BASIC

INSTRUMENTATI
ON
 CONTENTS $25,634,942 (18%)
State Appropriated Funds

OBJECTIVE OF INSTRUMENTATION AND CONTROL

SENSORS AND TRANSDUCERS
STANDARD INSTRUMENT SIGNALS
TRANSMITTERS AND TYPES
INSTRUMENT PROPERTIES AFFECT ON PROCESS
QUANTITES TO BE MEASURED
MEASUREMENT POINTS AND TYPE OF SENSORS USED
CALIBRATION INSTRUMENTS
OBJECTIVE OF INSTRUMENTATION &
$25,634,942 (18%)
CONTROL
State Appropriated Funds

“You cannot control what

You cannot measure”

SAFE AND EASY OPERATION OF PLANT

LOWEST COST OF GENERATION
LONGEST EQUIPMENT LIFE
MAXIMUM EFFICIENCY
ENERGY CONSERVATION
CONTINEOUSLY MONITOR & RECORDING THE PROCESS PERAMETER
SENSOR AND TRANSDUCER

A SENSOR IS A DEVICE THAT HAS A CHARACTERISTIC THAT

CHANGES IN A PREDICTABLE WAY WHEN EXPOSED TO
PROCESS VARIABLE

A TRANSDUCER IS A DEVICE THAT CONVERTS ONE

FORM OF ENERGY INTO ANOTHER
 STANDARD INSTRUMENTATION
SIGNALS

STANDARD INSTRUMENT SIGNALS FOR CONTROLLERS TO ACCEPT AS

INPUTS FROM INSTRUMENTATION AND OUTPUTS TO FINAL CONTROL
ELEMENTS ARE

PNEUMATIC
CURRENT LOOP
0 TO 10 VOLT
PNEUMATIC (3 TO 15 PSIG)

BEFORE 1960, PNEUMATIC SIGNALS WERE USED ALMOST EXCLUSIVEL

TO TRANSMIT, MEASUREMENT AND CONTROL INFORMATION

MOST OFTEN AN I/P (I TO P) TRANSDUCER IS USED.

THIS CONVERTS A 4-20 MA SIGNAL (I) INTO A PRESSURE SIGNAL
(3 TO 15 PSIG)
CURRENT LOOP (4-20 MA)

CURRENT LOOPS ARE USED BECAUSE OF THEIR IMMUNITY TO

NOISE
AND THE DISTANCES THAT THE SIGNAL CAN BE TRANSMITTED.

A DC MILLIAMP CURRENT IS TRANSMITTED THROUGH A PAIR OF

WIRES
FROM A SENSOR TO A CONTROLLER OR FROM A CONTROLLER TO
ITS
FINAL CONTROL ELEMENT

CONTROLLER OUTPUT IS CONFIGURED FOR 0% TO CORRESPOND TO

A
4 mA SIGNAL AND 100% TO CORRESPOND TO A 20MA SIGNAL

0 TO 10 VOLT

0 TO 10 VOLT IS NOT COMMONLY USED IN CONTROL SYSTEMS

BECAUSE THIS SIGNAL IS SUSCEPTIBLE TO INDUCED NOISE AND
THE DISTANCE OF THE INSTRUMENT OR FINAL CONTROL ELEMENT IS
LIMITED DUE TO VOLTAGE DROP
 TRANSMITTER AND ITS TYPES

TRANSMITTER IS A DEVICE WHICH IS USED TO MEASURE PHYSICAL VARIABLES

TRANSDUCER AND TO TRANSMIT SIGNAL INTO ELECTRICAL SIGNAL IN FORM
OF 4-20 mA or 1-5V DC SIGNAL

TYPES ARE

CONVENTIONAL TRANSMITTERS

SMART / INTELLIGENT TRANSMITTERS

CONVENTIONAL TRANSMITTERS

CALIBRATION CAN BE DONE AFTER DISCONNECTING THE TRANSMITTER FROM

FIELD
CALIBRATION CANNOT BE DONE BY USING HART(HIGHWAY ADDRESSABLE REMOTE
TRANSDUCER)
IT CONSISTS OF ZERO AND SPAN ADJUSTMENTS FOR THE CALIBRATION
SMART / INTELLIGENT TRANSMITTERS

A SMART TRANSMITTER IS A DIGITAL DEVICE THAT CONVERTS THE ANALOG

INFORMATION FROM A SENSOR INTO DIGITAL INFORMATION, ALLOWING THE
DEVICE TO SIMULTANEOUSLY SEND AND RECEIVE INFORMATION AND TRANSMI
MORE THAN A SINGLE VALUE

SMART TRANSMITTERS, IN GENERAL, HAVE THE FOLLOWING COMMON FEATURE

DIGITAL COMMUNICATIONS
CONFIGURATION
RE-RANGING
SIGNAL CONDITIONING
SELF-DIAGNOSIS

CALIBRATION CAN BE DONE BY USING HART COMMUNICATOR

ONLINE CALIBRATION CAN BE PERFORMED

FACTORS EFFECTING ON INSTRUMENTS

RANGE OF A SENSOR IS THE LOWEST AND HIGHEST VALUES IT CAN

MEASURE WITHIN ITS SPECIFICATION

SPAN OF A SENSOR IS THE HIGH END OF THE RANGE MINUS THE LOW
END OF THE RANGE

RESOLUTION IS THE SMALLEST AMOUNT OF INPUT SIGNAL CHANGE

THAT THE INSTRUMENT CAN DETECT RELIABLY

ACCURACY OF A MEASUREMENT DESCRIBES HOW CLOSE THE

MEASUREMENT APPROACHES THE TRUE VALUE OF THE PROCESS
VARIABLE

PRECISION IS THE REPRODUCIBILITY WITH WHICH REPEATED

MEASUREMENTS CAN BE MADE UNDER IDENTICAL CONDITIONS

SENSITIVITY OF A SENSOR IS THE RATIO OF THE OUTPUT SIGNAL TO

THE CHANGE IN PROCESS VARIABLE
 WHY IS PRECISION PREFERRED OVER ACCURACY

NOISE REDUCES THE ACCURACY AND PRECISION OF PROCESS

MEASUREMENTS

WE CAN REDUCE ELECTRICALLY INDUCED NOISE BY PROPER GROUNDING

TECHNIQUES,
USING SHIELDED CABLING, AND PHYSICALLY SEPARATING THE SIGNAL
CABLING FORM OTHER ELECTRICAL WIRING
QUANTITES TO BE MEASURE

PRESSURE

TEMPERATURE

FLOW

LEVEL
 PRESSURE

PRESSURE IS THE RATIO BETWEEN A FORCE ACTING ON A

SURFACE AND THE AREA OF THAT SURFACE
P = F/A

ABSOLUTE PRESSURE IS MEASURED RELATIVE TO A PERFECT VACUUM

UNITS : PSIA
GAUGE PRESSURE IS MEASURED RELATIVE TO AMBIENT PRESSURE
UNITS :PSIG OR PSI
DIFFERENTIAL PRESSURE USES A REFERENCE POINT OTHER THAN FULL VACUU
OR ATMOSPHERIC PRESSURE
TYPES OF PRESSURE MEASURING DEVICES

LIQUID COLUMNS

EXPANSION ELEMENTS

LIQUID COLUMNS

MANOMETRIC PRESSURE INSTRUMENTS

USED FOR LOW PRESSURE MEASUREMENT

EXPANSION ELEMENTS

USED IN MODERN POWER PLANTS

USUALLY METALLIC & ITS MOVEMENT INDECATES THE PRESSURE

EITHER DIRECTLY COUPLED WITH MECHANICAL LINKAGE OR INDIRECTLY

BY AN ELECTRICAL TRANSDUCER CONNECTED TO THE READOUT DEVICE

EXPANSION ELEMENTS

DIAPHRAGMS BELLOWS BOURDON TUBE

 DIAPHRAGMS

MOST COMMONLY CORRUGATED DIAPHRAGMS ARE USED BECAUSE LARGE

DEFLECTION CAN BE PRODUCED WITHOUT NON LINEARITY COMPARED WITH
FLAT TYPE

IN ORDER TO INCREASE THE DEFLECTION CAPABILITIES TWO OR MORE

CORRUGATED DIAPHRAGMS ARE WELDED AT CIRCUMFERENCE-CAPSULE ELEMENT
BELLOWS

MANUFACTURED FROM
BRASS, BRASS ALLOY

USED FOR LOW

PRESSURE
MEASUREMENT

FOR HIGH PRESSURE

MEASUREMET BELLOWS
ARE CONNECTED WITH
SPRING
BOURDON TUBE

C SHAPED & MADE INTO AN ARC

OF ABOUT 2700

MATERIAL FROM WHICH IT IS

MADE DEPEND ON PRESSURE
RANGE OF THE DEVICE

BOURDON TUBE ARE ALSO USED IN

FORMS OTHER THAN C TYPE
SPIRAL ELEMET LARGE
MOVEMENT THAN C TYPE
HELICAL ELEMENT  PRODUCE
MORE OR LESS CIRCULAR
MOVEMENT , WHICH IS USEFUL
FOR DRIVING RECORDER PEN
DIRECTLY
 PRESSURE TRANSDUCER

THE SENSOR THEN CONVERTS THIS DISPLACEMENT INTO AN ELECTRICAL OUTP

SUCH AS VOLTAGE (0-5V) OR CURRENT (4-20 mA)

PRESSURE TRANSDUCER

STRAIN GAUGE TYPE CAPACITANCE TYPE PIEZO ELECTRIC TYPE

STRAIN GAUGE TYPE

WHEN A CHANGE IN PRESSURE CAUSES

THE DIAPHRAGM TO DEFLECT,A
CORRESPONDING CHANGE IN
RESISTANCE IS INDUCED ON THE
STRAIN GAUGE

BRIDGE SENSORS ARE USED FOR HIGH

AND LOW PRESSURE APPLICATIONS,CAN
MEASURE ABSOLUTE, GAUGE, OR
DIFFERENTIAL PRESSURE
CAPACITANCE TYPE
WHEN PRESSURE IS APPLIED THE
CAPACITANCE BETWEEN METAL
DIAPHRAGM AND A FIXED METAL PLATE
CHANGES IF THE DISTANCE BETWEEN
THESE TWO PLATES CHANGES.

THESE ARE GENERALLY VERY STABLE

AND LINEAR

PIEZO ELECTRIC TYPE

THESE CRYSTALS GENERATE AN

ELECTRICAL CHARGE WHEN THEY ARE
STRAINED

PIEZOELECTRIC PRESSURE SENSORS DO

NOT REQUIRE AN EXTERNAL
EXCITATION SOURCE AND ARE VERY
RUGGED.
DIFFERENT PART IN PRESSURE
TRANSMITTER
 TEMPERATURE

“ TEMPERATURE IS A MEASURE OF DEGREE OF THE HOTNESS OR COLDNESS

OF AN OBJECT ”

TEMPERATURE IS MOST IMPORTANT PROCESS VARIABLE BECAUSE THE

EFFICIENCY OF GENERATION DEPENDS ON THE TEMP MEASUREMENT

TEMPERATURE IS MOST COMMONLY MEASURED BY

RESISTANCE TEMPERATURE DETECTOR (RTD)

THERMOCOUPLES

THERMISTORS (MAY ALSO BE FOUND EMBEDDED IN CONTROL EQUIPMENT)

LIQUID EXPANSION AND BIMETALLIC TYPE TEMP GAUGES

OPTICAL PYROMETERS
RESISTANCE TEMPERATURE DETECTOR (RTD)

A METALLIC WIRE CHANGES ITS

RESISTANCE WITH TEMP

USED WHEN APPLICATIONS REQUIRE

ACCURACY, FAST RESPONSE, LONG-
TERM STABILITY,LINEARITY AND
EPEATABILITY
THERMOCOUPLE
“ WHEN TWO DISSIMILAR METALS
ARE JOINED A PREDICTABLE
VOLTAGE WILL BE GENERATED THAT
RELATES TO THE DIFFERENCE IN
TEMPERATURE BETWEEN THE
MEASURING JUNCTION AND THE
REFERENCE JUNCTION ”
THERMOCOUPLE WIRING COLOR CODES
 THERMISTERS

THERMISTERS ARE NOT USED IN

THERMAL POWER PLANTS BECAUSE
ITS RANGE -60 T0 15 DEG.C

THERMISTORS ARE GENERALLY

MADE OF SEMICONDUCTOR
MATERIALS

LIQUID EXPANSION TEMP GAUGE

THESE ARE THERMOMETERS FILLED WITH
EITHER A LIQUID SUCH AS MERCURY. ANY
RISE IN TEMPERATURE PRODUCES EXPANSION
OF THE LIQUID
BIMETALLIC TEMP GAUGE
IT IS A WELL-KNOWN PRINCIPLE THAT IF
TWO METALS A RE RIGIDLY JOINED
TOGETHER AS A TWO-LAYER STRIP AND
HEATED, THE DIFFERENCE IN THE
EXPANSION RATE CAUSES THE STRIP TO
BEND
• OPTICAL PYROMETERS

• A PYROMETER IS A NON-CONTACTING DEVICE THAT

INTERCEPTS AND MEASURES THERMAL RADIATION.

• PYROMETERS ARE SUITED ESPECIALLY TO THE

MEASUREMENT OF MOVING OBJECTS OR ANY SURFACES
THAT CANNOT BE REACHED OR CANNOT BE TOUCHED.
 FLOW
THERE ARE VARIOUS METHODS USED TO MEASURE THE FLOW
RATE OF STEAM, WATER, LUBRICANTS, AIR, ETC., IN A
THERMAL POWER GENERATING STATION

DP CELL TYPE FLOW DETECTOR

TO MEASURE THE RATE OF FLOW

BY THE DIFFERENTIAL PRESSURE
METHOD, SOME FORM OF
RESTRICTION IS PLACED IN THE
PIPELINE TO CREATE A PRESSURE
DROP
ADV
HIGH DIFFERENTIAL PRESSURE
GENERATED
LOW PURCHASE PRICE AND
INSTALLATION COST
EASY REPLACEMENT
HIGH PERMANENT PRESSURE
LOSS IS A DISADVANTAGE
FLOW NOZZLE

FLOW NOZZLES ARE WIDELY USED

FOR FLOW MEASUREMENTS AT HIGH
VELOCITIES

THEY ARE MORE RUGGED AND MORE

RESISTANT TO EROSION THAN THE
SHARP-EDGED ORIFICE PLATE

MAGNETIC FLOW METERS

CONDUCTIVE LIQUID PASSES THROUGH THE
MAGNETIC FILED A VOLTAGE IS
GENERATED IN THE LIQUID WHICH IS
SENSED BY USING ELECTRODES
ADV
EXCELLENT ACCURACY
A PRIMARY BENEFIT OF THIS DESIGN
IS ITS ABILITY TO RECORD FLOW
RATES / TOTALS FOR FORWARD AND
REVERSE FLOW
 PITOT TUBE
• A PITOT TUBE IS A DEVICE
USED FOR MEASURING THE
VELOCITY OF FLOW AT ANY
POINT IN A PIPE OR
CHANNEL.
• THE PITOT TUBE CONSISTS OF
A TUBE, BENT AT RIGHT
ANGLE. THE DEVELOPED
DIFFERENTIAL PRESSURE
BETWEEN STATIC AND
DYNAMIC POINTS IS DIRECTLY
PROPORTIONAL THE SQUARE
OF THE FLOW RATE. AND IS
MEASURED IN M/S.
 ULTRASONIC FLOW METERS, TRANSIT TIME)
• Ultra sonic flow meters worked
Using the Transit Time
measurement principle.
• Ultrasonic Flow Meters are
compatible with a range of
metal and plastic pipe
materials and “corrosive
liquids” that would damage
standard flow meters. As a
result, the non-intrusive,
clamp-on ultrasonic sensors
feature enhanced flow
measurement with no pressure
drop in a range of applications
such as food or chemical
processing plants, oil
refineries, and more.
 LEVEL
THE PRESSURE AT THE BASE OF A VESSEL CONTAINING LIQUID
IS DIRECTLY PROPORTIONAL TO THE HEIGHT OF THE LIQUID
IN THE VESSEL. THIS IS TERMED HYDROSTATIC PRESSURE
DP transmitter is used for the purpose of measuring a level, it will be called a
Differential level transmitter

OPEN & CLOSED TANKS

IF THE TANK IS OPEN TO
ATMOSPHERE, THE HIGH-PRESSURE
SIDE OF THE LEVEL TRANSMITTER
WILL BE CONNECTED TO THE BASE
OF THE TANK WHILE THE LOW-
PRESSURE SIDE WILL BE VENTED
TO ATMOSPHERE.

FOR CLOSED TANKS LOW PRESSURE

SIDE CONNECTED TO PGAS
LEVEL MEASUREMENT IS VERY IMPORTANT ASPECT IN THERMAL POWER PLANT.
WE ARE HAVING LEVEL MEASUREMENTS IN THE FOLLOWING AREAS

1. HOT WELL LEVEL  DISPLACER TYPE PRINCIPLE

2. DEARATOR LEVEL  DIFFERENTIAL PRESSURE PRINCIPLE
3. DRUM  DIFFERENTIAL PRESSURE & DIFFERNTIAL RESISTANCE PRINCIPLE
4. LPH,&HPH LEVELS  DIFFERENTIAL PRESSURE PRINCIPLE

HYDRUSTEP

IT WORKS ON THE PRINCIPLE

OF RESISTIVE
DESCRIMINATION BETWEEN
STEAM & WATER

RESISTANACE VALUE >10M OHS

FOR STEAM AND BETWEEN 2K
OHM TO 100K OHM FOR WATER
HYDRAUSTEP DRUM LEVEL MONITORING
DISPLACER TYPE

LIQUID LEVEL IN THE VESSEL

CAUSE THE DISPLACER ELEMENT,
WHICH IS SUPPORTED ON A
SPRING, TO RISE OR FALL.
AROUND THE OUTSIDE OF THE
PRESSURE TUBE IN THE HEAD IS A
LINEAR VARIABLE DIFFERENTIAL
TRANSFORMER (LVDT), THE OUTPUT
OF WHICH IS PROPORTIONAL TO
THE POSITION OF THE CORE

ADV

LOW MAINTENANCE

SIMPLE INSTALLATION

LOCAL OR REMOTE CALIBRATION

MEASURING POINTS & TYPE OF
SENSORS USED
CALIBRATION INSTRUMENTS

BASIC LAB INSTRUMENTS FOR CALIBRATION ARE

LOOP ANALYSER

DEAD WEIGHT TESTER

VACCUME GAUGE TESTER

RTD SIMULATOR

TEMPERATURE BATH
THAN Q…