Report

Pressure and Temperature Transmitters

Submitted to Dr. Ing Naveed Ramzan

Submitted by Muhammad Jalal Hussain 07-CHEM-98

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Abstract

This report is intended to convey the importance and utilization of Temperature and Pressure Transmitters in instrumentation used in process industry and in the subject of industrial instrumentation. In this report theory of transmitter, types of transmitters, pressure transmitters, temperature transmitters, level transmitters, methods of signal transmission and transmitters available is the market are discussed. In this report an understanding of Temperature and pressure transmitter is tried to develop by discussing related commercial devices.

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Table of Contents
Transmitters .........................................................................................4 Smart and Intelligent Transmitters: ....................................................4 Force Balance Transmitter: ................................................................6 Motion Balance Transmitter: ..............................................................6 Pneumatic Transmitters: .....................................................................6 Pressure Transmitters .........................................................................7 Force-Balance Pneumatic Pressure Transmitter: ...............................7 Absolute Pressure Transmitter: ..........................................................7 Electronic Pressure Transmitters: .......................................................8 Temperature Transmitters .................................................................8 Pneumatic Temperature Transmitters: ...............................................8 Level Transmitters ..............................................................................9 Signal Transmission ............................................................................9 Current Signal Transmission: ...........................................................10 Pneumatic Signal Transmission: ......................................................11 Industrial Transmitters ....................................................................11 PX760 Series Differential Pressure Transmitter ..............................11 TX86 Universal Input temperature Transmitter ...............................13 OS1600, OS1700, OS1800 Infrared Temperature Transmitter .......14 PRTXD Series RTD Temperature Transmitters ..............................16 References ..........................................................................................17

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Transmitters
In the process plant, it is impractical to locate the control instruments out in the plant near the process. It is also true that most measurements are not easily transmitted from some remote location. Pressure measurement is an exception, but if a high pressure measurement of some a dangerous chemical is to be indicated or recorded several hundred feet from the point of measurement, a hazard will be created hazard may be from the pressure or the chemical carried in the line. This problem is solved by a signal transmission system. In process instrumentation, this system is usually either pneumatic or electrical. By using transmission system it will be possible to install most of the indicating recording and control instruments in one location. This helps in decreasing the number of operators in the plant and all the measurements can be visually seen at one point (control room). A transmitter is a transducer that responds to a measurement variable and converts that input into a standardized transmission signal. The transmitter used in industry are combination of a transducer and signal conditioning circuit that produces an output current preoperational to the measured variable. Most common types of Transmitters which are used in industrial control are: 1. Smart and intelligent transmitters. 2. Force balance transmitters. 3. Motion balance transmitters. 4. Pneumatic transmitters.

Smart and Intelligent Transmitters:

The transmitters is because of two factors: 1. Improved performance with reduced cost. 2. Development in technology. The most significant advances have resulted from the emergence of low power microprocessors and analog to digital converts (ADC) which, in junction with the basic junction circuits, can function of the limited power available at the transmitter in a conventional 4 to 20 mA measurement circuit. This has led to two different ways for improving the working of transmitters: progressed made in design of

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1. By enabling non-linear characteristic to be corrected. 2. By enabling secondary sensor to account for any effect on the primary sensor. Transmitters in which corrections are applied to the primary sensor signal, using microprocessors to the process information which is embedded in memory; or those in which a microprocessor is used in junction with a secondary sensor to derive for the primary sensor signal are called smart transmitters. In simple language a smart transmitter a transmitter in which a microprocessor system is used to correct non-linearity error of primary sensor through interpolation of calibration data held in memory or to compensate for the effect of secondary influences on the primary sensor by incorporating a secondary sensor adjacent to primary sensor and interpolating stored calibration data for both primary and secondary sensor. The microprocessor not only manages the smart function but also manages communication. Other functions which smart sensors can perform are 1. Setting or resetting the zero and span. 2. Location and application. 3. Running diagnostics and warning incase of malfunction. Smart sensors incorporating communication system are called Smart and intelligent transmitters. Intelligent transmitter is the one in which the microprocessor also performs following functions: 1. Deriving the primary measurement signal. 2. Processing transmitters information like location etc. 3. Managing the communication system.

Smart and intelligent features of such transmitters are summarized below:

Smart Features:
1. Linearization, characterization and Correction of Primary sensor characteristics. 2. Expression of the Measurement in engineering units.

3. Inclusion of control function and other algorithms.

Intelligent Feature:
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1. Adjustment of span and zero. 2. Adjustment of damping, time constant or response time. 3. Diagnostic routine and status information.

Force Balance Transmitter:

In force balance transmitters the measurement produces a force which tends to move the top of the force bar. This tiny motion moves he ferrite disc closer to the transformer, changing the output current. This changes the amplitude output of the oscillator, which is rectified and then amplified to generate a DC mA transmitter signal. This output signal is fed back through the voice coil on the armature of the force motor which moves the force bar again to its original by balancing the forces and the amplifier signal stabilizes.

Advantages:
1. By decreasing the motion of the pivot friction is reduced. 2. Hysteresis is minimized and greater accuracy can be achieved. No free motion.

Disadvantages:
1. It cannot be used to produce digital signal.

Motion Balance Transmitter:

In a motion balance transmitter the process measurement produces motion against a calibration ring resulting in a change of position corresponding to a change in the process variable. This change in position is measure d by the transducer. The output from the transducer is amplified and an electrical signal is used to stabilize the amplifier.

Pneumatic Transmitters:
The device that senses some process variables and transmits the measured value into an air pressure that is transmitted to various pressure receiver devices for indication recording, alarm generation and control is known as Pneumatic transmitter When transmission system is employed, the measurement is converted into a pneumatic signal by the transmitter scaled from 0 to 100 percent of the measured value. This transmitter is mounted close to the point of measurement in the process. The transmitter output air pressure for a pneumatic transmitter is piped to the recording control instrument. The standard output range of pneumatic transmitter is 3 to 15 PSI. These are the standard signals that are internationally used.

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Suppose we have field mounted pressure transmitter that has been calibrated to a pressure range of 100 to 500 PSI. When the pressure being sensed is 100 PSI the transmitter is designed to produce an output of 3 PSI air pressure. When the pressure sensed rises to 300 PSI the output will climb to 9 PSI. When pressure 500 PSI the output signal will be 15 PSI. The signal is carried by tubing to control room where it is either indicated recorded or feed in to the system. The receiving instrument uses bellows element to convert this signal in to pointer or pen motion. If the signal is feed to the controller, a bellow is also used to convert the signal for the use of the controller. Some basic types of pneumatic transmitters used in industry are: 1. Force balance transmitters. 2. Motion balance pressure transmitters. 3. Differential pressure transmitters. 4. Variable area flow transmitters. 5. Temperature transmitters. 6. Buoyancy transmitters. 7. Speed transmitters.[1]

Pressure Transmitters
Force-Balance Pneumatic Pressure Transmitter:
A pneumatic pressure senses a pressure and converts that pressure into pneumatic signal that can be transmitted over a reasonable distance. A receiving instrument is then applied to convert the signal into pen or pointer position or a measurement input signal to a controller. The Foxboro model 11GL force balance pneumatic pressure transmitter is a simple example. Operation of vital component: the flapper and nozzle, and the pneumatic amplifier. These two mechanisms are found almost in every pneumatic instrument. The flapper nozzle system converts the small motion or force into an equivalent pneumatic signal. Flapper movement of only 0.0015 will change the nozzle pressure by 0.75 PSI. This small change applied to pneumatic amplifier or relay becomes an amplified change of 3 to 15 PSI in the amplifier output. [2]

Absolute Pressure Transmitter:

The pressure being measured is applied at one side of the diaphragm in a capsule. The space on the other side of the diaphragm is evacuated, thus providing zero absolute pressure reference.

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The pressure exerts a force on the diaphragm that is applied to the lower end of the bar. The diaphragm seal serves as the 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 adjustment wheel. Any movement of the range bar causes a minute change in the clearance between the flapper and the nozzle. This produces a change in the output pressure front the relay to the feedback bellows until the force in the bellows balances the force on the diaphragm capsule. [2]

Electronic Pressure Transmitters:

Atcotran pressure transmitter this device uses a differential or movable core transformer. The transformer consists of a primary coil and two secondary coils inter connected with each other. The transformer core is suspended from the tip of the bourdon tube and moves up and down in response to changes in the process pressure which is being measured. The primary coil is connected to an alternating current source; the magnetic flux generated by primary coil is distributed by the core so that voltage is induced in the two secondary windings. If the core is position in such a way that (in the center of the two secondary coils) the voltage induced in the each of the two coils is equal, the alternating current output to the indicating instrument is zero because the two secondary coils are wound in opposite directions and the voltage induced in the one is 180 out of phase with other. So the transformers output corresponds to the difference between the two voltages induced in the secondary windings. An extremely small movement of the core suffices to produce a measureable voltage output. [3]

Temperature Transmitters
Pneumatic Temperature Transmitters:
There are basically four general classification of pressure creating thermometers can be employed with pneumatic pressure transmitters. If the signal is to be transmitted for more than 200 ft or if there are multiple points at which temperature is to be monitored visually. All the temperature measurements are nothing more than but a pressure measurement. The pneumatic pressure and temperature transmitters are essentially alike, differing slightly from each other.

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A very simple device in which the pointer is directly moved by a bourdon tube with the tube d device is connected which controls the position of the flapper. Let us consider an example; temperature is rising of the measured stream. This increase in temperature will move the flapper close to the nozzle. This will increase the pressure on the orifice, as a result an increase in pressure output of the pneumatic relay .The increase in output of the relay is sent in two ways. One to the remote gage and second to the transmitter feedback bellows which cause the flapper to move away from the nozzle until a new condition is established. Another method can be used for accomplishing the Pneumatic temperature transmittance. This method is used for the filled system. The pressure created by the liquid in the temperature sensing bulb tries to push the diaphragm up and the motion lever with it. Any movement of the motion lever will move the baffle in accordance with the nozzle. The movement of the baffle in the vicinity of the nozzle will be 40 to 50 times as greater as that of the motion of lever; the lever amplifies the motion of the diaphragm. The full range of the device can be obtained with a baffle movement of about 0.001 inch, it may be vary from instrument to instrument as per requirement. As the baffle moves away from the nozzle, the pressure in the tubing of the nozzle decreases. Because the relay is of the reverse acting type, this decrease of the pressure at the nozzle will create an Increase in output pressure of the relay. [4]

Level Transmitters
Level can be measured by using a pressure transmitter. The principle in level measurement by using a pressure transmitter is based on the measurement of the hydrostatic pressure produced by a column of liquid at a given height. [5]

Signal Transmission
For control purpose the there is requirement of a scheme for the transmission of data from instrument (sensor) to the controller system (PLC, DCS etc). Following are the methods used for the transmission measured variable.

1. Current Signal Transmission

2.

Pneumatic signal transmission

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Current Signal Transmission:

When a current loop is implemented using analog type electrical signal, the most common and frequently used method to transmit the analog signal is in the form of a current loop. When a process current loop is designed, an operating range is specified for the control variable to regulate according to the conditions. Thats why, it is necessary of define a set point anywhere within that range. According to one standard the signal conditioning is so that 4-20 mA current range on signal transmission wire represents the specified range of the variable, according to the given condition.

Following are the point regarding the significance and importance of using the current transmission to represent the controlled variable:

1. Load impedance:
We can avoid different errors introduced by attaching different loads to transmit the current while using current to carry analog information about the variable. Hence the delivered current is not changed by any change in the lead resistance or by insertion of a serried resistance in the circuit. Mostly the transmitting circuits are designed to work in to any load from 0 ohm to about 1000 ohm.

2. Interchangeability:
When we use a specified current to represent the variable range, we provide for interchangeability of the controller in the process control loop. Once we have changed all the dynamic variable range to a fixed current range then all control can be based on a set point and deviation as some percentage of this range. Thus the controller only gets a 4-20 mA signal, according to the process condition.

3. Measurement and power supply:

The current signal lines are also the power supply lines to energize the transducer and local signal conditioning. Only two wires are required to connect a transducer and signal conditioning measurement system to the rest of the loop. The signal conditioning is designed such that the circuit draws more or less current from the power source in proportion of the value of dynamic variable according to the process condition. Industrial instrumentation Page 10

Pneumatic Signal Transmission:

The final control element in a process control loop (whether PLC or DCS) is a pneumatic device or element. In most cases, an entire process control loop may be pneumatic, basically it depends on the plant and the process whether the whole control system is pneumatic or electrical (current driven). The standard transmission signal, mostly used in industry, is a pressure level of a range 3-15 PSI. A current to pressure converter is used to scale the 4-20 mA signal to 3-15 PSI pressure signal. [6]

Industrial Transmitters
Below are mentioned few Pressure and Temperature transmitters which are used in industries with their detail:

PX760 Series Differential Pressure Transmitter

PX760 series transmitter is a two wire microprocessor based device. It works on a digital signal from 4 to 20 mA. It has ceramic sensor. This transmitter measures and locally displays differential pressure and level from 1.8 to 2100 mbar (1 to 8430 in of H2O). temperature. It is smart sensor; it has build in temperature

compensator, linearization software and displays the sensor

A basic Block for diagram, which displays how this differential transmitter works, is given below.
Figure 1 PX760 Series Differential Pressure Transmitter

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Figure 2

In this transmitter the inputs are sampled and digitized by an Analog to Digital Converter (ADC). The sensor signal integrity is readily checked by a diagnostic routine. The data obtained from the sensor is linearised and converted to selected engineering units. The measurements are then adjusted to according to the lower and upper range values. This value is finally converted to a 4 -20 mA analog output signal. The configurations are kept in a permanent memory bank of the instrument. The transmitter also performs internal diagnostics to give maximum reliability and helps the user to identify any problem. [7]

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TX86 Universal Input temperature Transmitter

Figure 3

TX86 Universal Input temperature Transmitter

The TX86 is a two wire looped power temperature transmitter. It is a very versatile instrument which converts, indicates and transmits a signal from a thermocouple, RTD, Potentiometer sensors into a linearised 4-20 mA looped current needed by DCS, PLC, PC, SCADA system or recorder. TX86 has a microprocessor based advanced digital and analog electronics circuitry and a temperature measuring method which enables it to provide a high degree of performance and flexibility at reasonable cost and ease of use. The transmitter incorporates galvanic isolated solid state rely alarm output which can be programmed as high and low alarm trip system with normally open or close contacts for variety of control application. [8]

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OS1600, OS1700, OS1800 Infrared Temperature Transmitter

Figure 4

OS1600, OS1700, OS1800 Infrared Temperature Transmitter

The OS1600, OS1700, OS1800 Infrared Temperature Transmitter is sensitive to radiation or infrared energy given off by the object whose temperature is to be measured. When the instrument is aimed towards the target the radiation focuses on the infrared detector causing it to generate an electrical signal this signal is converted by the system electronics into a DC output current which varies with intensity of target radiation, a direct relation exists. The temperature transmitter produces a linear DC current electronic signal ranging from 4 to 20 mA which is directly proportional to the infrared energy emitted by the target. A readout device causes the meter to display the temperature of the target. A typical basic measurement loop is shown below.

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Figure 5

Instrument loop The OS1600, OS1700, OS1800 Infrared Temperature Transmitter family are non contact infrared two wire transmitters with temperature range from -45 to 2500 oC . These transmitters are very versatile and have high performance. The linear 4 20 mA output signal allows the sensor to be interfaced with a variety of remote devices like indicators, recorder, controller or computers. The sensors have an adjustable time of response of 0.2 to 5.0 seconds an emissivity adjustment of 0.1 to 0.99 and adjustable peak hold position. [9] Industrial instrumentation Page 15

PRTXD Series RTD Temperature Transmitters

The PRTXD series RTD temperature transmitters are microprocessor controlled industrial temperature indicator with a digital temperature display and 4-20 mA electrical signal device in a rugged housing. The PRTXD has a 2-wire connection and all operating power is supplied by the 4-20 mA current loop. The RTD temperature reading is linearized for both the digital display and the 4-20 mA output. It can display in both F or C scale and the 4-20 mA output may be set to correspond to a desired temperature range. It has a range from -50 to 200 oC. Its accuracy 0.1% of span plus maximum sensor error of 0.3C at 0C, 1.1C at 150C. Any DC supply/loop resistance that maintains a direct current of 8 V to 32 V at gauge terminals. Erratic operation may occur if loop voltage falls below specifications. [10]
Figure 6

PRTXD Series RTD Temperature Transmitters

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References
1. Singh, S.K, Industrial Instrumentation and Control, Tata McGraw Hill, India, 3rd edition, Page 551 to 557, 2009. 2. Anderson, N.A, Instrumentation for Process Measurement and Control, Chilton Company, USA, 3rd edition, Page 60 to 65. 3. Holzbock, W.G, Instruments for Measurement and Control, Reinhold Publishing corp., USA, 2nd edition, Page 84 to 85. 4. Fribance, A.E, Industrial Instrumentation Fundamentals, McGraw Hill company, USA, International Students Edition, Page 463 to 465. 5. Macmillan, G.K, Considine, D.M, Process/Industrial instruments and control Handbook, Tata McGraw Hill, 5th edition. 6. Jhonson, C, Process Control Instrumentation Technology, Prentice Hall, India, 4th edition, Page 24 to 25. 7. http://www.omega.com/pptst/PX760.html [ Retrieved on October 13th 2010] 8. http://www.omega.com/pptst/TX86.html [ Retrieved on October 13th 2010] 9. http://www.omega.com/pptst/OS1600_1700_1800.html [ Retrieved on October 13th 2010] 10. http://www.omega.com/pptst/PRTXD.html [ Retrieved on October 13th 2010]

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