Instrumentation Basic Course

Ahmed Khairy
 Agenda
• Introduction
• Documentation
• Type of instruments
• Standards
 Process Control
• Process control :can be defined as any operation that regulates some internal physical
characteristic that is important to a living organism.
• Most popular Physical characteristics
1.Pressure Measurement
2.Level Measurement
3.Temperature Measurement
4.Flow measurement
5.Density
Other
Weight-PH-Conductivity-ORP-Analyzers
 Process Control
Elements of a Process Control System

1-Process
2- Measurement
3-Evaluation
4-Control

Daily process control at home Hot water adjustment

1- Process:
2 -Skin sensing element(Measurement)
3- Evaluation(brain)
4- Control (Hand + Valve)
 Process Control
Elements of a Process Control System

1-Process
2- Measurement
3-Evaluation
4-Control
 Process Control
• Process control :can be defined as any operation that regulates some internal physical
characteristic that is important to a living organism.
 Process Control
Process Control System types
 Definitions
• Owner
company that hired a contractor to build a plant
• Contractor
company which is hired by the owner to design and build a plant
• Licenser
company or individual that has a process know-how which willingly provides the owner with
the technology to be used in the construction, operation and maintenance of a plant, or part
of the process in such a plant
• Vendor
manufacturer or distributor of a piece of equipment/instrument/package unit
 Owner Industries
• Petrochemical
• Oil and gas
• Chemical
• fertilizer
• Cement
• Steel
• Glass
Owner /Operator
Vendor /Manufacturer
Contractors
Contractors
Project Phases
 Definition
Pre-commissioning
phase during which the activities of non-operating adjustments, cold alignment checks, cleaning, and
testing of machinery take place

Mechanical completion
milestone which is achieved when the plant, or any part thereof, has been erected and
tested in accordance with drawings, specifications, instructions, and applicable codes
and regulations to the extent necessary to permit cold commissioning
Cold commissioning
phase during which the activities associated with the testing and operation of
equipment or facilities using test media such as water or inert substances,
prior to introducing any chemical in the system, take place
 Definition
Start-up
milestone marking the end of cold commissioning
Hot commissioning
phase during which the activities associated with the testing and operation of
equipment or facilities using the actual process chemical, prior to making an actual
production run, take place
Start of production
milestone marking the end of hot commissioning
Performance test
milestone at which time the production plant runs to its design capacity
Acceptance of plant
milestone in which the formal turnover of the plant from the contractor to the owner
is carried out
Field Instrumentation for the Process Industry

Ahmed Khairy
iccc.instrument@gmail.com
 Agenda

• Instrumentation Documentation
• Pressure Measurement
• Level Measurement
• Flow Measurement
• Temperature Measurement
• Others
P&ID
P&ID
 P&ID

Identification letters:
PIT: Pressure Indicator Transmitter
FIT: Pressure Indicator Transmitter
LCV: Level Control Valve
FIC: Flow indicator Controller
AT: Analyzer Transmitter
ZSL: Limit Switch Low
SSL: Speed Switch Low
LAL: Level Alarm Low
PSLL: Pressure Switch Low Low
FSHH: Flow switch High High
PDIT: Pressure Differential indicator Transmitter
TIC: Temperature Indicator Transmitter
PT: Pressure transmitter
PI: Pressure Indicator
TI: Temperature Indicator
FRC :Flow recorder Controller
YSV: Shut off valve
PSV: Pressure Safety Valve
Question :
What the different between the LALL, And LSLL?
P&ID
P&ID
 P&ID

Type of signal Valves Fail Action

• Pneumatic Fail to open/ Air To Close
• Electrical Fail to Close/Air to Open
• Digital Fail to last Position
communication
• Hydraulic signal
 P&ID

• Examples
 P&ID

• Examples
Pneumatic Control Loop
 P&ID
TAG number

Tag “numbers” are letters and numbers placed within

or near the instrument to identify the type and
function of the device.

Tag Number Description Examples:

FE11-PIC-120401
FE11-PIT-120401

Are Instrume Num

a nt ber

FE11 PIT 120401

Suez steel Company

 Instrumentation Documentation

• ISA 5(ISA5.1-ISA5.2-ISA5.3-ISA5.4-ISA5.5)
• Piping(process) and instrumentation Diagram (P&ID)
• Process Flow Diagram
• Instrument Loop Diagram
• Logic Diagram
• Instrumentation Location Drawing
• Instrumentation Hookup
 Process flow Diagram PFD

PFD: Describe the process it self , it similar to the P&ID but with less Details, and describe the process flow
 Instrumentation Documentation

Instrument Loop Diagram ISA 5.4

This standard describe the connection between the instrument (field) to the
controller/indicator/Recorder (control room)
Type of connection:
1- Pneumatic 0.2-1 bar/3-15 PSI
2-Electrical (0/4-20 mA/0-10V/RTD/Thermocouples)
3- Communication( PROFIBUS PA-Foundation Fieldbus)
Instrumentation Documentation

Pneumatic control loop

Instrumentation Documentation

Electronic control loop

Instrumentation Documentation

Electronic control loop with shared control device

Instrumentation Documentation
Instrumentation Documentation
 Instrumentation hook up

• Document describe the orientation and the installation of the instruments in the field
 Instrumentation hook up

Magnetic flow meter Hook UP

Instrumentation hook up
Instrumentation hook up
 Introduction
Pressure and temperature are among the most important physical variables. Pressure is defined
as a force acting evenly over a given area. Pressure .
This force can be exerted by liquids, by gases or vapors, or by solid bodies. Surface compression
takes place at the interface between two solid bodies, but for our purposes we can consider this
additional force negligible.
The basic unit of force in the U.S. is the Pound force (lb.) which is the force exerted by one pound of
mass.
If we take one square inch (in2) as the basic unit of area, then we can define pressure as:
lbs. per sq. inch (PSI, Pressure can also be expressed in terms of metric
(SI) units. The basic metric unit of force is the Newton (N) and the basic unit of pressure is the Pascal
(Pa).
 Introduction
1 Types of pressure
The different types of pressure differ only with respect to their reference point.
1.1 Absolute pressure
The most definite reference point is absolute zero pressure. This is the pressure of empty space in
the universe. When a pressure is based on this reference point, it is called absolute pressure. To distinguish it
from other types of pressures it is accompanied by the suffix "a" or "abs" (from the Latin: absolutus =
independent, separate from).
1.2 Atmospheric pressure
The most important pressure for life on earth is atmospheric air pressure Pamb (amb = ambiens, surrounding).
It is produced by the weight of the atmosphere surrounding the earth up to an altitude of about 300 miles.
Atmospheric pressure decreases continuously up to this altitude until it practically equals zero (full vacuum). 1.3
1.3 Differential pressure
The difference between two pressures P1 and P2 is referred to as the pressure differential ΔP = P1 - P2. The
difference between two independent pressures is called the differential
pressure.
1.4 Vacuum
The term vacuum is used if the measured pressure is below atmospheric pressure.
 Introduction
GAUGE
COMPOUND

ABSOLUTE

BAROMETRIC RANGE

ATMOSPHERIC PRESSURE
NOM. 14.7 PSIA

PRESSURE

TOTAL VACUUM - 0 PSIA

Pressure units
Pressure units
 Introduction
Hydrostatic pressure in a liquid can be calculated as
p=ρgh (1)
where
p = pressure in liquid (N/m2, Pa, lbf/ft2, psf)
ρ = density of liquid (kg/m3, slugs/ft3)
g = acceleration of gravity (9.81 m/s2, 32.17405 ft/s2)

h = height of fluid column - or depth in the fluid where pressure is measured (m, ft)
Hydrostatic pressure in a water column - or depth (density of water 1000 kg/m3):
Example - Pressure acting in water at depth 1 m
The density of water at 4oC is 1000 kg/m3. The pressure acting in water at 1 m can be
calculated as
p=ρgh

= (1000 kg/m3) (9.81 m/s2) (1 m) = 9810 Pa

 Pressure Instruments
Types of Pressure Instruments PRESSURE
Pressure Gauges TRANSMITTER
Pressure Switch
Pressure Transmitter
Differential Pressure Transmitter
Pressure Accessories

PRESSURE
SWITCH

DIFFERENTIALPRE
PRESSURE SSURE
GAUGE TRANSMITTER
46#
 Pressure Gauge

47#
 Pressure Gauge
Measuring Principle
Bourdon tube measuring element is made of a thin-walled C-shape tube or spirally wound
helical or coiled tube. When pressure is applied to the measuring system through the pressure
port (socket), the pressure causes the Bourdon tube to straighten itself, thus causing the tip to
move. The motion of the tip is transmitted via the link to the movement which converts the linear
motion of the bourdon tube to a rotational motion that in turn causes the pointer to indicate the
measured pressure.

Helical Bourdon

“C” Type Bourdon Coiled Bourdon

48#
 Pressure Gauge
Diaphragms
In diaphragm elements, measurements are taken from the elastic deformation s of the diaphragm,
which is held by its edges and loaded on one side. This deformation is converted by known methods
into a rotary movement.
Due to their shape and position, diaphragms have high mechanical resistance and are less shock
sensitive.
They are commonly made of steel or 300-series stainless steel. For aggressive fluids, special corrosion-
resistant materials such as tantalum, titanium, Hastelloy etc. are used, or the materials are
coated with PTFE or similar materials. Open flanged connections are used if the process fluid
is highly viscous, crystallizes or is contaminated.
Capsules
A capsule consists of two diaphragms that are welded or soldered together around their outer edge.
The center of just one capsule half is supported in the case so that both halves can move freely.
This design doubles the displacement of the diaphragm, allowing smaller pressures to be measured
without any reduction of the wall thickness. Capsule elements are currently being used for the
measurement of flowing gases, i.e. in chambers or fans.
Even micro pressures in the range of 0 to 0.5"H2O can be measured.
49#
 Pressure Gauge
Diaphragm Pressure Gauge
Capsule
Pressure gauge

Diaphragm
50# Pressure gauge
 Pressure Gauge

Bellows are used where a large displacement is required

in a restricted space. Bellows are thin walled cylindrical
containers with deep corrugations in their periphery.
When pressure is applied, the length of the bellows
changes. Depending on the application, a supporting
spring can be installed inside the bellows.
Bellows are notable for their good linearity. Generally
they are used in the range from 0 to 2.5 "H2O and 0 to
10 PSI.

51#
 Pressure Gauge
The Movement

A measuring element converts pressure into

displacement. The movement measures the
displacement
and converts it into a rotation. A movement consists of a
combined lever and gear. The
linear displacement of the measuring element is
converted into a pointer rotation. A displacement
of 2 mm, for example, can be converted into the
customary rotary movement of 270 angular degrees.
Depending on how big the displacement is, movements
with various mechanical advantages are used.
The movement consists of two platens with spacer
columns, in which the pointer shaft and the
toothed segment rotate
A hairspring ensures that the same faces and toothed
52#
flanks always mesh during the movement sequence.
 Differential Pressure Gauge
Measuring Principle:
• Differential pressure gauges have two inlet ports,
each connected to one of the volumes whose
pressure is to be monitored.
• In cases where either input can be higher or lower
than the other, a bi-directional differential range
should be used.

53#
 Pressure Switch
Measuring Principle:

• The device contains a micro switch, connected to a

mechanical lever and set pressure spring. The contacts get
actuated when process pressure reaches the set pressure
of the spring.

• It can be used for alarming or interlocking purposes, on

actuation.

• It can be used for high / high-high or low / low-low

actuation of pressure in the process . The set range can be
adjusted within the switch range.

• The sensing element may be a Diaphragm or a piston

54#
 Pressure Gauges Accessories
PULSATION DAMPENER PRESSURE SNUBBER

Threads onto a gauge socket and

• Used for dampening and filtering, the
provides
snubber has a metal disc available in four
restriction by means of a moving
standard grades of porosity.
pin, which may be placed in either of
• Due to the large filter area, the snubber
five different sized holes, and thus
has less tendency to clog than orifice type
allows the user to vary the amount of
devices.
dampening to suit requirements. The
pulsating pressure moves the pin up
and down, providing a self-cleaning
action. Dampeners are shipped with
a pin in the “middle” hole, and may be
used in either a vertical or horizontal
position.
Maximum pressure is 5000 psi.

55#
 Pressure Gauges Accessories
Siphon tubes
• In order to prevent live steam from entering a
pressure gauge water should be installed between
the gauge and the process line steam.
• Also use siphons whenever condensing hot vapors
(not just steam) are present.

COIL PIPE
PIG TAIL

56#
 Pressure Gauges Accessories
DIAPHRAGM SEALS

Designed for use with pressure gauges or switches or transmitters on process applications
where:
• Process element materials capable of withstanding corrosive effects of certain fluids
are not available.
• The process fluid being measured would normally clog the pressure measuring element.
• The process fluid in the measuring element might freeze due to changes in ambient
temperatures.
• A diaphragm assembly fabricated of materials that will withstand various corrosive
media encountered, separates the measuring element from the process fluid.
• Since the space between the diaphragm and the measuring element is solidly filled
with liquid, any movement of the diaphragm caused by a change in the process pressure
will be indicated by the instrument.
.

57#
Pressure Gauges Accessories

58#
 Pressure Gauges Accessories
STEEL NEEDLE VALVE

The steel needle valve is an economical, adjustable

throttling device for any

59#
Pressure transmitters
• Sensing Element
1. Piezo-resistive(Strain gauge)
2. Capacitive capsule
3. Resonant
4. Force-balance pressure transmitters
5. Pressure transmitter Accessories
• Pressure/Differential pressure Application
• Pressure transmitter Calibration and Maintenance

60
Pressure transmitters

61
1.Piezo resistive (Strain Gauge)

• Piezo resistive means “pressure-sensitive resistance,” or a

resistance that changes value with applied pressure. The strain
gauge is a classic example of a piezo resistive element,
• Electrical resistance of any conductor is proportional to the
ratio of length over cross-sectional area (R ∝ l/A)
• The tensile deformation (stretching) will increase electrical
resistance by simultaneously increasing length and decreasing
cross-sectional area while compressive deformation (squishing)
will decrease electrical resistance by simultaneously decreasing
length and increasing cross-sectional area.

62
 1.Piezo resistive (Strain Gauge)
Attaching a strain gauge to a diaphragm results in a device that changes resistance with applied
pressure. Pressure forces the diaphragm to deform, which in turn causes the strain gauge to change
resistance. By measuring this change in resistance, we can infer the amount of pressure applied to
the diaphragm.

Modern manufacturing techniques have made possible the construction

of strain gauges made of silicon instead of metal. Silicon exhibits very
linear spring characteristics over its narrow range of motion, and a high
resistance to fatigue. When a silicon strain gauge is over-stressed, it fails
completely rather than “flows” as is the case with metal strain gauges.
This is generally considered a better result, as it clearly indicates the need
for sensor replacement

(whereas a metallic strain sensor may give the false impression of continued function following an
over-stress event).

63
1.Piezo resistive (Strain Gauge)
the strain gauge works to convert an applied pressure into a measurable voltage signal which may be
amplified and converted into a 4-20 mA loop current signal (or into a digital “fieldbus” signal).

64
1.Piezo resistive (Strain Gauge)

• In some designs, a single silicon wafer serves as both

the diaphragm and the strain gauge so as to fully
exploit the excellent mechanical properties of silicon
(high linearity and low fatigue).
• However, silicon is not chemically compatible with
many process fluids, and so pressure must be
transferred to the silicon diaphragm/sensor via a non-
reactive fill fluid (commonly a silicone-based or
fluorocarbon-based liquid).
• A metal isolating diaphragm transfers process fluid
pressure to the fill fluid, which in turn transfers
pressure to the silicon wafer.

65
2.Differential capacitance sensor
• The diagram shows an electronic differential pressure
sensor. This particular type utilizes a two-wire capacitance
technique.
• Process pressure is transmitted through isolating
diaphragms and silicone oil fill fluid to a sensing diaphragm.
• The sensing diaphragm is a stretched spring element that
deflects in response to the differential pressure across it.
• The displacement of the sensing diaphragm is proportional
to the differential pressure.
• The position of the sensing diaphragm is detected by
capacitor plates on both sides of the sensing diaphragm.
• The differential capacitance between the sensing
diaphragm and the capacitor plates is converted
electronically to a 4–20 mA or 1-5 VDC signal.
• For a gauge pressure transmitter, the low pressure side is
referenced to atmospheric pressure.

66
2.Differential capacitance sensor

67
3.Resonant element sensors

The tension on each string is precisely adjusted to achieve the desired resonant frequency.

68
3.Resonant element sensors
• Process pressure enters through ports in two flanges,
presses against a pair of isolating diaphragms,
transferring motion to a single sensing diaphragm via
fill fluid where the resonant elements change
frequency with diaphragm strain.
• Motion of the sensing diaphragm in either direction
tenses one resonant element and compresses the
other, causing their frequencies to deviate from each
other.
• Electronic circuits within the upper housing measure
the two resonant elements’ frequencies and generate
an output signal proportional to their frequency
difference.
• This, of course, is a representation of applied
differential pressure.

69
Electrical Pressure transmitters

70
4. Force-balance pressure transmitters

• The pressure being measured is applied to the inside of the transmitter, the
pressure exerts a force on the capsule which is applied to the lower end of the
force bar.
• The diaphragm seal serves the both as a fulcrum for the force bar and as a seal
for the pressure chamber.
• The force is transmitted through the flexure connector to the range bar, which
pivots on the range wheel.
• Any movement of the range bar causes a minute change in the clearance
between the baffle( flapper) and the nozzle.
• This produces a change in the output of the relay( Pneumatic amplifier) to the
feedback bellows until the force in the bellows balances the force on the
capsule.
• The output pressure, which establishes the force-balance, is the transmitted
pneumatic signal which is proportional to the pressure being measured.
• The signal is transmitted to a pneumatic receiver(or to pneumatic to current
converter) to record , indicate, and /or control.

71
4. Force-balance pressure transmitters

72
5. Accessories
• Manifolds
• Siphon
• Condensate Pots
• Mounting bracket

73
 5.Diaphragm Seal System
• A diaphragm seal system consists of a pressure transmitter, diaphragm seals, a fill fluid, and
either a direct mount or capillary style connection.
• During operation, the thin, flexible diaphragm and fill fluid separate the pressure sensitive
element of the transmitter from the process medium. The capillary tubing or direct mount
flange connects the diaphragm to the transmitter.
• When process pressure is applied, the diaphragm transfers the measured pressure through the
filled system and capillary tubing to the transmitter element.
• This transferred pressure displaces the sensing diaphragm in the pressure-sensitive element of
the transmitter.
• The displacement is proportional to the process pressure and is electronically converted to an
appropriate current, voltage, or digital HART output signal.

74#
5. Accessories

2-Way Manifold

75
5. Accessories

3-Way Manifold

76
5. Accessories

5-Way Manifold

77
Pressure-d/p Transmitters Output
• Pneumatic 0.2-1 Bar/ 3-15 PSI
• Electrical 4-20 mA
• Electrical 4-20 mA with HART
• Fieldbus communication( Profibus PA/Foundation Fieldbus H1)

78
Pressure/Differential pressure Application

• Pressure Measurement of pipes and vessels (Vacuum-Absolute-

Gauge)
• Measuring Process vessels clogging
• Level Measurement
• Flow Measurement
• Density Measurement

79
Pressure/Differential pressure Application

• Measuring Process
vessels clogging
• Differential pressure used to detect if
the filter is clogged or blocked and
need cleaning or not
• PDIT reading indicate the filter
condition
• Negative or high reading indicate that
the filter is clogged

80
 Pressure/Differential pressure Application
Level Measurement
Pressure transmitters are a common and well
understood technology for liquid level measurement.
They are straightforward, easy to use and install, and
work in a variety of applications and a wide range of
conditions.
If a level measurement is being made on an open/
vented vessel, a gauge (GP) or differential pressure
(DP) transmitter is required. If the tank is closed or
pressurized, a DP measurement must be made to
compensate for the vessel pressure.
Hydrostatic Pressure = Height x Specific Gravity

Level = Differential Pressure / Specific Gravity

81
 Pressure/Differential pressure Application
Level Measurement
Limitation :
Advantages:
• Level measurement accuracy with pressure
• pressure transmitters are economical.
transmitters can be affected by changes in fluid
• easy to use and well understood.
density.
• pressure transmitters can handle almost any
• Special precautions are therefore required
tank and liquid, including slurries.
with thick, corrosive, or otherwise hostile fluids.
• They function in a wide pressure and
• In addition, some fluids (e.g., paper stock) tend to
temperature range, as well as in foam and
solidify as their concentration increases.
turbulence.
• Pressure transmitters do not work well with such solidified
states.
• When pressure transmitters are installed with impulse
piping (wet or dry legs), then ambient temperature changes
can affect the measurement due to density changes in the
wet leg fluid or condensation of fluid in dry legs.
• Closed capillary systems alleviate some of these issues, and
can be chosen to minimize the errors.
82
Calibration procedure
• Differential pressure or differential head pressure is used to calibrate transmitters for
pressure, level, flow and density.
• The transmitter has a high side, marked with an H, and a low side, marked with a L.
• The low side will typically go to atmospheric pressure or to the fixed height wet leg
measurement.
• The high side will typically go to the tank, where the varying height of fluid is to be measured.
• When calibrating an instrument remember: The low side is the negative scale, below zero, and
the high side is the positive scale, above zero.
• The transmitter’s sensor element is static in position or elevation and therefore the transmitter
itself is always equal to zero elevation.
The formula for calibration is:
(high side inches x S.G.) – (low side inches x S.G.) = lower or upper range value.
Note: lower range value when empty and upper range value when full.

83
Calibration procedure

84
Calibration procedure

85
Bubble tube method
• The bubble tube measures the level of the process fluid
by measuring the back pressure.
• This simple level measurement has a dip tube installed
with the open end close to the bottom of the process
vessel.
• A flow of gas, usually air or nitrogen, passes through the
tube and the resultant air pressure in the tube
corresponds to the hydraulic head of the liquid in the
vessel.
• The air pressure in the bubble tube varies proportionally
with the change in head pressure.

86
Bubble tube method

87
Density Measurement
• Head pressure and volume displacement can be used to
measure density. By using a differential head pressure
transmitter, calibrated in inches of water, with the high and
low lines connected to a tank at a fixed distance of
separation, such as 12”, and both taps completely
submerged below the lowest fluid level, the height
measured in inches of water divided by 12” is the S.G. of the
unknown fluid.
• If the fluid height measurement was divided into the fixed
12” of displacement, density would be measured.

88
Calibration Master Devices and software
• Dead weight Tester
• Hydraulic Hand Pump
• Pneumatic Hand Pump
• Calibrated Pressure gauge (Digital/Analog)
• Communicator Devices
• Computer software PDM: Process device Manager(Siemens)/PRM
Plant Resources Management (YOKOGAWA)/AMS(Asset Management
systems (EMRSON)

89
Calibration Master Devices

Hand Pump
Dead weight Tester
For Pressure and Vacuum

90
Calibration Master Devices

Hydraulic Hand Pump

Digital pressure gauge
WIKA CPP 700-H
WIKA CPG 1000
91
Calibration Master Devices

WIKA Multi Function For Calibrator WIKA CEP 1000

Calibration and measurement
CEP6000 92
Calibration Master Devices

93
Calibration Master Devices

94
Calibration Master Devices

95
Displacer
• Archimedes’ (c. 290 to 212 BC) principle states that a body wholly or partially immersed in a
fluid is buoyed up by a force equal to the weight of the fluid displaced
• A level or a density instrument is sensitive to the apparent weight of an immersed displacer.
• If the cross-sectional area of the displacer and the density of the liquid are constant, then a unit
change in level will result in a reproducible unit change in the apparent weight of the displacer.
• Floats should always be lighter than the minimum expected specific gravity of the process liquid

96
 References
• Instrumentation Symbols and Identification ISA 5.1
• Instrument Loop Diagrams ISA5.4
• Pressure Measurement, Mark Murphy, PE, Technical Director, Fluor Corp.ISA.
• WIKA-Handbook, Pressure and Temperature Measurement U.S. Edition.
• Engineering toolboxhttps://www.engineeringtoolbox.com
• Pressure gauge accessories, Ashcroft
• ISA Handbook Of Measurement Equations and Tables, 2nd Edition, Edited by Jim Strothman
• Lessons in industrial instrumentation, by Tony R. Kuphaldt, Version 2.11 (development) – Last
update June 5, 2015
• The Engineers Guide to Level Measurement, Rosemount, Emerson Process Edition 13
• Control Systems Engineering Exam Reference Manual, for the NCEES Professional Engineering (PE)
Licensing Examination Bryon Lewis, CSE, P.E.
• Instrumentation Sensors and transmitters , Training Manual ,Course EXP-MN-SI050, TOTAL.