Syllabus
Module-I
Characteristics of Measurement system: Elements of instruments, Static characteristics, Dynamic characteristics,
Estimation of errors, Applications of Laplace transforms in instruments, Responses of first & second order instruments
Module-II
Transducers: Classification of transducers, Pneumatic transducers, Electrical transducers, Optical transducers, Ultrasonic
transducers
Module-III
Temperature and Pressure Measurement: Temperature measuring instruments like Bimetallic, Vapour pressure,
Thermocouples, Automatic Potential Recorders, Resistance thermometers. Measurement of pressure and vacuum:
Manometers, Dead weight systems, Force-summing devices, Pressure spring,
Module-IV
Flow and Level Measurement: Head-type, velocity measurement type, mass flow measurement type and positive
displacement flow meters, Mechanical, optical, electrical and radiative level indicators, Viscosity and density
measurement
Module-V
Composition and other miscellaneous measurements: Humidity and moisture measurement, Conductivity and pH
measurement
Course Objective
The aim of the course is to make the students understand the purpose of instrumentation process industries
Provide adequate knowledge on various process instruments and their characteristics
Course Outcome
CO1 To Characterize instruments, evaluate responses and estimate errors.
CO2 To understand working of various transducers and evaluate associated parameters.
CO3 To understand measurement techniques for pressure and temperature and select appropriate instruments.
CO4 To understand measurement techniques for level, flow and flow related properties and select appropriate
instruments.
CO5 To understand measurement techniques for composition, humidity and turbidity and select appropriate
instruments.
Essential Reading
K. Krishnaswamy, Industrial Instrumentation, , New Age Publishers , 2010
A. Suryanarayana, Outline of Chemical Instrumentation and Process Control, Khanna Publisher , 2008
Supplementary Reading
J. Curtis, Process Control Instrumentation Technology, Prentice-Hall of India , 2005
R. S. Sirohi, H. C. Radha Krishna, Mechanical Measurements, New Age Publishers , 1991
Measuring Instruments: Used to measure important process variables in chemical process industries
Process variable?
Chemical process industry?
Process
variables
Process Control Instruments
industry room
Thermometer: Body temperature, lab-scale temperature
Thermocouple: Industrial scale temperature measurement
Fig.1
Fig.2
Fig.3
Fig.4
Types of measurement applications
Monitoring/Supervision
Control of processes Experimental
of processes and
and operations Engineering analysis
operations
Monitoring/supervision of processes and operations
You are monitoring the process, not controlling it.
You can measure locally vs Instrument Signal Monitoring in the control room
Monitoring at the site
Keep track of some quantity
Example: Water meter
Control of processes and operations LI: Liquid indicator measures the level
Not only monitor, it takes suitable actions.
Refers to automatic control of the process
Ex-1: Liquid level Sends the information to LC (level controller)
LC sends signal to control valve depending upon
the desired level
No change Open Close
Set point information is fed to the level controller. It
compares the set point value and value obtained from the
level indicator
Ex-2: Control of bath temperature
Temperature indicator
Measures the current bath
temperature
Sends the signal to the
temperature controller (TC)
TC compares the current
bath temperature with the
set point (SP) temp.
If SP≠CT
TC sends signal to control
valve to open more or close
Sometimes the signal goes from the measuring instrument to the comparator
Comparator compares the measured signal with the set point signal
Comparator send the error signal to the controller
Error signal = |set point – measured value|
Controller decides what should be done
Then controller sends the signal to the control valve or actuator, whatever decision is
being taken by the controller
In Industry
Sensor: Senses the information about the system being controlled
Comparator: Compares the current value with the set point value
Controller: Takes the decision what has to be done to the process
Actuator: Implement the decision
Disturbance
1
Comparator
4 5 6
Controller Actuator Plant/Process
Desired output
3
Sensor 2
(Measuring
element)
Experimental Engineering Analysis
Test the validity of predictions from theories
Build empirical models from data
Characterization of materials, devices, etc.
Measuring
Measurement Data Validity of data
instruments
It’s not always possible to build a model based on first principle; so empirical models has to be built
from the measured data
Characterizations of materials and devices.
Example: Battery modelling
Direct measurement Indirect measurement
Quantity to be measured is determined directly Quantity is not measured directly
Ex: Distance measurement by scale, weight of Ex: Use of telescope to calculate distance by
your body optical method, electrical resistance
Various types of functions of an instrument
Primary objective Measure process While doing so, it performs
Instrument
variables several functions
Several functions
Transmitting Signaling Registering Indicating Recording
Transmitting
Instrument conveys the information concerning the measured quantity over some distance/to remote point
Thermometer vs Thermocouple
Signaling
Instrument indicates the general value or range of values of its measured quantity
Ex: A grocer’s scale (weighing balance) – Measurement against a standard value (signal about range of value of the quantity)
Registering
Instrument indicates by numbers or some other symbol of discrete increments
Ex: cash register
Indicating
An indicating instrument indicates the instantaneous value of the variable being measured at the time
Ex: Clock, Ammeter, Voltmeter, Wattmeter
Recording
Instrument takes a written record of the value of the measured quantity against some other variable or against time
Functional elements of an instrument
Perform specific function in converting a
Instruments Various parts
variable quantity to a corresponding indication
How to identify functional elements associated with these instruments?
Functional elements of an instrument
Perform specific function in converting a
Instruments Various parts
variable quantity to a corresponding indication
How to identify functional elements associated with these instruments?
Thermometer (bulb) dipped into the medium
Mercury (fluid) receives thermal energy from the medium
Undergo restricted expansion (expansion of the volume of Mercury)
Pressure is developed and Mercury will go up by capillary action
Finally, it will rest at a point
That point is the measure of temperature
Thermocouple
Hot junction (measuring junction) + Cold junction (reference junction)
Bring the medium in contact with the hot/measuring junction
Reference junction is kept at a constant temperature (fluctuation may give error)
Measuring junction receives information about the temperature of the medium
Produced EMF (range in millivolt) is the measure of temperature
When the junction is heated or cooled, a small voltage is generated in the electrical circuit of the thermocouple which
can be measured, and this corresponds to temperature. A thermocouple, also known as a "thermoelectrical
thermometer", is an electrical device consisting of two dissimilar electrical conductors forming an electrical junction.
The output of a thermocouple is typically a very small voltage, and it is inherently AC. This is because a
thermocouple generates a voltage in response to the temperature difference between its two junctions, and this
voltage fluctuates with changes in temperature.
Temperature measuring
instrument
There is a component which
Primary sensing element
will interact with the medium
Pressure measuring
instrument
Bourdon tube
Bourdon tube (Pressure measurement) – Metallic tube
Movement of the tip of the Bourdon tube (tip deflection is the measure of pressure)
Pressure thermometer
Bulb
Fluid
Temperature
Primary Variable Pressure Data
Measured measured
sensing conversion transmission Tubing
medium quantity
element element element
Pressure
Data Magnify Variable Motion Variable
Observer presentation manipulation conversion
element Motion element element
Pointer & scale Gear & linkage Bourdon tube
Functional elements of Pressure Gauge
Piston
Fluid
Pressure
Primary Variable Force Data
Measured measured
sensing conversion transmission Piston rod
medium quantity
element element element
Force
Data Magnify Variable Motion Variable
Observer presentation manipulation conversion
element Motion element element
Pointer & scale Gear & linkage Spring
Classification of instruments
Mechanical Electrical Electronic
Associated with electrical power or Associated with flow of electrons to
Utilizes mechanical principles
charge perform a specific task
Deals with the measurement,
Measure, control, manipulate and Deals with electronic components
control, etc. of electrical
transmit mechanical forces or like transistors, diodes, integrated
components like voltage, current,
motion circuits, etc.
etc.
Ex: Thermometer, Pressure gauge,
Ex: Resistor, capacitor, inductor, etc. Ex: Semiconductor devices
valve, spring, pulley
Application: Multimeters,
Application: Oscilloscopes,
Application: Calipers, Speedometer Ammeters, Voltmeters
Electrochemical workstations
Order of response in these instruments
Electronic ˃ Electrical ˃ Mechanical
Other ways of classifications
1. Classification on the basis of energy consideration: passive and active
2. Classification on the basis of analog and digital mode of operation
3. Deflection vs null principle
4. Contacting vs non-contacting
5. Manual vs automatic
Passive Active
Output energy is completely supplied by
Power operated instruments
its input
Ex: Ordinary glass (Mercury)
Ex: Electrochemical workstations
thermometer
Analog Digital
Continuous in nature Discrete in nature
Ex: Computers, electrochemical testing
Ex: Human voice, natural sound
devices (less noisy)
Deflection type Null type
Associated with some mechanical
Attempts to maintain deflection at zero
displacement or deflection
Ex: Voltmeter, Ammeter Ex: Equal arm measuring balance
Contacting type Non-contacting type
Instrument measures variable without
Physical contact of the instrument with
being in physical contact with the
measuring medium is necessary
measuring medium
Ex: Thermometer, pressure gauge Ex: Optical pyrometer
Automatic instrument Manual instrument
Does not require the assistance of any
Requires the service of an operator
operator
Ex: Mercury-in-glass thermometer Ex: Electrochemical workstation
Microprocessor based instruments
1. Multipurpose programmable electronic devices
2. Ex: ATM, automatic washing machine
Primary sensing &
variable conversion
element
Variable Analog to
Measured
Transducer manipulation digital
medium
element converter
Display with
Microprocessor
interface
Receives digital signal
Input-output configuration of instrument
Transfer
Input (I) Output (O)
function
Thermometer
Input: Hot water temperature
Hot water
Bulb of thermometer Output: Displacement of Mercury in the capillary
Classification of input quantities
Desired output = h Let, P1=P2 Let, P1=P2
P1-P2 = ρgh h=0 h=0 Component
ΔP α h h ≠ 0 (acceleration) h ≠ 0 (tilt) of Gravity
Input-output configuration of instrument
Desired input, ID Output component due to ID & IM
TF_D
TF_M, D
Modified input, IM
+
Final output
+
TF_M, I
Interfering input, II
TF_I
Output component due to II & IM
Corrective measures for interfering and modifying inputs
1. Input filtering (or, output filtering)
2. Method of opposing such inputs
Desired input, ID
TF_D
TF_M, D
Modified input, IM
+
Input filtering (or,
Final output
output filtering)
+
TF_M, I
Interfering input, II
TF_I
Desired input, ID
TF_D
+
Opposing inputs
Final output
Unavoidable
interfering input, II1 +
TF_ II1
+
Intentionally
introduced
interfering input, II2 -
TF_ II2
Input filtering (or,
Opposing inputs
output filtering)
