressure compensation required
Linear output (as temperature differential is proportional to mass flow)
Can be used on corrosive process streams if proper materials are
specified
DC voltage or 4 to 20 mA dc outputs available
DISADVANTAGES OF THERMAL MASS FLOWMETER

Practical for gas flows only
Subject to blockage by foreign particles or precipitated deposits due to
small openings in flowmeter
Power requirements excessive in larger pipe sizes

Has to taken out of process line for servicing
Accurate field calibration is difficult
CORIOLIS MASS FLOWMETER

When a moving mass is subjected to an
oscillation perpendicular to its direction of
movement, Coriolis forces occur depending on
the mass flow.
When the tube is moving upward during the
first half of a cycle, the fluid flowing into the
meter resists being forced up by pushing down
on the tube.
On the opposite side, the liquid flowing out
of the meter resists having its vertical motion
decreased by pushing up on the tube. This
action causes the tube to twist.
This twisting movement is sensed by a pick
up and is directly related to mass flow rate
When fluid is moving through the sensor's tubes, Coriolis

forces are induced in both the inlet and outlet legs of both
flow tubes. These forces cause the flow tubes to twist in
opposition to each other.
The mass flow moving through the inlet legs of the flow
tubes generate a Coriolis force that resists the vibration of
the flow tubes. As the mass flow moves through the outlet
legs, the Coriolis force adds to the vibration of the flow
tubes.
It is the opposite direction of the Coriolis force between
the inlet and outlet legs that result in the twisting motion that
is used to measure mass flow rate.
CORIOLIS MASS FLOWMETER (DENSITY)
Coriolis Mass Flow meters also measures density. Natural Frequency is basis of
measurement of density in coriolis mass flow meter.
Drive coil causes the tube to oscillate at natural frequency. As the mass in
process fluid increases, natural frequency decreases. As the mass of process fluid
decreases, natural frequency of tube increases.
Frequency is measured in cycles per second and Tube period is the reciprocal
of natural frequency. Coriolis Mass Flow meter measures density by measuring
tube period in microsecond per cycles.
Fluid Density is directly related to measure tube period.
Coriolis Mass Flow meter
FEATURES OF CORIOLIS MASS FLOWMETERS

Design Pressure: 345 bar
Design Temperature: 200 to 426 Deg. C
Sizes: 1.5 mm to 150 mm

Fluids/ Applications : Liquids (clean/ dirty/viscous/ slurries) clean /liquified
gases
Flow range: 0 25000 lb/m
MOC: mostly in stainless steel, hastelloy/titanium
Accuracy is + 0.15% to + 0.5% of flowrate
ADVANTAGES OF CORIOLIS MASS FLOWMETERS

Capable of measuring difficult handling fluids
Independent of density changes, flow profile and flow turbulence.
Hence straight lengths are not required.
No routine maintenance required since no moving parts
High accuracy
DISADVANTAGES OF CORIOLIS MASS FLOWMETERS

Not available for large pipes (upto 150 mm only)
High flow velocities required for detection resulting in high pressure drop
Expensive compared to other flowmeters

Difficulty in measuring low pressure gases.
APPLICATIONS OF FLOWMETERS
CLEAN LIQUIDS/ GASES
Orifices
Venturi
Annubar
Variable Area
Magnetic (only liquids)
Ultrasonic
Vortex
Coriolis Mass Flowmeters
Thermal mass flowmeter (only gases)
PD meters
DIRTY LIQUIDS
Most suited
Magnetic
Limited applications
Venturi meters
DIRTY GASES
Most suited
Vortex meters
Venturi meters
Thermal mass flowmeter
Variable area flowmeter
CORROSIVE LIQUIDS
Magneticflowmeters
Ultrasonic flowmeters
VISCUOUS LIQUIDS
Coriolis
Magnetic
Positive Displacement Meters
ABRASIVE SLURRIES
Magnetic flowmeters
FIBROUS SLURRIES
Magnetic flowmeters
Coriolis Mass Flowmeters (limited applications)

SATURATED STEAM
Most suited
Orifice DP meters
Vortex flowmeters
Venturi meters
Variable area meters
SUPERHEATED STEAM
Most suited
Orifice DP meters
Venturi meters
CRYOGENIC ( Low Temperatures)
Venturi meters
Orifice plates
LEVEL INSTRUMENTATION
TYPES OF LEVEL INSTRUMENTS

LEVEL GAUGE
MAGNETIC LEVEL GAUGE
RELEX GLASS TYPE LEVEL GAUGE
FLOAT & TAPE TYPE LEVEL INDICATOR
LEVEL TRANSMITTER
DISPLACER TYPE
RADR LEVEL TRANSMITTER
SERVO GAUGE TYPE LT
DP TYPE LT
NUCLEONIC TYPE LT
ULTRASONIC TYPE LT
LEVEL SWITCHES
VIBRATION FORK TYPE LEVEL SWITCHES

CAPACITANCE TYPE LEVEL SWITCHES
FLOAT TYPE LEVEL SWITCHES
REED TYPE LEVEL SWITCHES
LOOK AT HOOK UP OF LEVEL INSTRUMENTS
RADAR LEVEL
INSTRUMENTS:- Used for Continuous Noncontact Level
measurement of Liquids,
Paste and Slurries.
-For High Pressure and
Temperature.
- Accuracy +/- 1 to 10 mm
- Dielectric Constants shall
be > 1.4
Radar Level Transmitter (Antena Type)
RADAR LEVEL INSTRUMENTS:-
Radar Level measurement using

the Time-of-Flight principle.
Radar works with high-frequency

radar pulses which are emitted
by an antenna and reflected from
the product surface. The time of
flight of the reflected radar pulse
is directly proportionate to the
distance traveled. If the tank
geometry is known, the level can
be calculated from this variable.
GUIDED WAVE RADAR LEVEL INSTRUMENTS: Guided Wave radar works with high-frequency radar pulses which are guided
along a probe. As the pluses impact the medium surface, the characteristic
impedance changes and part of the emitted pulse is reflected.
The time between pulse launching and receiving is measured and analyzed by
the instrument and constitutes a direct measure for the distance between the
process connection and the product surface.
Reliable and maintenance-free measurement in liquids, also in turbulent media
and foam. Unaffected by density, temperature, conductibility and humidity.
No impairment by outgassing media (steam pressure).
Process temperatures up to +400 C
Process pressures up to 400 bar
GUIDED WAVE RADAR
LEVEL INSTRUMENTS: Up to 45 meter tank.
Used for Interface Level,
continuous Liquid Level
and solid level
measurement.
Accuracy +/- 2 mm to 10
mm.
DP TYPE LEVEL
INSTRUMENTS:Used for Liquid Level
Measurement.
Accuracy +/- 0.5 to +/0.075% of FS
DP TYPE LEVEL INSTRUMENTS: The pressure difference which acts
on both sides of the sensor leads to
a deflection of the diaphragm. This
deflection is converted into a
pressure-proportionate output
signal.
Unaffected by dielectric constant,
foam, turbulence and baffles. High
overload resistance.
Process temperatures up to +350

C
Servo Gauge Level Instruments:
Servo Tank Gauging measurement is

based on the liquid displacement
principle. A displacer is suspended in
a liquid by a wire. The weight of
the displacer is measured, compared
to a target value, and the result of this
comparison is output as level or
density data.
For continuous contact level
measurement of liquids and liquefied
gases, including liquid surface level,
the interface between 2 liquids, and
tank bottom. It is also applicable for
density measurement.
Servo Gauge Level Instruments: Accuracy +/- 0.7 mm
Measures two clear interface levels and specific
gravity of up to three liquid phases
Tank mounted intelligence makes ideal for single or
multi-task installation, converting a wide range of
measurement functions including:
Liquid level Interface level, Spot density, Density
profile, Tank bottom, Water dip
Typical areas of apllication includes - Oil (fules),
LPG/LNG, Chemicals, Water /chemical interface
measurement, Foods, Liquid Food
Capacitance Type Level Instruments: A capacitance probe may be compared to an electric
condenser. As the tank is filled, the probe capacity
increases. This change is electrically analyzed.
Available with active build-up compensation for
highly viscous media.
High temperature probe or applications involving
extremely high temperatures.
Process temperatures up to +400 c, Process
pressures up to 500 bar
Capacitance Type Level Instruments: Used for continuous measurement of liquid .
Used for point detection level in solids, liquids.
Capacitance Type Level Instruments:-
NUECLONIC LEVEL INSTRUMENTS:The gamma source, a cesium or cobalt isotope, emits radiation
which is attenuated as it passes through materials. The measuring
effect results from the absorption of radiation by the product to be
measured which is caused by level changes
Non-invasive measurement from outside for all extreme
applications, e.g. very corrosive, aggressive and abrasive media.
Any process temperature
Any process pressure
NUECLONIC OR RADIOMETRIC LEVEL
INSTRUMENTS:-
NUECLONIC OR RADIOMETRIC LEVEL LIMIT DETECTION:-
NUECLONIC OR RADIOMETRIC LEVEL LIMIT
DETECTION:The gamma source, a cesium or cobalt isotope, emits radiation which is
attenuated as it passes through matter.
The measuring effect results from the absorption of the radiation by the
product.
Non-contact from outside.
For all extreme applications like toxic or highly aggressive media or rocks.
Any process temperature
any process pressure
Vibrating Level Switch
A sensor in form of a tuning fork is excited at its resonant frequency. The
drive works piezoelectrically. The oscillating frequency or the amplitude
changes as the fork enters the medium.
The change is analyzed and translated into a switching signal.
Free of calibration and maintenance. For all liquids, also if build-up,
turbulence or air bubbles occur, unaffected by the electric properties of
the medium.
Vibrating Level Switch
Magnetic Level Gauge
Float Type Level Switch: As the switch floats up and down on the surface of a liquid, an
installed sensor detects its position and triggers the switching operation.
Simple and price-effective. For liquids like water, waste water, acids.
Float Type Level Switch:-
Reflex Type Level Gauges:-
INSTRUMENTATION
Pressure Instruments
Temperature Instruments
Level Instruments
PRESSURE INSTRUMENTATION
Diaphragm Type Pressure Gauges :- Used
Bourdon Tube type Gauges

Diaphragm Type Gauges
Diaphragm Seal Type Gauges
Bellows
Material:- .
All wetted parts shall be minimum SS 316.
Movement SS304 minimum
Bourdon Tube PG:
Used normally up to 60 DegC.

Range Min. -1 to 1600 Kg/cm2g.
Argon Arc Welded 316 SS Bourdon Tube.
Dial Size 40, 50, 63, 100, 150, 250 mm.
Normally used 150 mm.
Connection 3/8, , up to 1.5 NPT,
BSP threads.
Connection Bottom, Back as specified.
Bourdon Tube Pressure Gauge
Bourdon Tube PG:

Mounting Field or Panel.
Connection NPT (M) normally used.
Bourdon Tube PG:
Over range protection : 130% of FSD.

Accuracy: - +/- 1 % of FSD
Zero point adjustment.
Blow out disc for safety.
Glycerin filled used for vibration, shocks.
Diaphragm seal type PG: Used where fluid is corrosive, viscous,

sediments, tendency to freeze, hazardous
fluid.
To isolate Bourdon tube from process fluid.
Seal Fluid inert Liquid, Silicon DC200,
DC750 based on Temperature.
Direct mounted or else capillary to be used for
remote mounting.
Diaphragm seal type PG: Connection Bottom, to 3 flanged, 150#

to 2500#, RF, RTJ, FF available.
Diaphragm Material SS316, Hastelloy C,
SS316+PTFE, Inconel, Nickel based on
application.
Std. Capillary length 3 mtr.
Diaphragm sensing are also used without seal
for low pressure sensing, where 0 10000
mmWC.
Diaphragm seal PG Construction-
Diaphragm seal PG-
Diaphragm seal PG-
Diaphragm seal remote PG (with Capillary):-
Pressure Switches: Pressure switches are used detect high or low,

normally it is blind pressure switches.
Differential pressure switches are used to detect lo or
hi Differential pressure.
Indicating switches are also available.
Pressure & DP Transmitters:-
Diaphragm Seal type Direct Mounted Pressure
Transmitters:-
Diaphragm Seal type Remote Pressure
Transmitters:-
Diaphragm Seal type Remote & Inline Pressure
Gauges / :-
Differential Pressure Gauge
Accessories: Syphon :- Used in steam service to reduce

temp.
Snubber:- Used at Pump Discharge to reduce
fluctuation, provides dampening effect.
Gauge Saver:- Used where maximum
pressure exceeds the over range pressure of
gauge.
2-Valve manifold for PG
3-Valve Manifold for Differential Pressure
Indicators.
3-way valve Manifold
5-way Manifold
Accessories:-
Accessoris:- 2 Valve Manifold
TEMPERATURE INSTRUMENTATION
Bimetal Dial Thermometers
Bottom , Back entry

Every angle type
Range -50 to 600 DegC
Protection 125% of FSD.
NPT (M) standard.
Thermo well Required
Accuracy - +/- 1% of FSD
Micro pointer adjustment for zero.
Mercury filled, Gas Filled Thermometer or

Temp. Gauge :
For Remote Mounted Temp. Gauge.

Inert Gases are used.
Range -200 to 800 DegC
Thermo well Required
Accuracy - +/- 1% of FSD and above
Bimetal Temp. Gauge :
Gas Filled Capillary Temp. Gauge :
Different Types of Temp. Gauge :
Bimetal Temp. Gauge :
Thermo well :
Flanged Thermo well :
Different Thermo well :
Temperature switches are also available

Thermo well material shall be min. SS316, can
be available in SS316L, Hastelloy.
Connection shall be 1.5 300#RF ANSI Flange
standard.
Can be available in Threaded, welded also.
Based on requirement & application.
Temperature Element :- RTD, Thermocouple

RTD :- Resistance Temperature Detector
PT-100, PT-1000, CU-2000
Principle :- Change in Resistance is directly

proportional to Temperature.
3 wire RTD
4 wire RTD
RTD Assembly
Thermocouple
Thermocouple :
K-type normally used.
E Type, J type, R Type, S Type, T type.
Principle : Works on Seebeck Effect, which is
when two dissimilar metal junction heated, a
potential difference is developed at other end.
Thermocouple
Thermocouples Types
E Type , Chromel (+ve) Constantan(-ve),
Recommended Range -184 to 982 DegC
J Type , Iron (+ve) Constantan(-ve),
Recommended Range 0 to 815 DegC
K Type , Chromel (+ve) Alumel (-ve),
Thermocouples Types
R Type , Pt87-Rh13(+ve) Platinum(-ve),
S Type , Pt90-Rh10 (+ve) Platinum(-ve),
T Type , Copper (+ve) Constantan (-ve),
RTD/TC:-
Thermo well with Temp. Element
Installed thermo well in pipe line :-
Installed thermo well in pipe line :-
Temperature Transmitter:-
CONTROL VALVE
Section 1
What is a control valve?
Typical Pressure Control Loop
Pneumatic
3-15 PSIG
Positioner
P1 = 75-100 psig
Steam
Supply
PC
Supply
50
PSIG
TANK
Analog
Electro-Pneumatic
Control Signal
4-20mA
Process Variable
4-20mA
PIT
Positioner
P1 = 75-100 psig
Steam
Supply
50
PSIG
TANK
Digital
Bi-directional Digital
communication
Control Signal
Process Variable
PIT
Positioner
P1 = 75-100 psig
Steam
Supply
50
PSIG
TANK
CONTROL VALVE
What is control valve?

It is one of the final control elements
Controls/Regulates flow rate of fluid
Controls compressable(gas) and noncompressable(liquid) fluids
The other final control elements are ID fan/FD fan
dampers, VFD(for pump sped control), over head
water tank float valve
Based on the application control loops are
functionally termed as Flow control valve(FV), Level
control valve(LV),Pressure control valve(PV),
Temperature control valve(TV )
CONTROL VALVE
What are the various types of control

valves
- Globe: very widely used for most of
applications
- Butterfly: low pressure drop and for sizes
more than 4 generally
- Ball: tight shut off and on/off applications
- Diaphragm: corrosive and slurry services
CONTROL VALVE
What are various parts of control valve?

- Body : consists of trim (closure member)
- Bonnet: The portion of the valve which encloses the
pressure retaining parts such as packing rings, stem
- Yoke: the connecting part between body and Actuator
- Actuator: where Instrument air acts for operating the
valve
- Positioner: the component which positions the valve
stem at required position based on the control signal
- Travel limit switches: which gives feed back signal of
valve travel
CONTROL VALVE
The device that positions the throttling
element inside the valve body
Lever
Yoke
Stem (Piston Rod)
Travel Indicator
Body Subassembly
Throttling Element
Stem Connector
Diaphragm
Piston
Pneumatic single spring diaphragm actuator

VENT
DIAPHRAGM
PLATE
DIAPHRAGM
INPUT SIGNAL
DIAPHRAGM
CASINGS
ACTUATOR
SPRING
ACTUATOR STEM
SPRING SEAT
SPRING ADJUSTER
YOKE
INDICATOR
STEM CONNECTOR
SCALE
GLAND STUDS
LOCK NUT
STUFFING BOX
BONET FLANGE
CONTROL VALVE
Linear motion control valves

- Globe
- Gate
- Diaphragm
- Pinch
Rotary motion control valves
- Ball
- Butterfly
- Plug
CONTROL VALVE
Basic relation of Flow rate & Pressure drop
- Flow rate is proportional to square root of pressure drop

- The proportionality between flow rate and square root of
pressure drop holds true only for fully turbulent fluid
behavior
CONTROL VALVE
Steps for sizing of control valve

Inputs
- Fluid status(liquid/gas/steam)
- Flow rate maximum/normal/minimum
- Pressure drop
- Density /specific gravity of fluid
- Temperature of fluid
- Pipe line size
CONTROL VALVE
Valve flow coefficient, Cv

- Number of U.S gallons per minute of water
that will pass through a given flow
restriction with a pressure drop of one psi
- a Cv of 12 means the control valve at full
open position passes 12 US gallons of
water per minute with one psi pressure
drop across it. It is a capacity index.
CONTROL VALVE
Calculating Cv for liquid flows
- Cv = (q/N1*Fp)*Gf/p1-p2
For gas flow
- Cv = q/N7*Fp*p1**GgT1Z/x
Cv= valve flow coefficient
q= volumetric flow rate
N= numerical constant
Gg= gas specific gravity
Gf=specific gravity at flowing temp
T1=absolute inlet temperature
Fp=piping geometry
factor
p1=upstream pressure
p2=downstream pressure
= gas expansion factor
x = pressure drop ratio dp/p1
Z = gas compressibility factor
CONTROL VALVE
Control valve size should typically not be less

than half size of the line size where it is
installed i.e in a 6 line CV should not be 2. It
can be 6 or 4 or 3 based on Cv calculated.
Using line size valve with reduced trims
following advantages
- saves cost on reducers( However, the cost of
reducers vs CV cost to be evaluated before
making this conclusion)
- permits increasing future throughput
- permits the design of piping system before
final CV selection
SIZING CONTROL VALVES

Factors to be considered
Liquid sizing
Understanding Bernoullis equation
Choked Flow
Pressure recovery coefficient
Cavitation
Flashing
Noise
Gas sizing
Trim characteristics
Material selection
Stelleting
Pipe velocity limitations
Trim exit velocity limitations

Liquid service pressure recovery curve
P1 Inlet Pressure
Single Stage Letdown
VVc
V1 Inlet Velocity
P2 Outlet Pressur
PVc
Valve inlet
Pv Vapour Pressure
Valve outlet

Flashing service
P1
Inlet Pressure
VVc
V2
V1 Inlet Velocity
Outlet Velocity
Pv Vapour Pressure
PVcP
P2 Outlet Pressure
Vc
Valve inlet
Valve outlet

Cavitating service
P1 Inlet Pressure
VVc
V2
V1 Inlet Velocity
P2 Outlet Pressu
PVc
Valve inlet
Pv Vapour Pressu
Valve outlet

Cavitation and Flashing
Cavitation & Flashing are liquid phenomena
There is bubble formation when the static pressure of the fluid falls below
the vapour pressure.
The bubbles formed collapse when the static pressure increases above th
vapour pressure. This is cavitation.
The bubbles formed are carried downstream if the outlet pressure is less
than vapour pressure. This phenomena is flashing.
Both Cavitation and Flashing can cause excessive erosion on Trim parts,
body and downstream pipe.
Cavitation can be fully eliminated by offering suitable trim but not flashing
Low recovery valves are less prone for cavitation
SIZING CONTROL VALVE

Cavitation service: solution
Reduction of operating temperature
Reduction in differential pressure drop
Location of the valve
Selecting Valve with low recovery
Selecting multistep valve
Cascading

Cavitation service: solution
CONTROL VALVE
Control valve basic characteristics

The relation between flow rate through a
valve and the valve travel
- Equal %
- Linear
- On/off
CONTROL VALVE - Characterstics

Trim characteristics
100
Quick opening
80
60
Flow rate
Linear
40
Equal percentage
20
0
20
40
60
80
100
CONTROL VALVE
How to select required valve characteristic

- select =% if the system decreases with
increasing valve load
- if the pressure drop is varying i.e not
constant pressure drop
- Typical applications with above conditions
are Pressure control and nonlinearised
flow control
CONTROL VALVE
Linear characteristic selected for following

applications
- pressure drop is constant
Typical applications are:
- level control
- pump minimum flow bypass control
- split range
CONTROL VALVE
Quick opening characteristic

- typically selected for On/off valve
applications
- Depressurising applications
CONTROL VALVE
Input data for selecting proper MOC

- Design pressure & temperature
- Piping specifications
CONTROL VALVE
Some special applications

- Coker valves used in DCU plant
- As the coke is very turbid / tendency to solidify at
low temperature valves need special
attention/design to work in these harsh
conditions
- Due to high pressures Motorised actuators are
used instead of conventional pneumatic
- Knife edge valves are used in slurry/pulp
services

Control Valve Leakage
Maximum Leakage
ANSI/FCI 70-2
Test Medium
0.5% valve capacity at full travel
Class II
Water / Air
Class III
Class IV
0.0005ml/min/psid/in. port dia
Class V
Water
Bubbles per
Port dia.
mL per Min.
Min.
Class VI
1
1 - 1/2
2
2 - 1/2
3
4
6
8
1
2
3
4
6
11
27
45
0.15
0.30
0.45
0.60
0.90
1.70
4.00
6.75
Air
Pressure and temperature

Service DP or 50 PSID
whichever is lower at 10 to
52deg C
Service DP at 10 to 52deg C
Service DP or 50 PSID
whichever is lower at 10 to
52deg C
FF LOOP (DCS)
Control Valve
Globe Control Valve
Rotary Control Valve
Control Valve
CONTROL VALVE
COMPONENTS
Control Valve Accessories
-
Positioners
Position Transmitters
Limit Switches
Solenoid Valves
Air Filter Regulators
Lock-up relays
Volume Tanks
Positioners
-
Pneumatic
Electro pneumatic
SMART / HART Type
Foundation Fieldbus Digital Positioners
CONTROL VALVE ACTUATORS

Actuator Types
Actuators
Pneumatic
Linear
Piston
Hydraulic
Rotary
Diaphragm
Electric
CONTROL VALVE
CONTROL VALVE
COMPONENTS
DIFFERENT TYPES OF CONTROL VALVE
Ball valve
3-way valve
Globe valve
Butterfly valve
V-ball valve
Angle valve
CONTROL VALVE
CONTROL VALVE
CONTROL VALVE
INSTALLATION PRACTICES
PERFORMANCE
Max straight run in inlet pipe A good thumb rule -10 to 20 D
Allow straight run in outlet pipe 3 to 5 D
straight run in inlet pipe steady inlet flow steady & repeatable
flow
Location of PG &
Location of CV with respect to indicator of controlled parameter
1
2
AVOID
AVOID
4
3
INSTRUMENTATION
Boiler Controls
Distillation Column Controls
Boiler Control Loops
Boiler Control Loops (3 Element)
Distillation Column
Distillation is very common and widely
used for process of separation.
Used to isolate & purify volatile materials.
Separates a mixture on the basis of
difference in the composition of liquid and
that of the vapor formed from the liquid.
Distillation Column
Distillation column is energy separating
agent equilibrium process that uses the
difference is relative volatilities or
difference in relative boiling points of
components to be separated out.
Most commonly used in oil & Gas
Refinery, Petrochemical & Chemical
plants etc.
Distillation Column Objective

Column Operating objectives : Operating objectives includes the composition
specification for the top and the bottom product
streams.
Other Objectives can include increasing throughput,

enhancing column stability, and operating equipment
constraints.
Distillation Column
Proper instrumentation for distillation
column operation is vital to achieve
maximum product of satisfactory purity.
Instrumentation is used to solve equations

necessary for proper control of distillation
column.
Distillation Column
Primary application of instrument & control
in column is to control product purity.
Secondary application is to minimize

upsets to unit caused by change in
process inputs.
Distillation Column Flow Sheet
Distillation Column Equipments
Column
Pre heater
Condenser
Accumulator
Reflux pump
Re-boiler

Reflux System : The overhead vapor leaving column is sent to a
cooler or condenser and is collected as a liquid in
accumulator or receiver.
A part of accumulated liquid is returned to column
as a reflux.
The remainder is withdrawn as overhead product
or distillate.

Re-boiler System : The liquid leaving the column bottom is heated in
a re-boiler (A re-boiler is a special type of heat
exchanger used to provide the heat necessary for
distillation).
Part of this liquid is vaporized and returned into
the column as a boil up.
The remaining liquid is withdrawn as a bottom
product or residue.
Column Re-Boiler
Variables for Distillation Operation
Distillation Column Controlled

variables
Column Controlled variables : As we know controlled variables can be affected by
several manipulated variables, only one
manipulated variables used to directly affect the
value of controlled variable.
Minimum following controlled variables for a column
need to be considered.
Distillation Column Control

Configuration

Configuration

Configuration

Configuration
Internals of Column

Instrumentation GDR

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INSTRUMENTATION

IT IS WINDOW TO PROCESS OF PLANT.

o Vibrations of Compressor, Pumps

WHAT IT CONSISTS OF?

INSTRUMENTATION CLOSED LOOP.

WHAT IT CONSISTS OF?

WHAT IT CONSISTS OF?

FINAL CONTROL ELEMENT :

General software used

Marshalling Rack Room

DCS Operator Station

Snap Shot of Control Room

HAVE LOOK AT CONTROL LOOP

FEEDBACK CONTROL LOOP

TYPES OF FLOW MEASUREMENTS

SELECTION/ APPLICATION OF A FLOWMETER

DIFFERENTIAL HEAD TYPE FLOWMETERS (ORIFICE)

DIFFERENTIAL HEAD TYPE FLOWMETERS (ORIFICE)

Types of Orifice plates

Tappings for the Orifice plates

D and D/2 taps ( <= 14)

FEATURES OF ORIFICE PLATES

Rangeability is 3:1 to 5:1.

ADVANTAGES OF ORIFICE PLATES

DISADVANTAGES OF ORIFICE PLATES

High permanent pressure loss & hence high energy consumption to

Impractical for systems with low static pressure.

FEATURES OF VENTURI METERS

Design Temperature: No limitation. Limited by DP transmitter/ pipe pressure

Rangeability is 3:1 to 5:1.

ADVANTAGES OF VENTURI METERS

Larger and heavier to handle.

MOC: Brass / steel/ stainless steel/ Hastelloy

Upstream length/ Downstream straight length is

Hot tapping: Insertion/ installation without system shutdown

VARIABLE AREA FLOWMETER

VARIABLE AREA FLOWMETER

Does not require external impulse or lead lines.

Metal tube meters more expensive.

FEATURES OF MAGNETIC FLOWMETERS

Design Temperature: Upto 120 deg.C with teflon liners /

ADVANTAGES OF MAGNETIC FLOWMETER

density, consistency, viscosity, turbulence, or piping

Highly accurate due to absence of moving parts/ external sensing lines

Vortex meters make use of a natural phenomenon

FEATURES OF VORTEX FLOWMETERS

MOC: mostly in stainless steel, some in plastic

ADVANTAGES OF VORTEX FLOWMETERS:

Correct installation is critical as a protruding gasket or weld beads can cause

FEATURES OF ULTRASONIC FLOWMETERS

ADVANTAGES OF ULTRASONIC FLOWMETERS

Portable models available for field analysis and diagnosis

Higher initial set up cost

FEATURES OF TURBINE FLOWMETERS

Sizes: 5 mm to 600 mm (Full bore type)/ > 75 mm for insertion type

ADVANTAGES OF TURBINE FLOWMETERS

Can be damaged by overspeeding (over 150 percent) or by hydraulic shock.

POSITIVE DISPLACEMENT METERS

Accuracy is + 0.5% to + 1% of flowrate

Low to medium initial set up cost

THERMAL MASS FLOWMETER

The temperature transducer monitors the actual

The measured heater current is therefore a