Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Share10
Introduction
Pressure measurement and control is the most used process variable in the process
control industry many segments. In addition, through the pressure it is possible infer
a series of other process variables, like level, volume, flow and density. This article
will cover the main technologies of the most important technologies used in pressure
sensors, as well as some details concerning pressure transmitter installations,
market and trends.
In the past few decades, with the advent of the digital technology, an enormous
variety of equipment spread through the market in multiple applications. The
pressure characterization was really valued from the moment it was translated in
measurable values.
The entire pressure measurement system is constituted by a primary element, which
will be in direct or indirect contact with the process where the pressure changes
occur, and a secondary element (the pressure transmitter) whose task will be
translating the change in measurable values for use in indication, monitoring and
control.
Figure 4 shows a parallelepiped with a side A and length L area on one side, where
the pressure on its upper face and its lower face are given respectively by P D = hpg
and PU = (h + L) pg. The resulting pressure is equal to PU - PD = lpg. The pressure
employed by a force perpendicular to the fluid surface is called static pressure. The
Pascal principle states that any increase on the liquid pressure will be transmitted
equally to all points on the liquid. This principle is used on hydraulic systems (like
car brakes) and can be illustrated by figure 5. In other words: the applied forces have
intensities proportional to the respective areas.
Also, is worth quoting Staven Law (1548-1620): on a homogeneous and
uncompressible fluid on equilibrium under the action of gravity, the pressure grows
linearly with the depth; the difference of pressure between two points is equal to the
product of the fluid specific weight by the difference of level between the points under
consideration.
Figure 5 – The pressure is perpendicular to the surface and the forces applied
have intensities proportional to the respective areas
Observe now the pressure applied by the moving fluids on a tube transversal section.
Let´s take figure 6, where:
F1 = force applied to surface A1;
P1 = ratio between F1 e A1;
ΔL2 = distance displaced by the fluid;
V2 = speed of displacement;
h2 = heigh relative to the gravitacional reference.
and
F2 = the force applied to surface A1;
P2 = ratio between F1 e A1;
ΔL2 = distance displaced by the fluid;
V2 = speed of displacement;
h2 = height relative to the gravitational reference.
Figure 6 – Bernoulli equation – The pressure applied by the moving fluids on the
tube transversal section.
Supposing an ideal fluid without viscosity, it is displaced with friction and so without
energy loss.
The work carried out by the resultant of the forces acting on a system is equal to the
variation of the kinetic energy, the work-energy theorem. With this, we have:
P1+ (1/2) ρ .v12 + ρ . g . h1 = P2 + (1/2)ρ . v22 + ρ . g . h2
This is the Bernoulli equation that proves that the pressures total along a tube is
always constant on an ideal system. The interesting thing on this equation is that the
following pressures can be recognized:
This ratio is very useful to calculate de fluid speed, given the impact pressure and
the static pressure. From this ration, there may be calculated, for example, the fluid
flow:
The C values are experimental results and for each type of primary measurement
element and impulse-take system, C varies in function of the piping diameter (D),
the number of Reynolds (Rd) and the ratio of the diameters related to section A1
and A2 ()
C = f(D,Rd,β)
mmH2
inH2O mmHg inHg
atm bar kPa kgf/cm2 O psi
@20oC @0oC @32oF
@20oC
inH2O 0,0024 0,2486 0,0025 1,8649 0,0734 0,0360
1 0,0025 25,4000
@20oC 9 4 4 7 2 6
407,51 1,0132 101,32 1,0332 759,99 29,921 14,695
atm 1 10350,8
3 5 5 3 9 3 9
402,18 0,9869 100,00 1,0197 750,06 29,530 14,503
bar 1 10215,5
5 2 0 2 2 0 8
4,0218 0,0098 0,0100 0,0102 7,5006 0,2953 0,1450
kPa 1 102,155
5 7 0 0 2 0 4
394,40 0,9678 0,9806 98,066 735,55 28,959 14,223
kgf/cm2 1 10017,9
7 4 6 2 8 0 3
mmH2
0,0393 0,0001 0,0001 0,0097 0,0001 0,0734 0,0028 0,0014
O 1
7 0 0 9 0 2 9 2
@20oC
mmHg 0,5362 0,0013 0,0013 0,1333 0,0013 0,0393 0,0193
13,6195 1
@0oC 0 2 3 2 6 7 4
inHg @ 13,619 0,0334 0,0338 3,3863 0,0345 25,400 0,4911
345,935 1
32oF 5 2 6 8 3 0 5
27,729 0,0680 0,0689 6,8947 0,0703 51,714 2,0360
psi 704,333 1
6 5 5 5 1 9 2
Note that the gauge pressure is given by the difference between the absolute and
the atmospheric pressure.
2) Piezo-electric
The piezo-electric material is a crystal that produces a differential tension
proportional to the pressure applied on its faces: quartz, Rochelle salt, barium
titanium, tourmaline, etc. This material cumulates electric loads in certain areas of
its crystal structure, when they suffer physical deformation by the action of a
pressure. The piezo-electricity was discovered by Pierre and Jacques Curie in 1880.
Their disadvantage is that they require a high impedance circuit and a high gain
amplifier and are susceptible to noises. Furthermore, due to their dynamic nature
they do not perform solid state pressure measurement. However, their advantage is
a quick response.
The relation between electric load and the pressure applied to the crystal is
practically linear:
q = Sq x Ap
p – applied pressure, A - electrode area, Sq - sensitivity,
q - electric load, C – crystal capacity, Vo –voltage output
Figure 9a – Piezoelectric Sensor
3) Resonant
They generally follow the technology principle known as vibrating wire. A magnetic
wire coil is attached to the diaphragm, which oscillates when subject to a magnetic
field that will conduct an electric current. The oscillation frequency is proportional to
the wire voltage square root (expansion/compression). The Resonant Silicon sensor
does not employ a wire but the silicon to resonate with different
expansion/resonance frequencies (a 1/f2 function). The sensor is formed by a silicon
capsule set on a diaphragm that vibrates when a pressure differential is applied and
the vibration frequency depends on the applied pressure. Some resonant sensors
require temperature compensation techniques via complicated hardware/software
temperatures, by increasing the number of components, which need more electronic
plates in some equipment.
4) Capacitive
These sensors are the most reliable and have been used on million of applications.
They are based on transducers whose pressure applied to diaphragm sensors
produces a variation of capacitance between them and a central diaphragm, for
instance. This variation is typically used to vary an oscillator frequency, used as a
capacitor bridge element and also to vary an oscillator frequency. This frequency
can be measured directly by the CPU and converted into Pressure. In this case there
is no A/D conversion and contributes to the exactness and elimination of drifts
encountered on analog/digital conversions. It is worth remembering that this reading
principle is totally digital and is used by Smar since the middle 80s. Smar is the only
Brazilian company and one of the few in the world to make this type of sensor. They
have linear and practically insensitive to temperature variations, being the favorite
for instrumentation and process control, as they have excellent performance on
stability, temperature and static pressure. Some of their best features:
The sensitivity of fiber sensors, namely, the less intense measurable disturbance,
may depend on:
Changes on the properties of the used light, when the fiber is the channel through which
the light goes back and forth to the location being tested.
Optical fiber sensors are compact and show sensitivity comparable to similar
conventional devices. Pressure sensors are built using a moving membrane on one
of the fiber ends. The advantages of these sensors are: high sensitivity, small size,
flexibility and resistance, low weight, long life span, long transmission distance,
low material chemical reactivity, ideal to operate on intrinsically safe, high voltage
and hazardous ambient , electric isolation, electromagnetic immunity, multiplexing
of signals, i.e., a single fiber can have dozens of sensors to measure vibration,
pressure, temperature, multiphase flow, deformation, etc.
A technique used on optical sensor construction is the Fabry-Perot Interferometer,
a device generally utilized to measure high precision wave lengths, whose two
partially reflecting mirrors (of glass or quartz) are aligned and provide a maximum
fringe contrast and the distance between them through mechanical variation. The
distance variation could be generated by pressure and it would work as a pressure
sensor.
Fabry-Perot cavity length Stainless steel diaphragm Feed -through
connector Optical Fiber Cable
Users must be cautious about some points to avoid paying higher prices for
something they will not use or is not required by their application:
• Exactness & Rangeability:if they really need equipment with these features,
analyze the exactness formulas and note that sometimes exactness is not
announced on all ranges. Watch also other characteristics like response time,
totals, PID block, etc. as they are likely to be more useful on their applications.
• Protection to the investment: analyze the cost of spare parts, the
interchangeability between models, simplicity of specification, upgrade to
other technologies (Foundation Fieldbus, Profibus PA), technical services,
technical support, reposition term, etc. These are factors that may impair the
plant availability.
Electronic Diagram
Open tank
PL = Patm (atmospheric pressure)
PH = Patm + h. p. g
DP= PH - PL = n. p. g = K. h
Closed tank
PL = Ptop (steam pressure)
PH = Ptop + h . pg
DP= PH - PL = h. p. g = K. h
• Flow measurement
Figure 16 –Pitot tube flow measurement
Pitot Tube
PL = Pstatic (static pressure)
PH = Pstatic + Qv2 . k
DP= PH - PL =Qv2 . k
Qv =K. √ DP
What to measure?
Manometric pressure, absolute pressure, differential pressure, other greatnesses
inferred from measurement, like flow, level, volume, force, density pressure, etc.
Note that pressure measurements lower than atmospheric pressure do not
necessarily require absolute pressure transmitters. Absolute pressure transmitters
are recommended only to prevent the influence of atmospheric pressure variations.
This influence will be critical only when measuring very close pressures, over or
under the atmospheric pressure. Anywhere else, manometric pressure transmitters
can be used without problems.
• Local indicator: this item is not too costly and is very useful, as it not only
allows the reading of variables in engineering units (kgf/cm2, bar, mmH2O,
Pa, psi, etc.) but also facilitates configuring the transmitter when a
configurator is not available.
• Manifold: product bundling ( transmitter + manifold purchase) has commercial
advantages and avoids technical incompatibilities on mounting.
• Support for 2” pipe: an almost compulsory item. Some supports also allow
mounting on flat surfaces. At least stainless steel nuts and bolds should be
specified, for better resistance to corrosive atmospheres.
• Cable clamps: this item can be ordered with the transmitter. However, it
should be included on the mounting material, in order to ensure the
compatibility with the gauge of the specified cable.
Communication protocol?
The most common communication protocols are: 4-20 mA + HART, Foundation
Fieldbus and Profibus PA.
Some manufacturers market transmitters that change their protocol version by
simply substituting the electronic circuit board or just the firmware to allow their use
on different systems.
Also, they offer with the transmitters, CDs with all the archives (DDs and DTMs) that
ensure communication and interoperability edge with the several existing control
systems.
Special tools?
Transmitters with Foundation Fieldbus or Profibus PA protocols do not require
portable configurators, since the network configuration tools installed on supervising
computers or any engineering station is also capable of accessing and configuring
the devices. For conventional projects (4-2-mA + HART), it is recommended the
acquisition of hand-held configurators. In some transmitters, the configuration can
be done directly on the devices, with the use of resources like the magnetic
screwdriver or local buttons.
Pre-configuration?
On conventional transmitters it is possible to request to the maker, generally at no
additional cost, some pre-configurations: square root extraction; calibrated range;
display indication in engineering units and/or special units, for example: m3/h, l/h,
m3. In this case, the unit and scale should be indicated previously.
Certifications?
It is common for the user to request to the manufacturer calibration certificates
issued by metrology laboratory tracked by RBC. Standardized certificates are
generated and issued during the device production stage. Other calibration
certificates, when issued by RBC-tracked labs may require longer delivery terms and
involve additional costs.
Another important certification must be observed when the transmitters are used in
hazardous areas. The projects for these cases adopt regulations compliant to
explosion proof, increased safety or intrinsic safety. The certificates are distinct ones
and the user is responsible for its correct utilization. The same applies to SIS, Safety
Instrumented Systems.
Special connections?
In applications with aggressive fluids, high temperature or viscosity, suspended
solids, remote seal or integral transmitters are recommended. Integral seal
transmitters are called level transmitters. Whenever possible, the use of seals must
be avoided, as these degrade the measurement exactness, raise the transmitter
response time and suffer great influence from the ambient temperature. Seals with
flanged connections must be compatible with the process flanges and respect the
pressure classes established on pressure tables and the temperature of the
respective standards.
Functional resources
Some transmitters have very interesting functional resources. For Foundation
Fieldbus protocol transmitters it is important to know the functional block library
available. The user must be informed not only about the diversity of these blocks,
but also about the marketing policy for these resources. Some makers supply the
device with some basic blocks and charge extra price to include advance blocks. It
is also important to be aware of the number of blocks that can be processed on a
single transmitter. This limit can be critical in projects with more complex control
loops.
For conventional 4-20 mA + HART transmitters the use of additional functionalities
is also possible.
PID control
With this configuration the transmitter executes the PID algorithm, by comparing the
process variable with a pre-adjusted set-point and generates the current output
signal to be directly connected to the control valve positioner. This resource is valid
for simple control loops that do not need operator intervention, always on automatic
with constant set-point.
Flow totals
The differential pressure transmitter when used on flow measurement can be
configured for local indication of the total flow, besides the instantaneous indication.
Conclusion
This article presented some highlights on the history of pressure measurement, its
importance in automation and process control, peculiarity of some sensor types,
combined with the pressure transmitter technological advancements. We also
examined the care required in relation to transmitter installations and
specification and market trends.
References
Copyright Statement
All illustrations, trademarks and products mentioned in this article are the property
of their respective owners, as well as any other form of intellectual property, being
herewith used strictly in educational character.