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)