This sample review copy provided for evaluation of the training material from General Physics Corporation, at http://nucleartraining.gpworldwide.com/gfe.

aspx

ACAD BASIC CURRICULUM

INSTRUMENTATION & CONTROL

CHAPTER 3 PRESSURE SENSORS AND DETECTORS

INSTRUCTOR GUIDE REV 2

2003 General Physics Corporation, Elkridge, Maryland
TM

All rights reserved. No part of this book may be reproduced in any form or by any means, without permission in writing from General Physics Corporation.

KFI03Lr02_Pressure Sensors and Detectors 08Nov08

THIS DOCUMENT IS A SAMPLE OF THE INSTRUCTOR GUIDE

provided for evaluation of the training material from General Physics Corporation, at http://nucleartraining.gpworldwide.com/gfe.aspx

for more information contact John Galamback - JGalamback @gpworldwide.com 410.340.3463 Sam Shoppell - SShoppell@gpworldwide.com 803.295.5209 Jeff Klein - JKlein@gpworldwide.com 803.295.5210

ACAD BASIC CURRICULUM

INSTRUCTOR GUIDE
TIME REV 2
DATE _____________ _____________ _____________ _____________ _____________

VOLUME: INSTRUMENTATION & CONTROL INSTRUCTOR GUIDE: PRESSURE SENSORS AND DETECTORS
RESPONSIBILITY Origination Review/Concurrence Review/Concurrence Approval/Objectives Approval/Final SIGNATURE _____________________ _____________________ _____________________ _____________________ _____________________ TITLE _____________________ _____________________ _____________________ _____________________ _____________________

hrs

REVIEW COPY 2003 GENERAL PHYSICS CORPORATION REV 2 www.gpworldwide.com 2 of 28 I&C - CHAPTER 3 PRESSURE SENSORS AND DETECTORS ACADBasics@gpworldwide.com

KFI03Lr02_Pressure Sensors and Detectors 08Nov08

ACAD BASIC CURRICULUM

INSTRUCTOR GUIDE
TIME REV 2 hrs

VOLUME: INSTRUMENTATION & CONTROL INSTRUCTOR GUIDE: PRESSURE SENSORS AND DETECTORS

OBJECTIVES
Upon completion of this chapter, the student will be able to perform the following objectives at a minimum proficiency level of 80%, unless otherwise stated, on an oral or written exam.

1.

EXPLAIN how a bellows-type pressure detector produces an output signal including: a. b. Method of detection Method of signal generation

2.

EXPLAIN how a bourdon tube-type pressure detector produces an output signal including: a. b. Method of detection Method of signal generation

3. 4. 5. 6. 7. 8. 9.

STATE the three functions of pressure measuring instrumentation. DESCRIBE the three alternate methods of determining pressure when the normal pressure sensing devices are inoperable. STATE the three environmental concerns that can affect the accuracy and reliability of pressure detection instrumentation. LIST the parameters that can be measured using a differential pressure (D/P) cell. For a D/P sensing instrument, EXPLAIN the purpose and use of an equalizing valve. DESCRIBE instrument response to equalizing valve operation. EXPLAIN how a strain gauge pressure transducer produces an output signal including: a. b. Method of detection Method of signal generation
REVIEW COPY

2003 GENERAL PHYSICS CORPORATION REV 2 www.gpworldwide.com

3 of 28

I&C - CHAPTER 3 PRESSURE SENSORS AND DETECTORS ACADBasics@gpworldwide.com

KFI03Lr02_Pressure Sensors and Detectors 08Nov08

ACAD BASIC CURRICULUM

INSTRUCTOR GUIDE
TIME REV 2 hrs

VOLUME: INSTRUMENTATION & CONTROL INSTRUCTOR GUIDE: PRESSURE SENSORS AND DETECTORS

K/A - CROSS REFERENCE MATRIX

The table below shows a matrix of INPO documents and the fundamental knowledge statements listed as areas for study in this topic.
90-003 90-016 92-008 93-008 97-012 98-004 00-003 LO OBJ STA NLO MNT RADPRO CHEM ESP 1,2,3 Pressure Sensors XXX XXX 1,2,3 Vacuum Sensors XXX 6,7,8 Differential Pressure Sensors XXX Describe the principles of operation, typical applications, and failure modes of the following detectors and instrument strings: Bourdon Tube Pressure/ Differential Pressure Detector 1,2 XXX Pressure/Differential Pressure Switches 6,7 XXX Describe the effect of environmental conditions on the following instrumentation: Reactor Coolant System XXX Pressure 4,5

NOTE TO INSTRUCTOR This text refers to taking a differential pressure gauge out of service and returning it to service. Determine if the audience you are training will be involved with operating differential pressure gauge isolation and equalizing valves. Different facilities have different rules about who is allowed to operate the valves. Ensure your presentation addresses the facility rules for operation and control of differential pressure gauge isolation and equalization valves.

REVIEW COPY 2003 GENERAL PHYSICS CORPORATION REV 2 www.gpworldwide.com 4 of 28 I&C - CHAPTER 3 PRESSURE SENSORS AND DETECTORS ACADBasics@gpworldwide.com

KFI03Lr02_Pressure Sensors and Detectors 08Nov08

KEY POINTS, AIDS, QUESTIONS/ANSWERS

INSTRUCTOR GUIDE
I. LESSON INTRODUCTION A. Greet students 1. Introduce self and lesson title. 2. Explain overall structure and format of lesson. 3. Encourage questions. 4. Encourage student contribution of information. 5. Explain sequence of presentation.

OBJECTIVES TP 3-1 ,2

B. Read the objectives. 1. Relate the objectives to the job. 2. Objectives define the lesson required knowledge. 3. Objectives will be reviewed during the lesson. 4. Objectives are directly related to exam questions. C. Create interest. II. PRESSURE SENSORS AND DETECTORS

REVIEW Ptotal = Pstatic + Pdynamic Pdynamic = v /2gc

2

A. Two types of pressures are monitored in industrial facilities and power plant systems. 1. The two types are dynamic and static. a. Dynamic pressure is that of a fluid in motion and static pressure is that of a fluid at rest. 2. Pressure sensors and detectors can be used for other applications besides pressure applications. a. Pressure sensors and detectors can be scaled and calibrated to indicate level and flow signals. 3. Pressure measurement is a necessary function in the safe and efficient operation of industrial facilities and power plants
REVIEW COPY

This chapter looks at static pressure Chapter 5 Flow looks at dynamic pressure

2003 GENERAL PHYSICS CORPORATION REV 2 www.gpworldwide.com

5 of 28

I&C - CHAPTER 3 PRESSURE SENSORS AND DETECTORS ACADBasics@gpworldwide.com

KFI03Lr02_Pressure Sensors and Detectors 08Nov08

KEY POINTS, AIDS, QUESTIONS/ANSWERS

INSTRUCTOR GUIDE
B. Pressure Detector Functions 1. Although the pressures that are monitored vary slightly depending on the details of facility design, all pressure detectors are used to provide up to three basic functions:

Objective 3

1) Indication 2) Alarm 3) Control 2. Since the fluid systems may operate at both saturation and sub-cooled conditions, accurate pressure indication must be available to maintain proper cooling. 3. Some pressure detectors have audible and visual alarms associated with them when specified preset limits are exceeded. 4. Some pressure detector applications are used as inputs to protective features and control functions. 5. If it is necessary to provide isolation between a system and a pressure sensor (i.e., to transmit a signal) then a tube, bellows, or diaphragm may be used. 6. To provide a pressure signal, pressureelectrical switches and transducers are used. a. The pressure signal trips bistables to control processes and displays, and to annunicators in a control room. 7. In a plant, pressures are measured: a. On the suction and discharge sides of pumps b. Inside containers, such as a pressure vessel c. Across orifices that measure fluid flow

REVIEW COPY 2003 GENERAL PHYSICS CORPORATION REV 2 www.gpworldwide.com 6 of 28 I&C - CHAPTER 3 PRESSURE SENSORS AND DETECTORS ACADBasics@gpworldwide.com

KFI03Lr02_Pressure Sensors and Detectors 08Nov08

KEY POINTS, AIDS, QUESTIONS/ANSWERS

INSTRUCTOR GUIDE
8. The measurements are made to: a. Determine volumetric quantities in tanks b. Control turbine inlet steam c. Set safety-relief valves d. A host of other reasons C. Manometers 1. Manometers are one of the oldest, simplest, and most accurate sensors used to measure pressure. a. A manometer is a direct way to measure pressure. b. Frequently manometers are used as a differential pressure detector. c. The manometer differential pressure detector in conjunction with a flow restriction (orifice) can be used to measure flow. 2. The simplest type of manometer is the U-tube manometer. a. It consists of a tube (usually made of glass or another transparent material) bent into the shape of a U with both ends of the tube open.

Figure 3-1 / TP 3-3

ATMOSPHERIC PRESSURE APPLIED PRESSURE ATMOSPHERIC PRESSURE GRADUATED SCALE

b. The tube is then filled with a liquid, usually water or mercury. 1) A basic U-tube manometer is shown in Figure 3-1. c. With both ends of the tube subjected to the same pressure, the fluid levels on each side will be equal.

REVIEW COPY 2003 GENERAL PHYSICS CORPORATION REV 2 www.gpworldwide.com 7 of 28 I&C - CHAPTER 3 PRESSURE SENSORS AND DETECTORS ACADBasics@gpworldwide.com

KFI03Lr02_Pressure Sensors and Detectors 08Nov08

KEY POINTS, AIDS, QUESTIONS/ANSWERS

Figure 3-2 / TP 3-4
ORIFICE PLATE

INSTRUCTOR GUIDE
d. If the pressure applied to one of the tube ends is increased, the water column in the opposite tube end will increase. e. The difference in height between the two levels is equal to the differential pressure.

HIGH PRESSURE TAP

LOW PRESSURE TAP PRESSURE DIFFERENTIAL

Figure 3-3 / TP 3-5

PRESSURE INPUT = ATMOSPHERIC ATMOSPHERIC 2.5 2.0 1.5 1.0 0.5 0.0 PRESSURE INPUT = 2 PSIG ATMOSPHERIC 2.5 2.0 1.5 1.0 0.5 0.0

3. A commonly used manometer is the well-type manometer (Figure 3-3). a. Well-type manometers operate on the same basic principle as the U-tube manometers. b. The major difference is that the tube end connected to the desired area of pressure measurement has a fluid reservoir with a larger area than the tube.

Figure 3-4 / TP 3-6

3 PRESSURE INPUT 1 0 2

4. Another type of manometer is the inclined tube manometer or draft gauge (Error! Reference source not found.). a. It is a variation of the well-type manometer. b. The water column is positioned almost horizontally, not vertically. c. In effect, this lengthens the graduations of the scale. d. This allows smaller changes in pressure to be measured. e. The inclined tube manometer is very accurate but is cumbersome due to its large size.

REVIEW COPY 2003 GENERAL PHYSICS CORPORATION REV 2 www.gpworldwide.com 8 of 28 I&C - CHAPTER 3 PRESSURE SENSORS AND DETECTORS ACADBasics@gpworldwide.com

KFI03Lr02_Pressure Sensors and Detectors 08Nov08

KEY POINTS, AIDS, QUESTIONS/ANSWERS

Figure 3-5 / TP 3-7
P1 P2 FLUID (S) z FLUID (S)

INSTRUCTOR GUIDE
D. U-Tube Manometer 1. A simple, yet accurate, device for measuring differential pressure is a U-tube manometer, represented by Figure 3-5.

R A B

LIQUID (T)

a. It consists of a clear U-shaped tube filled with a liquid (T) that is heavier than the fluid (S) in the system. 2. If the pressures at point 1 (P1) and point 2 (P2) are equal, the level in the manometer will be equal. a. As the flow rate increases, the head loss increases. b. The pressure at point 2 will be lower than the pressure at point 1. 3. If the pressure on one leg (P1) is greater than the pressure on the other leg (P2), the level of liquid (T) rises in the lower pressure leg and lowers in the higher pressure leg. a. The larger the differential pressure, the larger the height difference between the levels in the two legs. b. This difference in the levels is called the reading (R) of the manometer. 4. The relationship between the reading and the differential pressure can be developed by making a pressure balance at positions at the same level in both legs, shown in Error! Reference source not found., as Points A and B. a. Since this fluid is not moving, the pressure at Points A and B are equal.

REVIEW COPY 2003 GENERAL PHYSICS CORPORATION REV 2 www.gpworldwide.com 9 of 28 I&C - CHAPTER 3 PRESSURE SENSORS AND DETECTORS ACADBasics@gpworldwide.com

KFI03Lr02_Pressure Sensors and Detectors 08Nov08

KEY POINTS, AIDS, QUESTIONS/ANSWERS

INSTRUCTOR GUIDE
b. The pressure at point A also equals pressure P1 plus the pressure due to fluid S above point A. c. The pressure at point B equals pressure P2 plus the pressure due to liquid T and fluid S above point B.

Equation 3-1 / TP 3-8 PA = P1 + S (z + R ) PB = P2 + S z + T R

d. These relationships can be expressed mathematically as shown in Error! Reference source not found..

PA = PB
P1 + S z + S R = P2 + S z + T R P1 P2 = R ( T S ) D / P = R ( T S ) Where: PA = pressure at point A (lbf /ft2) P1 = system pressure at location P1 (lbf /ft2) S = density of fluid S (lbm /ft3) z = distance between liquid T and location of P2 (ft)

R = manometer reading (ft) PB = pressure at point B (lbf /ft2) P2 = system pressure at location P2 (lbf /ft2) T = density of liquid T (lbm /ft3) D/P or (P1-P2) = differential pressure (lbf /ft2)

REVIEW COPY 2003 GENERAL PHYSICS CORPORATION REV 2 www.gpworldwide.com 10 of 28 I&C - CHAPTER 3 PRESSURE SENSORS AND DETECTORS ACADBasics@gpworldwide.com

KFI03Lr02_Pressure Sensors and Detectors 08Nov08

KEY POINTS, AIDS, QUESTIONS/ANSWERS

INSTRUCTOR GUIDE
5. Disadvantages if the difference in pressure is too large or the high pressure applied too quickly the fluid can be pushed out of the manometer tube and into the system. a. The manometer must be refilled to be used again. 6. Advantages Inexpensive, simple construction, good for measuring differential pressure, which allows the device to be used to measure pressure, flow, or level. E. Bellows-Type Detectors 1. The need for a pressure-sensing element that was extremely sensitive to low pressures and provided power for activating recording and indicating mechanisms resulted in the development of the metallic bellows pressuresensing element. a. The metallic bellows is most accurate when measuring pressures from 0.5 to 75 psig.

Objective 1a, 1b

1) However, when used in conjunction with a heavy range spring, some bellows can be used to measure pressures of over 1,000 psig. 2. Figure 3-6 shows a basic metallic bellows pressure-sensing element. 3. The bellows is a one-piece, collapsible, seamless metallic unit that has deep folds formed from very thin-walled tubing. a. The diameter of the bellows ranges from 0.5 to 12 in. and may have as many as 24 folds. 4. System pressure is applied to the internal volume of the bellows. 5. As the inlet pressure to the instrument varies, the bellows will expand or contract.

Figure 3-6 / TP 3-9

REVIEW COPY 2003 GENERAL PHYSICS CORPORATION REV 2 www.gpworldwide.com 11 of 28 I&C - CHAPTER 3 PRESSURE SENSORS AND DETECTORS ACADBasics@gpworldwide.com

KFI03Lr02_Pressure Sensors and Detectors 08Nov08

KEY POINTS, AIDS, QUESTIONS/ANSWERS

INSTRUCTOR GUIDE
a. The moving end of the bellows is connected to a mechanical linkage assembly. b. As the bellows and linkage assembly moves, either an electrical signal is generated or a direct pressure indication is provided. 6. The flexibility of a metallic bellows is similar in character to that of a helical coiled compression spring.

See Materials Science for more details

7. Up to the elastic limit1 of the bellows, the relation between increments of load and deflection is linear. a. However, this relationship exists only when the bellows is under compression. 8. It is necessary to construct the bellows such that all of the travel occurs on the compression side of the point of equilibrium. a. Therefore the bellows must always be opposed by a spring, and the deflection characteristics will be the resulting force of the spring and bellows. F. Bourdon Tube-Type Detectors

Objective 2a, b

1. The bourdon tube pressure instrument is one of the oldest pressure sensing instruments in use today. a. The bourdon tube (refer to Figure 3-7) consists of a thin-walled tube that is flattened to produce a cross-sectional area elliptical in shape, having two long flat sides and two short round sides. 1) The tube is bent lengthwise into an arc of a circle of 270 to 300 degrees. 2) The tube is permanently fastened at one end.

Figure 3-7 / TP 3-10

More detail on elastic limit provided in Material Science. REVIEW COPY 12 of 28 I&C - CHAPTER 3 PRESSURE SENSORS AND DETECTORS ACADBasics@gpworldwide.com

2003 GENERAL PHYSICS CORPORATION REV 2 www.gpworldwide.com

KFI03Lr02_Pressure Sensors and Detectors 08Nov08

KEY POINTS, AIDS, QUESTIONS/ANSWERS

INSTRUCTOR GUIDE
a. Recall from basic electrical theory that the current flow through an inductor is found by the applied voltage divided by the inductive reactance. b. The inductive reactance is directly proportional to the frequency and the inductance. c. Inductance is a characteristic of the coil itself AND the core. d. If more of the magnetic core moves into the coil, the inductance increases. e. Less in the core and inductance decreases. f. Therefore, the current through the coil will increase as the inductance decreases (core moves out of coil) and decrease as the inductance increases (core moves into coil).

Figure 3-16 / TP 3-21

NON-CONDUCTIVE TUBE MOVEABLE IRON CORE

CENTER TAP

AC COILS

4. For increased sensitivity, the coil can be separated into two coils by utilizing a center tap, represented by the line between the AC sources shown in Figure 3-16. a. As the core moves within the coils, the inductance of one coil will increase, while the other will decrease. 5. Another type of inductance transducer, illustrated in Figure 3-17, utilizes two coils wound on a single tube and is commonly referred to as a Differential Transformer. 6. Recall from Electrical Science that to generate an electrical current the only things required are a magnetic field, a conductor to carry the current, and relative motion between the magnetic field and the conductor. a. In this arrangement the primary coil supplied with an AC current provides the magnetic field.
REVIEW COPY

AC

FORCE PRESSURE DETECTOR

Figure 3-17 / TP 3-22

NON-CONDUCTIVE TUBE MOVEABLE IRON CORE

OUTPUT

AC INPUT PRIMARY COIL

FORCE PRESSURE DETECTOR

2003 GENERAL PHYSICS CORPORATION REV 2 www.gpworldwide.com

26 of 28

I&C - CHAPTER 3 PRESSURE SENSORS AND DETECTORS ACADBasics@gpworldwide.com

KFI03Lr02_Pressure Sensors and Detectors 08Nov08

KEY POINTS, AIDS, QUESTIONS/ANSWERS

INSTRUCTOR GUIDE
b. As the alternating current flows through the primary coil the magnetic field created expands and collapses. c. The magnetic field is expands and collapses across the secondary coils, which creates relative motion. d. The wire in the secondary coils provides current carrying conductor, thus the requirements to generate electricity have been met. e. The primary coil is wound around the center of the tube. f. The secondary coil is divided with one half wound around each end of the tube. 1) Each end is wound in the opposite direction, which causes the voltages induced to oppose one another. g. A core, positioned by a pressure element, is movable within the tube. h. When the core is in the lower position, the lower half of the secondary coil provides the output. i. When the core is in the upper position, the upper half of the secondary coil provides the output. 7. The magnitude and direction of the output depends on the amount the core is displaced from its center position. a. When the core is in the mid-position, there is no secondary output. D. Variable Capacitance Transducers 1. A variable capacitance detector is a differential pressure cell that uses a capacitance type pressure sensor.

REVIEW COPY 2003 GENERAL PHYSICS CORPORATION REV 2 www.gpworldwide.com 27 of 28 I&C - CHAPTER 3 PRESSURE SENSORS AND DETECTORS ACADBasics@gpworldwide.com

KFI03Lr02_Pressure Sensors and Detectors 08Nov08

KEY POINTS, AIDS, QUESTIONS/ANSWERS

INSTRUCTOR GUIDE
2. It converts differential pressure to flow, level, or pressure.

Figure 3-18 / TP 3-23

3. Capacitive-type detectors, illustrated in Figure 3-18, consist of two flexible conductive plates and a dielectric. a. In this case, the dielectric is the fluid. 4. As pressure increases, the flexible conductive plates will move farther apart, changing the capacitance of the transducer. a. This change in capacitance is measurable and is proportional to the change in pressure. IV. SUMMARY

Direct trainees to refer to learning objectives in the student text. Point out where answers may be found in student text.

A. Review all objectives ensuring student understanding

B. Evaluation Ask Summary Questions following to ensure trainees mastery of objectives. 1. Informal evaluations during class 2. Formal evaluations with a. Quizzes b. Chapter Tests c. Final Examination C. Closing Remarks Point out how the lessons learned in this class are applicable to future lessons and plant applications.

REVIEW COPY 2003 GENERAL PHYSICS CORPORATION REV 2 www.gpworldwide.com 28 of 28 I&C - CHAPTER 3 PRESSURE SENSORS AND DETECTORS ACADBasics@gpworldwide.com