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SENSORS,TRANSMITTERS,ANDTRANSDUCERS
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INTRODUCTION
The operation of complex industrial plants would be difficult, if not
impossible, without the measurement and control of critical process
variables.
Large plants typically have hundreds or thousands of process
variables that are repetitively measured online every few seconds or
minutes.
In addition, important product properties are measured in quality
control labs less frequently – e.g. once per hour, once an eight hour
shift, or daily.
Consequently, the design and maintenance of accurate, reliable
measurement system is a critical aspect of process control.
tRANSDUCERS
It is often necessary to convert an instrumentation signal from one
form to another. A device that performs this conversion is referred to
as a transducer.
SENSORS – SELECTION
CRITERIA
The selection of a measurement device should consider the
following factors:
1.Measurement range (span). The required measurement for the
process variable must lie entirely with the instrument’s range of
performance.
Typical sensors
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If the sensor power fails, the transmitter output signal has a value of OmA , which would move
the controller output to and final control element to their minimum or maximum values. If this
action could lead to an unsafe condition, the transmitter output signal could be inverted to give
the highest value in operating range.
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20 mA – 4 mA = 16 mA .
1000 kPa – 100 kPa 900 kPa
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• The transmitter has 2 knobs which can be
adjusted to change its span or its zero.
• P transmitter converts
inches H2O into mA
100 in H2O
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Dynamic characteristics of
sensor-transmitters.
Many sensor-transmitters respond quickly to and have measurement
dynamics that are negligible compared to slower process dynamics.
and τm is theYmeasurement
m (s) K m time constant.
=
Y (s) ms +1
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Control valves
There are many different ways to manipulate the flows of
material and energy into or out of a process; for example,
the speed of a pump drive, screw conveyor, or blower can
be varied.
Control valves
The control valve components include the valve body, trim, seat, and
actuator.
Valve body - contains an orifice that allows for the flow of liquids and/or gases;
Trim/Plug - modulates the flow rate and can be a plug, ball, disk, or gate;
Actuator - provides the force for opening and closing the valve;
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Spring – provides the energy to move the valve in the opposite direction of the
diaphragm loading motion; this provision is made so that the valve can be
opened and closed proportionally with the instrument signal; the spring
provides the energy to return the valve back to its fail-safe condition.
Control valves
Control valves are either linear (rising stem /
reciprocating) or rotary in design.
Linear valves – usually globe valves that open and close the valve
by moving a plug vertically away from the orifice and the seat; this
movement changes cross sectional area available for fluid flow.
Rotary valves – are closed by a 90o turn of the closing element
(also called quarter-turn valves); these valves are used both for on
off and flow modulating control valves.
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Control valves
Control valves typically utilize some type of mechanical driver to
move the valve plug into and out of its seat, it can either be:
A DC motor or a stepping motor that screws the valve stem in and out in much
the same way as a hand valve would be operated.
A pneumatically operated diaphragm device that moves the stem vertically
against the opposing force of a fixed spring, called a rising stem valve.
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Control valves
Single seated
Two general areas: the
actuator and the body
The actuator is the part of the
valve that converts the energy
input to the valve mechanical
motion to increase or decrease
the flow restriction.
Body: single-seated and
double-seated valves, split
body valve
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Double seated
Double-seated valves can handle high
process pressure with a standard actuator.
However, when tight shut-off is required,
single-seated valves are generally used.
Double-seated valves tend to have greater
leakage when closed than single-seated
valves.
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SPLIT BODY
This type of body is
frequently used in process
lines where frequent changes
of plug and seat are required
because of corrosion.
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Three way
Can either be diverging or
converging
Consequently, they can either split
one stream into two other streams
or blend two streams into only one.
They are sometimes used for
control purposes.
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CAGE
have hollow plugs with
internal passages
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BUTTERFLY
consist of a disk rotating about a shaft.
This type of valve requires minimum
space for installation and provide high-
capacity flow at low cost.
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BALL
commonly used to handle slurries or
fibrous materials. They have low
leakage tendency, are small in size
and can also provide high-capacity
flow at low cost.
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Types of actuators
Pneumatically Operated Diaphragm Actuators – these are the most
common actuators in the process industries. These actuators consist
of a flexible diaphragm placed between two casings.
One of the chambers resulting from this arrangement must be made
pressure-tight.
The force generated within the actuator is opposed by a “range”
spring.
The controller air pressure produces a force that is used to overcome
the force of the actuator’s range spring and the forces within the valve
body.
The action of the valve (FC or FO, is determined by the actuator.
Some valves can also have the action set at the body so that the stem
always moves down. In these, cases the valve is either FC or FO when
the stem moves down.
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Types of actuators
The size of the actuator depends on the process pressure against w/c
it must move the stem and on the air pressure available.
The most common air pressure range is 3 to 15 psig but ranges of 6 –
30 psig and 3 – 27 psig are sometimes also used.
These diaphragm actuators are simple in construction and also
dependable and economical.
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Types of actuators
Piston Actuators
Piston actuators are normally used when
maximum thrust output is required along
with fast response.
This usually occurs when working against
high process pressure.
These actuators operate using high air
pressure supply, up to 150 psig.
The best designs are double-acting to give
maximum thrust in both directions.
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Types of actuators
Electrohydraulic and Electromechanical Actuators
These are becoming more common with the use of electrical control
signals.
They require electric power to the motor and an electric signal from
the controller.
The most common in this family of actuator is probably the solenoid
actuator.
Solenoid valve can be used to actuate a double-acting piston
actuator.
By making or breaking an electric current signal, the solenoid
switches the output of a connected hydraulic pump to either above
or below the actuator piston.
Accurate control of valve position can be obtained with this unit.
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Manual-Handwheel Actuators:
Used where automatic control is not
required. They are available for
reciprocating stem and rotary stem
valves.
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U (s) Kv
= Gv( s ) =
P(s) vs +1
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ACCURACY IN
INSTRUMENTATION
accuracy and inaccuracy of control is important
accuracy requirements are inherently related to control system
objectives:
ex: a)cooling water flow errors on the order of 10% (of the
measured flow rate might be acceptable in a control loop
regulating the temperature of a liquid leaving a condenser, as long
as the measurements are simply biased from the true value by this
constant amount
b) On the other hand, errors in the feed flow rate to a process on the
order of 1-2% might be unacceptable if the inventory calculations
must be made with these data
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The term full scale refers to the span of the instrument. Suppose
that the %FS error of a temperature transmitter is 1% and the zero
and span are adjusted so that the instrument operates over the
range 10-70 C.
Since the span is 70-10 = 60 C, the measurement error is 1% of 60
C, or 0.6 C. Consequently, the relative error (obtained by dividing
the error by the value of the measurement) at 10 C is 0.6/10 = 6%
Thus, when an instrument accuracy is expressed as %FS, the
relative error can be quite large for small values of the measured
variable
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EXAMPLE
Consider a hypothetical experiment with some device
measuring the flow rate of a liquid
Under conditions that should yield a constant flowrate, we
make a number of measurements and record them,
assuming the instrument can be read to the nearest 0.01
flow unit
The following figure might result
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Types/sources of instrument
error
1)Nonlinearity - was a significant source of error prior to
the availability of digital instrumentation
2)Hysteresis – characterized by an output result that
depends on the direction of change of the instrument
input, usually from nonideal magnetic or electrical
components
3)Backlash – the mechanical equivalent of hysteresis,
usually from friction effects or gears with play
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Calibration of instruments
Any measurement instrument from which a high degree
of accuracy is expected should be calibrated both initially
(before commissioning) and periodically (as it remains in
service)
In recent years, the use of so-called smart sensors has
become more widespread. These devices incorporate a
microcomputer as part of the sensor/transmitter, which
greatly reduce the need for in-service calibration and
checkout
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-end-
Prepared by Engr. Ronald Ringor, ChE
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Sensors - pressure
MECHANICAL
Manometers – (differential)
Pitot -
Bourdon Gauge
ELECTRONIC
Strain Gauge
Capacitance
Potentiometers
Piezoelectric elements
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SENSORS-TEMPERATURE
Thermometers
Thermocouple
Thermistors
Pyrometers
Bimetal thermometers
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Sensors-level
DIRECT /MECHNICAL MEASUREMENT
Floats
Rotary (paddles)
Vibrating
Dipsticks
ELECTRONIC MEASUREMENT
Ultrasonic (propagation of sound waves)
Capacitance (change in capacitance)
Optical (refraction of light)
Radio Frequency (change in frequency)
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Sensors-flow
DIFFERENTIAL PRESSURE (obstruction in flow)
Variable Area
Orifices
Flow Nozzles
Venturi tubes & Flow Tubes
Pitot tubes
Target meters
V-cones
Elbow meters
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Sensors-flow
OPEN CHANNEL
Weirs
Parshall flumes
VELOCITY
Turbines & Paddlewheels
Ultrasonic
Electromagnetic
Vortex shedding
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Sensors-flow
MASS
Coriolis
Thermal
POSITIVE DISPLACEMENT
Oval Gear & Impeller
Helical Rotors
Rotary Vanes
Reciprocating Pistons
Nutating Disks
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composition
ANALYZERS (GAS)
In situ
Extractive
CHROMATOGRAPHY (separation)
GC
HPLC
TLC
SPECTROMETERS (light wavelengths)
Atomic – absorption, emission, fluoresence
Molecular – Spectrophotometers, mass spectrometers, Infrared
spectrometers etc.
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Other sensors
TURBIDIMETERS (relative clarity of fluid)
COLORIMETERS (absorbance & transmittance of light)
CONDUCTIVITY METERS
HUMIDITY MEASUREMENTS
pH MEASUREMENT