Utilities and Instrumentation in Chemical Plant

Diploma Semester V, Chemical Engineering

Unit
Unit Name Major Learning Objectives Topics and Sub Topics
No.
Introduction of Process
Justify need for
Measurement:
instrumentation in
Importance of instrumentation
chemical plant.
in chemical plant
Classify instruments in Classification of instruments
chemical plant
Describe Basic elements of Basic elements of instruments
Introduction to
instruments.
Process
3 Measurement Compare Static and Static and dynamic
(3 hr, 8 marks) Dynamic Characteristics of characteristics
instruments
Selection criteria for various
Select appropriate measuring devices in chemical
instrument for industry for:
measurement based on Temperature
instrument range. Pressure
Flow measurement Liquid level

1.1 Introduction (Measurement)

Measurement is an essential activity in every branch of science and technology.

Measurement means quantification of a parameter or quantification of a quantity
or condition. A measuring instrument is thus a device the determines the value of a
quantity or condition an instrument converts a physical or chemical plant condition
for example, heat pressure or light to a signal which is often electrical, but not
necessarily. So, that can be measured or interpreted is measurement.

A Simple Instrument Model

Simple instrument model is as follows. Suppose we have a process or measured

medium. Suppose we are interested in measuring the temperature of a liquid in a
tank. So, this is the process or measured medium for us. In order to measure the
temperature we use a temperature measuring device. This temperature measuring

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

instrument interacts with the process, and produces an output which is in some
sense related to this input and this output should be in a form which can which can
be interpreted by the observer.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

1.2 Purpose of Measurement

Lord Kelvin said “…when you can measure what you are speaking about, and
express it in numbers, you know something about it; but when you cannot measure
it, when you cannot express it in numbers, you knowledge is of a meagre and
unsatisfactory kind.”

The fundamental purpose of measurements in industry is to aid/help in the

economics of industrial operations by improving either the quality of the product or
improving the efficiency of production. One must always keep in mind that:
Why is the measurement being made?
What measurement is made?
What should the measurement mean?
What is the result of making this measurement?

1.3 Types of Measurement

We can measure a quantity either directly or indirectly. According measurement can
also be classified as Direct Measurement and Indirect Measurement.

Direct Measurement
This type of measurement is an important approach in modern industry. For example
in manufacturing a mechanical part in a lathe section of a machine shop, the purpose
is to produce a part with a given physical conditions. During and after the production
of the part, the measurements are usually made. This type of measurement is direct
measurement in which the meaning of measurement (determining the physical
dimensions) and purpose of processing operation (producing goods of given
specification) are both the same.
Thus if the primary purpose of making a measurement is to determine the quality of
product one must use Direct Measurement.
Examples:
The measurement of temperature of fluid by means of thermocouple/thermometer;
measurement of pressure in the reactor using pressure gauge/ differential pressure
transmitters; measuring the level of liquid in a tank using sight glass tube; measuring
the flow of fluid through pipe using a rotameter etc. are some examples of direct
measurement.

In-Direct Measurement
This can be well understood by taking an example of temperature measurement in
milk pasteurizer. The purpose of pasteurizing is to remove bacteria. This is indirect

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

measurement, wherein meaning of measurement (temperature of milk) and the

purpose of measurement (to remove/eliminate bacteria) are not the same but are
related to each other. Thus in indirect measurement an empirical relation is
established between the measurement actually made and the results obtained.

1.4 Functions of Instruments

A measuring device is simple a device/instrument used for determining the value of a
quantity or a condition. There are various functions to be fulfilled by an instrument.
It has to determine a value, indicate the same, record, register, signal or process a
given set of information /values. Some of the basic functions to be served by an
instrument are as below:

Transmitting
Here the instrument conveys information concerning the measured quantity over
some distance to a remote point. So, the instrument will measure the quantity and
convey the information from one place to another a homely example is telephone.

Signaling
Here the instrument indicates the general value or range of values of its measured
quantity. Some grosses scale indicates the general value of what it has measured.

Registering
The instruments merely indicate by numbers or some other symbols of discrete
increments the value of some quantity. For example, a water meter which uses
discrete numbers to indicate how much of water has been consume

Indicating
The instrument indicates, the value of the measured quantity using a calibrated
pointer and scale. For example some of instruments used in laboratory like use for
pressure gauge which uses a pointer and scale to indicate the value of the measured
quantity which is pressure in case of pressure gauge.

Recording
The instrument keeps a written record of measured quantity and usually it is
recorded against time.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

1.5 Classification of Instruments

The instruments can be classified in various ways. So, depending on the basis of
classification that we chose of instruments various instruments can be classified
variously.
We can classify the instruments on the basis of Energy Consideration; that means,
weather it is self operating instruments or it requires an auxiliary source of power
or like, weather it is automatic instrument or a manual instrument, on the type of
signal on which it works/produces analog or digital instrument whether it is
necessary to bring the instrument in intimate contact with the measuring medium or
it is not necessary to bring the instrument in close contact with the measuring
medium i.e contacting or non-contacting instruments.

On the basis of energy consideration we can classify instruments into two categories
Passive Instruments and Active Instruments. Passive instruments are those whose
output energy is supplied entirely almost entirely by its input signal or by the energy
of the input signal. These instruments do not need any auxiliary source of power
here. These instruments are Self Operated Instruments; it may be noted here, that
the output signal and the input signal may be of same form or they are may be an
energy conversion. Some of the examples of passive instruments are ordinary
mercury in glass thermometer or clinical thermometer, a bourdon tube, which is use
for measurement of pressure or a pitot tube.

On the other hand Active Instruments are those, which require an auxiliary source of
power. So, these not self operated instruments, but are Power Operated
Instruments. Again the output and input signals may be of the same form or there
may be an energy conversion involved. Examples of active instruments are electronic
amplifier differential transformer for displacement measurement, etc.

We can also classified the instruments on the basis of analog and digital mode of
operation, if the instrument follows analog mode of operation we call the
instruments, as Analog Types of Instruments or if the instruments follows digital
mode of operation, we call those as Digital Types of Instruments. Majority of the
primary sensing elements are of analog types. They present the information of about
the measure variable in the form of continuous variation with respect to time. On the
other hand digital types of instruments represent the measure variables by discrete
quantities or digital quantities, which are discrete in nature.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

The next classification is based on whether the instrument is contacting type or non
contacting type. As the name suggest the instrument as contacting type, when it is
necessary to bring the instrument in direct contact with the measuring medium. For
example clinical thermometer, the ordinary clinical thermometer used to determine
the temperature of human body is a Contacting Type of Instrument. On the other
hand an optical pyrometer or radiation pyrometer measures the temperature of the
furnace; but you do not have to bring the pyrometer in direct contact with the
furnace which is an example of Non Contacting Type of Instrument.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

1.6 Elements of Instruments

An instrument consists of several elements. These elements perform prescribed
functions in converting a quantity or a condition (measuring medium) into a
corresponding indication (measured value).
Scheme-1
An instrument generally consists of the following functional elements:
i. Primary Sensing Element
ii. Signal Conditioning Element
iii. Signal Processing Element
iv. Data Presentation Element

Primary Sensing Element or Primary Element

The sensing element interacts with the process. It first produces an output which is
related to process variable being measured.

Signal Conditioning Element or Secondary Element

The signal conditioning element convert the output signal of the sensing element to
a form or to a signal which is more suitable for further processing. It converts the
output signal of the sensing element to another signal which is more suitable for
further processing

Signal Processing Element or Manipulation Element

The output of the signal conditioning element goes to signal processing element. A
signal processing element converts the output signal from the signal conditioning
element to a form which is more suitable for presentation for presentation to the
observer.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

Data Presentation Element or Functioning Element

The data presentation element presents the data to the observer and it has to be in a
form which the observer can recognize. So, the data presentation element presents
data to the observer in a recognizable form

Scheme-2
An instrument generally consists of the following functional elements:
i. Primary Sensing Element
ii. Variable Conversion Element
iii. Variable Manipulation Element
iv. Data Transmission Element
v. Data Presentation Element

Primary Sensing Element

The first functional element which is call primary sensing element receives inter
interacts with the measuring medium first and receives information about the
measured quantity and produces an output, which is somewhere related to the input
to the primary sensing element that comes from the measuring medium.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

Variable Conversion Element

The variable conversion element convert the physical nature of the output signal
from the primary sensing element, if it is required for the purpose of measurement.
So, this output signal can be different from this input signal. .

Variable Manipulation Element

If it is necessary to magnify the magnitude of this signal we can have a variable
manipulation element.

Data Transmission Element

If the different parts of the instruments are separated by distance; we need to
transmit data from one point two another, so we have a data transmission element
which will transmit data from one point to another .

Data Presentation Element

Finally, will have an element which will present the data in a recognizable form to the
observer so we have a data presentation element.

Ques: Functional Elements of a Pressure Thermometer

Pressure Thermometer is an instrument used for measurement of temperature. It

has a Bulb filled with liquid, and then a Tube is connected to the bulb and the other
end of the tube, goes to a Pressure Measuring Element. The entire part of the bulb
and the capillary tube and the inside of this spiral bourdon tube used are filled with a
liquid called filling liquid. In certain applications gas is also used.

Primary Sensing and Variable Conversion Element

The bulb interacts with the measuring medium and gets the information about
Temperature. Because of which the thermal expansion of the liquid takes places. As a

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

result Pressure is developed within the bulb. The Temperature Signal is being
converted to a Pressure Signal. This is also a Variable Conversion Element. Both the
functions are performed by bulb. Thus it is a Primary Sensing Element and Variable
Conversion Element.

Data Transmission Element

Due to the thermal expansion of the filling liquid, pressure gets developed inside the
bulb and this signal is no more a temperature signal, but a pressure signal. Then this
Pressure is transmitted through The Capillary Tube. So, this tube box as a Data
transmission element.

Variable Conversion Element

Then is pressure goes to Bourdon Tube, which convert, which converts this pressure
signal to a Displacement or Motion Signal. Because of the pressure applied the tip of
the bourdon tube will deflect. So, the bourdon tube receives pressure as input signal
and gives motion or displacement as output signal. So, bourdon tube is Variable
conversion element.

Variable Manipulation Element

The output of the bourdon tube is no more a pressure signal, but a Displacement or
Motion Signal. This goes to this goes through gear linkage system, which magnifies
the reflection. So, gear linkage system works as a Variable manipulation element.

Data Presentation Element

Then this signal is presented to the observer by this pointer and scale. So, pointer
and scale works as Data presentation element.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

1.7 Characteristics of Instruments

Characteristics of Instruments are those quantitative bases used for comparing the
performance of instrument with possible alternatives.
Two classes of characteristics are used to evaluate or compare instruments namely
Static Characteristics and Dynamic Characteristics.

Static Characteristics are associated with static measurement. These are set of
criteria that are used when you measure a quantity or a condition that is either
constant or changes very slowly with time. So, Static Characteristics are those
characteristics which we must consider to analyze the performance of an instrument
i.e. measuring a medium which is constant or varying very slowly with time.
The Static Characteristics can be classified into two categories Desirable Static
Characteristics and Undesirable Static Characteristics. Under Desirable Static
Characteristics we have Accuracy, Sensitivity and Precision as various characteristics.
Similarly under Undesirable Static Characteristics we have Static Error, Dead zone
and Drift.
Desirable Static Characteristics Un-Desirable Static Characteristics
Accuracy Static Error
Reproducibility Drift
Sensitivity Dead Zone

Range:
The range of an instrument is the lowest and highest values it can measure within its
specifications.

Span:
The span of an instrument is the high end of the range minus the low end of the
range.
Example:
The lowest point of calibration is “a” units.
The highest point of calibration is “b” units.
The range of instrument is “a to b”.
The span of instrument is “ b-a”.

Resolution:
Resolution is the smallest amount of input signal change that the instrument can
detect reliably.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

Accuracy:
Accuracy of a measurement describes how close the measurement approaches the
true value of the process variable. So, it is a measure of how close the measured
value is to the true value.
Accuracy can be expressed in many ways accurate within plus minus x percent
means accurate to within plus minus x percent of instrument span at all points of the
scale.
Accuracy can also be expressed in terms of percentage True Value which can be
expressed as Measured Value minus True Value divided by True value multiplied by
100.
% True Value = [{(Measured Value) – (True Value)}/ (True Value)]*100

Similarly, accuracy can also be expressed in terms of percentage Full scale deflection
and this can be represented as Measured Value minus True Value divided by
Maximum Scale Value multiplied by 100.
% True Value = [{(Measured Value) – (True Value)}/ (Maximum Scale Value)]*100

Static Error:
If, accuracy is measure of how close the measured value is to the true value static
error must be the difference between the measured value and the true value of the
quantity under static conditions. It is usually expressed as “+a units” or “-a units”.

Static error is the difference between the measured value and the true value of the
quantity.
True Value + Static Error = Instrument Reading
The static correction of an instrument is given as
True Value = Instrument Reading + Static Correction
Thus static error and static correction are related as
Static Correction = -Static Error

Reproducibility:
The reproducibility of an instrument is the degree of closeness with which a given
value may be repeatedly measured.

Drift:
Drift is the change in the indicated reading of an instrument over time when the
value of the measuring quantity remains constant. Drift can be a Zero drift or Zero
Error, Span drift or Sensitivity Drift, and finally Zonal Drift.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

Zero Drift:
If the calibration of the equipment changes gradually by a same amount over a
period of time it is called as a Zero Drift. This can be seen in some of the instruments.
For example a pressure gauges. In a pressure gauge when there is no pressure input
to the instrument, the instrument still shows of small positive value which is a zero
error. We should take a note of this zero error, so that we can apply the correction
factor to the measured value being indicated by the instrument.

Span Drift:
A span drift involves a gradual change in which the calibration from zero upward
changes a proportional amount. This may be cause by gradual change in the spring
characteristics of the instruments.

Zonal Drift: It is a combination of both Span drift and Zero drift.

Precession:
Precision is the Ability of an instrument to reproduce a certain set of readings with a
given accuracy.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

Sensitivity:
It is defined as Ratio of change in the output or response of instrument to a change
of input or measured variable.

Dead Zone:
Dead Zone is the Largest range of values of a measured variable to which the
instrument does not respond. This is sometimes called dead spot or hysteresis. It
generally occurs due to friction in an indicating or recording instrument. The
Hysteresis is the characteristic loop we find when the instrument is calibrated first in
one direction and then, in the other direction this is caused by friction or backlash.

Dynamic Characteristics
Dynamic Characteristics are associated with dynamic measurements. Dynamic
Characteristics are those characteristics which we must consider if inputs are varying
with time.
Similar to static characteristic we have few Desirable Dynamic Characteristics and we
have few corresponding Undesirable Dynamic Characteristics. The Desirable dynamic
Characteristics are Speed of response and Fidelity and the undesired Dynamic
Characteristics are Lag and Dynamic Error.

Desirable Dynamic Characteristics Un-Desirable Dynamic Characteristics

Speed of Response Lag
Fidelity Dynamic Error

Speed of Response & Lag

It is defined as the Rapidity with which an instrument responds to changes in the
measured medium or measure input. So, speed of response is the rapidity with
which an instrument response to changes in the measuring medium. Lag is Delay in
response.

Fidelity & Dynamic Error

It is the degree to which an instrument indicates the changes in measured value
without dynamic error. Dynamic Error is the difference between the true value of
the quantity and measured value of the quantity both changing with respect to time.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

1.8 Selection criteria for various measuring devices in chemical industry for
Temperature, Pressure, Flow measurement Liquid level
1.8.1 Selection criteria for various measuring devices in chemical industry for
Temperature
Selecting measuring devices for temperature in the chemical industry requires
careful consideration of several factors to ensure accuracy, reliability, and safety.
Some key criteria to consider are as below:
a) Principle of Measurement: On the basis of principle of measurement
appropriate temperature measuring device must be selected which are as
below:
Thermal Expansion
Solid Expansion Bimetallic Thermometer
Liquid Expansion Liquid in Glass Thermometer, Pressure
Thermometer
Gas Expansion Vapor Pressure Thermometer, Gas Thermometer
Thermostatic Sensor Thermocouple
Electric Resistance Resistance Temperature Detector (RTD)
Sensor Thermistor
Radiation Method Optical Pyrometer
Radiation Pyrometer

b) Accuracy: The accuracy of temperature measurement is critical in the

chemical industry to ensure precise control of processes and product quality.
One should select device with high accuracy levels.
c) Range: Consider the temperature range required for your specific processes.
Some applications may require measurement in extreme temperatures, so
selecting devices with suitable ranges is essential.
Bimetallic Thermometer Between -70°C and +600°C

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

Liquid in Glass Thermometer, Between -80°C to +330°C

Pressure Thermometer, Between -250°C to +2000°C
Vapor Pressure Thermometer, Between 20°C to 350°C
Gas Thermometer Between -150°C to +600°C
Thermocouple Between -200°C to +1800°C
Resistance Temperature Detector (RTD) Between -200°C to +850°C
Thermistor Between -55°C to +114°C
Optical Pyrometer Between 700°C to 4000°C
Radiation Pyrometer Between 700°C to 2000°C

d) Response Time: The speed at which a temperature measuring device

responds to changes in temperature is crucial, especially in dynamic
processes. One should select device with faster response time so that
necessary control action can be taken.
e) Calibration and Maintenance Requirement: Regular calibration is necessary
to ensure the accuracy of temperature measuring devices. One should select
device which do not need calibration and maintenance frequently.
f) Compatibility with Process Requirement: Ensure that the selected
temperature measuring devices are compatible with the process conditions,
including mounting options, insertion lengths, and connection interfaces.
g) Reliability and Durability: One should select device which are more reliable
and highly durable. The longevity of the device is essential to minimize
replacement and maintenance costs.
h) Cost effectiveness: When selecting any temperature measuring device, the
initial cost, as well as long-term operating and maintenance expenses must be
taken into consideration. One should select devices that provide the best
value over their lifecycle.
i) Regulatory Compliance: Ensure that the selected devices meet relevant
industry standards and regulatory requirements for temperature

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

measurement in the chemical industry, such as ISO, ASTM, and ANSI

standards.

1.8.2 Selection criteria for various measuring devices in chemical industry for
Pressure
Selecting measuring devices for pressure measurement in the chemical industry
requires careful consideration of several factors to ensure accuracy, reliability, and
safety. Some key criteria to consider are as below:
a) Principle of Measurement: On the basis of principle of measurement
appropriate pressure measuring device must be selected which are as below:
Measurement of pressure by balancing Various Manometers
against a column of liquid of known
density
Balancing against a unknown force Piston Type, Ring Balance, Bell
Type Gauge
Balancing a force produced on a known Bourdon Tubes, Diaphragm Tube,
area against a stress in an elastic medium Bellows
Moderate Pressure Measurement
Device
Liquid Column Elements Barometers, Various Manometers
Mechanical Displacement Type Ring Balance manometer
Elastic Pressure Transducer Bourdon Tube,
Diaphragm Tube,
Bellows gauge
Electric Pressure Transducer Resistance Type, Inductive Type,
Piezoelectric Type etc.
Very High Pressure Measurement Electric gauge based on change in
Device resistance of Manganin or gold-
chrome wire.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

High Vacuum Measurement Mcleod gauge, Thermal

conductivity gauge, Ionization
gauge etc.

b) Accuracy and Precision: The accuracy of pressure measurement is critical in

the chemical industry to ensure precise control of processes and product
quality. One should select device with high accuracy levels and should also
consider the precision needed for consistent and reliable measurements.
c) Range: Consider the pressure range required for your specific processes.
Some applications may require measurement in extreme pressures, so
selecting devices with suitable ranges is essential.
Below 1 mm of Hg Manometers or low pressure measuring
instruments.
Between 1 mm of Hg to 1000 atm Elastic pressure transducers such as
Bourdon tube, diaphragm gauges, bellows
etc.
High vacuum (upto 10-9 torr) Mcleod gauge, thermal
Conductivity gauge ionization gauge etc.
High pressure (1000 atm and above) Electrical resistance type.

d) Response Time: The speed at which a pressure measuring device responds to

changes in pressure is crucial, especially in dynamic processes. One should
select device with faster response time so that necessary control action can be
taken.
e) Calibration and Maintenance Requirement: Regular calibration is necessary
to ensure the accuracy of pressure measuring devices. One should select
device which do not need calibration and maintenance frequently.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

f) Compatibility with Process Requirement: Ensure that the selected pressure

measuring devices are compatible with the process conditions, including
mounting options, insertion lengths, and connection interfaces.
g) Reliability and Durability: One should select device which are more reliable
and highly durable. The longevity of the device is essential to minimize
replacement and maintenance costs.
h) Cost effectiveness: When selecting any pressure measuring device, the initial
cost, as well as long-term operating and maintenance expenses must be taken
into consideration. One should select devices that provide the best value over
their lifecycle.
i) Regulatory Compliance: Ensure that the selected devices meet relevant
industry standards and regulatory requirements for pressure measurement in
the chemical industry, such as ISO, ASTM, and ANSI standards.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

1.8.3 Selection criteria for various measuring devices in chemical industry for Flow
Measurement
Selecting measuring devices for flow measurement in the chemical industry requires
careful consideration of several factors to ensure accuracy, reliability, and safety.
Some key criteria to consider are as below:
a) Principle of Measurement: On the basis of principle of measurement
appropriate flow measuring device must be selected which are as below:
Flow of fluid in closed pipe
Constant area – variable Orifice plate, venturi meter, pitot tube, flow
pressure drop nozzle
Variable area – constant Rotameter
pressure drop
Mass flow meter Coriolis
Flow of fluid through open Weir and Notches
channel
Type of flow Laminar, Turbulent and Transition Flow

b) Accuracy and Precision: The accuracy of flow measurement is critical in the

chemical industry to ensure precise control of processes and product quality.
One should select device with high accuracy levels and should also consider
the precision needed for consistent and reliable measurements.
Flowmeter In-accuracy
Orifice meter ± 2% to ± 5%
Venruimeter ± 1%

c) Rangeability: Rangeability refers to the minimum and maximum measurable

flow rates with specified accuracy. For example, if the maximum flow rate is
100 litre per minute and the minimum flow rate is 10 litre per minute, then
the Rangeability of a given flow meter is 10 to 100.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

d) Turndown ratio: Turndown ratio conveys the same information as

Rangeability, but in a slightly different way turndown is the ratio of maximum
flow to minimum flow. For the same flow meter as discussed above, the
turndown ratio would be 100:10 i.e 10.
e) Response Time: The speed at which a flow measuring device responds to
changes in flow is crucial, especially in dynamic processes. One should select
device with faster response time so that necessary control action can be
taken.
f) Pressure drop: For a flow within a tube or pipe, a flow meter with a less
pressure drop should be selected.
g) Calibration and Maintenance Requirement: Regular calibration is necessary
to ensure the accuracy of flow measuring devices. One should select device
which do not need calibration and maintenance frequently.
h) Compatibility with Process Requirement: Ensure that the selected flow
measuring devices are compatible with the process conditions, including
mounting options, insertion lengths, and connection interfaces.
i) Reliability and Durability: One should select device which are more reliable
and highly durable. The longevity of the device is essential to minimize
replacement and maintenance costs.
j) Cost effectiveness: When selecting any flow measuring device, the initial cost,
as well as long-term operating and maintenance expenses must be taken into
consideration. One should select devices that provide the best value over their
lifecycle.
k) Regulatory Compliance: Ensure that the selected devices meet relevant
industry standards and regulatory requirements for flow measurement in the
chemical industry, such as ISO, ASTM, and ANSI standards.

1.8.4 Selection criteria for various measuring devices in chemical industry for Level
Measurement

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

Selecting measuring devices for level measurement in the chemical industry requires
careful consideration of several factors to ensure accuracy, reliability, and safety.
Some key criteria to consider are as below:
a) Principle of Measurement: On the basis of principle of measurement
appropriate level measuring device must be selected which are as below:
Direct Level Measurement Indirect Level Measurement
Dipstick Hydrostatic head type
Hook Type Purgle Type (Bubbler)
Sight Glass Capacitance Type
Float type Ultrasonic Type
Displacer Type Radiation Type

b) Accuracy and Precision: The accuracy of level measurement is critical in the

chemical industry to ensure precise control of processes and product quality.
One should select device with high accuracy levels and should also consider
the precision needed for consistent and reliable measurements.
c) Range: Consider the level range required for your specific processes. Some
applications may require measurement in extreme levels, so selecting devices
with suitable ranges is essential.
d) Response Time: The speed at which a level measuring device responds to
changes in level is crucial, especially in dynamic processes. One should select
device with faster response time so that necessary control action can be
taken.
e) Calibration and Maintenance Requirement: Regular calibration is necessary
to ensure the accuracy of level measuring devices. One should select device
which do not need calibration and maintenance frequently.
f) Compatibility with Process Requirement: Ensure that the selected level
measuring devices are compatible with the process conditions, including
mounting options, insertion lengths, and connection interfaces.

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 Utilities and Instrumentation in Chemical Plant
Diploma Semester V, Chemical Engineering

g) Reliability and Durability: One should select device which are more reliable
and highly durable. The longevity of the device is essential to minimize
replacement and maintenance costs.
h) Cost effectiveness: When selecting any level measuring device, the initial cost,
as well as long-term operating and maintenance expenses must be taken into
consideration. One should select devices that provide the best value over their
lifecycle.
i) Regulatory Compliance: Ensure that the selected devices meet relevant
industry standards and regulatory requirements for level measurement in the
chemical industry, such as ISO, ASTM, and ANSI standards.

Prepared By: Dhaval N. Yadav (Lecturer in Chemical Engineering) Page 23 of 23