Process Instrumentation

CHE426
Dr. Fahad Rehman
Department of Chemical Engineering
CUI, Lahore Campus
CLOs covered in this lecture
• CLO1: Describe the fundamentals of Process Instrumentation

• Contents
• We will talk about some fundamentals definitions used in measurements,
data types, sampling method and Transducers
Some fundamental definitions
• Accuracy
The quality or state of being correct
Or
The degree to which the result of a measurement, calculation, or
specification conforms to the correct value or a standard.

• It depends on linearity, hysteresis, offset, and sensitivity. The resulting

discrepancy is stated as a plus-or-minus deviation from true reading, and
is normally specified as a percentage of reading, span, or of full-scale
reading or deflection (% FSD), and can be expressed as an absolute value.
Accuracy
• A pressure sensor has a span of 25 to 150 psi. Specify the error when
measuring 107 psi, if the accuracy of the gauge is (a) ±1.5% of span,
(b)±2% FSD, and (c) ±1.3% of reading.
• a. Error =±0.015 (150 −25) psi=±1.88 psi.
• b. Error =±0.02 × 150 psi=±3 psi.
• c. Error =±0.013 × 107 psi=±1.391 psi.

• Sometimes accuracy vaires with the reading !!!

Some fundamental definitions
• Precision
The quality or state of being Precise: Exactness
or
The degree of refinement with which an operation is performed or a
measurement stated
Accuracy vs Precision
Data types and Sampling
• Variables, hence the data, are analog in nature.
• Before the digital processing evolved, sensor signals were processed
using analog circuits and techniques which still exists. However, most
modern systems now use digital techniques for signal processing.
• An analog signal is a continuous signal that represents physical
measurements such as reading on pressure gauge or speed meter on
a motor bike.
• Digital signals are time separated signals which are generated using
digital modulation. It uses a continuous range of values that help you
to represent information. Digital signal uses discrete 0 and 1 to
represent information.
Analoge vs Digital
Data types and Sampling
• Pneumatic Data
• Pneumatic Signal is pressure of a gas (or air) in a pipe, instead of electrical
current.
• Pressure is used for data transmission before the use of electrical signals.
• Used in conditions where high electrical noise could affect electrical signals
• Or hazardous conditions where an electrical spark could cause an explosion
or fire hazard.
• The most common range for pneumatic data transmission is 3 to 15 psi (20
to100 kPa in SI units), where 0 psi is a fault condition.
Data types and Sampling
• Pneumatic Data
• It is difficult to control very low pressures accurately with a simple
regulator
• Provide vacuum to allow for calibration and measurement hysteresis
& repeatability errors
Sampling
• Discrete Sampling/measurement
• Carried out at a fixed time interval
• When the requirements are flexible or not a safety risk

• Continuous sampling measurement

• When the measured variable is absolutely crucial for product quality
or plant safety
• The data is usually transferred continuously electrically to the control
room
Calibration
• How would know you instruments/sensor are providing the accurate
reading?

• How would you determine the temperature shown by thermocouple is

accurate or your pressure differential cell is indicating the right pressure.

• You calibrate them with standard devices such as Thermometer

• Such as DO probe or TDS probe…….

Transducers
• Transducer is defined as a device, which converts physical quantity
such as pressure or temperature to into electrical signal.

• These are widely used and essential in measurements because not all
quantities that need to be measured can be displayed as easily as
others.
Continued….
• For example, How does a
thermocouple work ?
• Does it really measure
Temperature?
• Mercury thermometer converts variations in
temperature into variations in the length of a
column of mercury.
• Since the variation in the length of the mercury
column is rather simple to measure, the mercury
thermometer becomes a convenient device for
measuring temperature.
Continued….
• On the other hand, the actual temperature variation is not as easy to
display directly.
• Another example is manometer, which detects pressure and indicates
it directly on a scale calibrated in actual units of pressure.

Let’s take a slight detour!!!

 Continued….
• How do we know the temperature
and or a pressure of a system in the
first place? When no transducer or
instrument was invented???
• The answer is we Don’t!!!
• We only know the reference points
such as melting point and boiling
point. And we have divided these
points in several different intervals.
• I would like to know how do we
make reference points for pressure
??? Lets discuss in our online
interactive session.
Continued….
• Moral: Thus the transducer is a device, which provides a usable
output in response to specific input measured, which may be physical
or mechanical quantity, property or condition.

• The transducer may be mechanical, electrical, magnetic, optical,

chemical, acoustic, thermal nuclear, or a combination of any two or
more of these.
Next Lecture
• We will continue with Transducers, their classification, working,
characteristics and selection criteria and Assignment 1.