Pressure Measurement Elements

Bourdon tubes
A Bourdon tube is a metallic coil constructed from a metal tube, closed at one end and fixed to a pressure
source at the other. It has the desired elasticity that makes the tube tends to deform to straighten under
pressure. The pressure applied will results in movement at the free end causes a mechanical linkage to
move a pointer. Bourdon tubes come in several form i.e C tube, spiral, or helix.
Bellows
Bellows pressure element is formed from seamless tubes that are roll-formed. It looks like thin-walled
corrugated cylindrical containers. Bellows is flexible along its axis in such a way that it will change its
length proportional to the applied pressure.
Diaphragm
The diaphragm sensor is a thin flexible metal disk. Pressure applied to one side of the disk causes a
deflection that actuates a pointer. To measure very low pressures, the diaphragm requires to be very thin.
In this case it is difficult to be produced and its stability becomes poor. For this application, capsule can
be used. It is produced from two diaphragms welded together, so that doubles the displacement of the
diaphragm, allowing smaller pressures to be measured without degrading its performance.

Temperature Element Instrument

There are several temperature element instrument types widely used to measure temperature of a process
substance . These types are categorized into mechanical temperature element and electronic temperature
element. Mechanical temperature element uses the principle of thermal expansion i.e. the element
expands if the temperature rise and vice versa. Electronic temperature element use the principle of
electrical properties change following of temperature variation.
Mechanical Based Temperature Element
Solid element
Bimetallic is temperature element instrument formed from two types of metal which have different
thermal expansion properties. These two metal are bonded together become one strips. The metal strips
will bend if temperature changes. At free end of bimetal, the pointer is attached to indicate the result of
temperature measurement.
Gas element
Gas filled system is temperature element instrument based on principle of the ideal gas law. It consist of
bulb/stem, capillary and bourdon tube. The sensing element is a rigid bulb or stem containing a gas. If the
temperature rises, the volume remain constant since the bulb is rigid, while the gas pressure increase
proportionally. The change in gas pressure is measured by a pressure element such as bourdon tube.
The bulb and the bourdon tube is connected by a capillary tube allowing the temperature indacator to be
located not directly attached to the piping/vessel being measured. This advantages allows the temperature
gauge indicator being mounted on the convenient location whereas the tapping point of process fluid to be
measured is not permanently inaccessible.
However the capillary might loss heat therefore the addition of compensation is required to eliminate the
error. www.instrumentationportal.com
Liquid element
Liquid temperature element utilizes mercury constrained within a bulb/stem. Mercury is no longer
preferred in most process application although it provides fast response and good accuracy. Mercury
mostly used in glass stem thermometer for non-process industry such as body temperature measurement.
Electronic based Temperature Instrument
The most two commonly used electronic temperature element are Resistance Temperature Detector
(RTD) and Thermocouple. To indicate the temperature measurement, these elements need to be
connected to control system by wired directly or using temperature transmitter.
Resistance Temperature Detector
Resistance Temperature Detector (RTD) works based on principle that resistance of a metal varies with its
temperature. RTD is the most commonly used type in process measurement due to its good stability,
accuracy, repeatability.
Thermocouple
Thermocouple consist of two dissimilar metals of which the junction generates a voltage proportional to
the junction temperature. The Thermocouple is selected for service which requires wide range (very high
low temperature). The other advantages of thermocouple over RTD are it has more rugged design and
also provide faster response.

Basic Process Control System (BPCS)

Basic Process Control System (BPCS) is a system which handles process control and monitoring for
the facility. It will take inputs from sensor and process instruments and provide output based on control
functions in accordance with approved design control strategy.
Typically, Basic Process Control System (BPCS) performs the following functions:

Control the process within pre-set operating condition, optimize plant operation to produce a good
quality product and attempt to keep all process variables within its safety limit.
Provide operator interface for monitoring and control via operator console (Human Machine
Interface)
Provide alarm/event logging and trending facilities
Generate production data reports
Basic Process Control System (BPCS) is also considered as one of safety layer preceding Safety
Instrumented System (SIS) within a facilities.

Fail Safe
Fail safe means that when the power source is lost, the controller causes the process go to a safe state.
Safe state mostly requires equipment to be shutdown, production to be halt and sometime process
material to be released. Fail safe makes the process system in safer state if either of the following
condition occurs: abnormal process condition, loss of power, loss of instrument air supply, or field cable
faults.
To have system which operates in fail safe, the following condition should be fulfilled:

Switch shall have sensor contacts to be closed and the loop is energized during normal process
operation.
In the event of power failure, valve will move to a predetermined position, which could be open or
closed and other final element would stop to operate such as motor would stop, heater would be
turned off.
Status indication contact shall be closed to indicate running and open to indicate stop.

Manual Call Point

Manual Call Point is a manually operated switches which purpose is to provide means of manual initiation
of fire alarm by operator. Manual Call Point is simple electrical switch that requires manual activation and
set in open position during normal operation to prevent spurious alarm. There are several operation
mechanisms of manual call point:
Break Glass Type
A box with a breakable window at the front. Inside there is a switch, usually held in the open position
by means of a spring-steel arm positioned against the window. When the window is broken the spring
switch mechanism is released and the contacts close, initiating an alarm.

Lift Flap and Push

This type uses a guarded pushbutton. Some types require an operator to lift a spring-loaded cover to
access a pushbutton (or pull-button). This action closes the contact, initiating an alarm.

PSV Types Selection

Mention three types of Pressure Safety Relief Valve (PSV) and explain how to select the
right type for specific application?
Three types of Pressure Safety Relief Valve (PSV) are conventional, balanced bellows and pilot operated.

Conventional safety relief valves can be used on all services for liquid, gas, or vapor service if the total
backpressure is less than 10 percent of the set pressure.
Balanced bellows safety relief valve is used where the total backpressure exceeds 10 % of the set pressure
but does not exceed 50% of the set pressure, or where the superimposed back pressure varies widely
compared to the set pressure. It may also be selected to protect the spring and trim where corrosive fluid
may damage these parts.

Pilot operated safety relief valve shall be used when operating pressure is above 90% of set pressure or
where total backpressure may exceed 50% of set pressure as the valve lift is not affected by back pressure.

Heat Detector: Fusible Loop System

Besides producing flame, fire also produces smoke and heat. Hence to detect the existence of fire, heat
detector can be used. Compared to flame detector and smoke detector, heat detector is slow in detecting
fire because it only activates once a fire has produced sufficient heat of which heat detector could respond.
However, heat detector could provide useful back up or as alternative to flame and smoke detectors. One
mean to sense heat is by utilizing Fusible Loop System.
The Fusible Loop System consists of the following:
- Fusible plug which melt at set temperature
- Tubing network
- Fusible loop charge panel

During start-up, fusible loop is charged to allow air from instrument air system pressurizing the loop. The
pressure remains constant during normal operation. If there is fire and the surrounding temperature
rises, the fusible plug will melt. The air in the loop relieves and subsequently the pressure inside the
tubing reduces. Loss of pressure in the loop will be detected by pressure transmitter in the fusible loop
charge panel and it will signal the control room. Next action in the control system could be activate fire
alarm, trigger ESD, open deluge valve, etc.
Fusible Plug is non-resettable type. To restore the system into normal surveillance after activation will
require replacement of parts i.e. the fusible plug.
The other disadvantage of fusible loop is that the plug could melt by other source of heat other than fire
such as hot surfaces, motors, etc.

Voting Logic ESD Transmitter

ESD transmitters serving critical shutdown level in Safety Instrumented System are recommended to
have voting logic configuration. Voting logic is applied to minimize the occurrence of complete loss of
production caused by single transmitter fault or spurious trip shutdown. The voting configuration can be
2oo3 or 1oo2D based on SIL assessment and verification.
There are some consideration when applying voting logic in the process:
Transmitters not to have common tapping to the process line/equipment.
The transmitters forming the same voting logic shall not be assigned on the same I/O module of
Safety Instrumented System.
Each instrument cable is routed diversely.
Transmitters are set with the same calibration range.
It is also recommended to have transmitters from different manufacturer to avoid manufacturing defect
causing common mode failure. Also on this voting logic configuration, SIS needs to compare the
transmitters value and initiate alarm on Human Machine Interface (HMI) for any deviations on
measurement among the transmitters.
On a 2oo3 voting transmitter, any single abnormal process variable detection by one transmitter will
initiate an alarm. The shutdown will be initiated if two transmitters reach the trip set point.

Here are some application examples where the ESD transmitter with voting logic are used, typically it is
part of higher level in shutdown hierarchy level:
Instrument air header
Export Pipeline
KO Drum