This is Atul training Report. . . Which We made during One Month Vocational Training at Atul Chemical Ltd, Valsad, Gujarat

1. A
PROJECT REPORT
ON
STUDY OF DIFFERENT TYPES OF FIELD
INSTRUMENTS
Prepared by:
1) MiteshkumarChandubhaiDomadiya (ID no. 093008)
2) Amit VinubhaiKachhadiya(ID no. 093015)
3) BhaveshkumarParabatbhaiKachhot(ID no. 093016)
4) Dhara Yogeshbhai Patel (ID no. 093030)
5) Hardik Pravinbhai Lad (ID no. 093017)
Guided by:
Prof. Ashish G. Patel,Mr. Bhagvan J. Koshti,
Instrumentation & Control Department, Manager (Instrumentation),
Faculty of Technology, Color Division,
Dharmsinh Desai University, Site-West,
Nadiad– 387001. Atul Ltd.,

2. Atul- 396
020
Faculty of Technology
Dharmsinh Desai University
Nadiad – 387 001
Certificate
This is to certify that the work reported in this Project Report titledTo Study of
Different Types of Field Instrumentsis the bonafide work of Mr. /
MissMiteshkumarChandubhaiDomadiya, Roll No. IC-11, Identity No. 093008 of
Bachelor of Technology Semester-VI in the branch of Instrumentation & Control
Engineering, during the academic year 2011-2012.
Prof. Ashish G. Patel Prof. Saurin R. Shah

3. Project Guide Head of the Department
Faculty of Technology
Dharmsinh Desai University
Nadiad – 387 001
Certificate
This is to certify that the work reported in this Project Report titledTo Study of
Different Types of Field Instrumentsis the bonafide work of Mr. /
MissBhaveshkumarParabatbhaiKachhot, Roll No. IC-17, Identity No. 093016 of
Bachelor of Technology Semester-VI in the branch of Instrumentation & Control
Engineering, during the academic year 2011-2012.
Prof. Ashish G. Patel Prof. Saurin R. Shah
Project Guide Head of the Department

4. Faculty of Technology
Dharmsinh Desai University
Nadiad – 387 001
Certificate
This is to certify that the work reported in this Project Report titledTo Study of
Different Types of Field Instrumentsis the bonafide work of Mr. / MissDhara
Yogeshbhai Patel, Roll No. IC-11, Identity No. 093008 of Bachelor of Technology
Semester-VI in the branch of Instrumentation & Control Engineering, during the
academic year 2011-2012.
Prof. Ashish G. Patel Prof. Saurin R. Shah
Project Guide Head of the Department

5. Faculty of Technology
Dharmsinh Desai University
Nadiad – 387 001
Certificate
This is to certify that the work reported in this Project Report titledTo Study of
Different Types of Field Instrumentsis the bonafide work of Mr. / MissHardik
Pravinbhai Lad, Roll No. IC-18, Identity No. 093017 of Bachelor of Technology
Semester-VI in the branch of Instrumentation & Control Engineering, during the
academic year 2011-2012.
Prof. Ashish G. Patel Prof. Saurin R. Shah
Project Guide Head of the Department

6. Faculty of Technology
Dharmsinh Desai University
Nadiad – 387 001
Certificate
This is to certify that the work reported in this Project Report titledTo Study of
Different Types of Field Instrumentsis the bonafide work of Mr. / MissAmit
VinubhaiKachhadiya,, Roll No. IC-16, Identity No. 093015 of Bachelor of
Technology Semester-VI in the branch of Instrumentation & Control Engineering,
during the academic year 2011-2012.
Prof. Ashish G. Patel Prof. Saurin R. Shah
Project Guide Head of the Department

7. ACKNOWLEDGEMENT
We would take an immense pleasure in thanking our guide Mr. BhagvanJ. Koshti (Manager of–
Instrumentation Division), and our mentorMr. Bharat Patel well as other engineers and staff for
imparting us technical and practical knowledge. They helped us in understanding various
technical aspects, by practical applications with a lot of patience, consideration and concern.
In addition to, we have a respect for all the technicians of the organization who helped us a lot
in nurturing our technical aspects.

8. CONTENTS
CHAPTER NO CHAPTER TITLE
1 INTRODUCTION
2 TEMPERATURE MEASUREMENT
3 LEVEL MEASUREMENT
4 FLOW MEASUREMENT
5 PRESSURE MEASUREMENT
6 OTHER FIELD INSTRUMENTS
7 CONTROL VALVES

9. CHAPTER-1
INTRODUCTION
Company Profile:
Atul Limited is a member of the Lalbhai Group, one of the oldest business houses in India.
Today, Atul is one of India's largest integrated chemical companies, with a turnover of Rs 1500
crore. The Company is rated among the top five global producers in several niche chemicals; it
serves a number of industries in India, as well as around the world, in the fields of aerospace,
automobiles, agriculture, construction, fragrance and flavors, and paper and textiles.
History:
ATUL, nestled within the green and tranquil environs, is one of the largest chemical complexes
of its kind in Asia, a dream of a farsighted and enlightened industrialists, the late Shri
KasturbhaiLalbhai.
The story of ATUL began in 1945, when Shri KasturbhaiLalbhai met Mr. Sidney C Moodey, the n
the President of American Cyanamid, and the idea of setting up a Dyestuff unit in India was
conceived. This was the time when the independence moment in India has reached a
crescendo, and the desire to be self- reliant was widely prevalent. Shri KasturbhaiLalbhai saw, in
this proposal, self-reliance for India in Dyes on the one hand, and backward integration of his
businesses of textiles on the other. It was Shri B K Muzumdar, a scholar and economist, who
translated Shri KasturbhaiLalbhai’s vision in to reality.
In 1947, ATUL, meaning ‘Incomparable’, was set up on bank of the river Par, in Valsad District in
Gujarat, 200km north of Mumbai. The first manufacturing plant was inaugurated by India’s first
Prime Minister Pandit Jawaharlal Nehru. From a modest beginning with few dyes, ATUL ltd has
today emerged as a chemical giant, manufacturing an extensive range of dyes, Agrochemicals,
Basic chemicals, Bulk drugs, Speciality chemical, Polymers, Pharmaceuticals and Intermediates
thereof.

10. Over the years ATUL joined hands with American Cyanamid Imperical Chemical Industries (ICI),
saw spun off to Zeneca and Ciba-Geigy to promote Cyanamid India, Atic Industries and Cibatul
ltd respectively. In 1995, Zeneca diversted its shareholding in Atic to ATUL thereby Broadening
the product range of Dyes in ATUL. In 1999, Cibatul also merged with ATUL. A giant chemical
complex, spread over 1200 acres of afforested land, was once a barren and backward area. The
complex provides direct employment to about 2700 people.
Atul is one of India's largest integrated chemical companies and among the top five global
producers of several niche chemicals. The Company caters to the aerospace, automobiles,
agriculture, construction, fragrance and flavors, and paper and textiles industries. Atul produces
over 700 diverse products through its seven business divisions:
1)Aromatics
2)Colors
3)Crop Protection
4)Floras
5)Pharma& Inters
6)Polymers
We at the Atul Limited are placed in Colors (CO) Division for undergoing our UG level Project.
Colors (CO) Division:
Colors division is the largest business division of ATUL ltd, manufacturing a wide range of
dyestuffs for the textiles, leather, paper, wool and silk industries. The CO division is one of the
leading supplier of dyestuffs in India and export nearly 55% of its production to more than 75
countries worldwide. It has a wide range of over 350 dyes.
The division manufacturing operation started with sulphur dyes in 1952. In quick succession,
other classes of dyes were added to the product range making ATUL as a pioneer in its field of
business.

11. Atic Industries ltd, a 50:50 joint venture between ATUL ltd and Zeneca plc was established in
1955. Off late 1995, when Zeneca decided to diversted its textile colors business worldwide,
ATUL bought over Zeneca’s stake in Atic Industries. Subsequently in the same year, Atic
industries was amalgamated in to ATUL and the integrated dyestuff business was formed under
the umbrella of CO division.
The range of dyes offered are:
*Acid dyes *Dye intermediates
*Azoic coupling components *Fluorescent brightening agents
*Azoic developing components *Reactive dyes
*Disperse dyes *Sulphur dyes
*Direct dyes *Vat dyes
The Colors Division has received a highest export award for a large scale unit(2002-03) by
Dyestuff Manufacturer’s Association of India.
We also have received ISO 9001 Certificate. We are a member of ETAD.
Besides India, major market for colors are Germany, USA, Bangladesh, UK, Switzerland, China,
Turkey, Mauritania, Brazil, Hong Kong, Egypt, Italy, Spain and Australia.

12. CHAPTER-2
TEMPERATURE MEASUREMENT
What is temperature?
Temperature is a measure of the average heat or thermal energy of the particles in a substance.
Temperature does not depend on the size or type of object.
The sensors used for measuring temperature are listed below
Different types of thermometers
Thermocouples
Resistance thermometer
Pyrometers etc.
They are used according to their range.
Temperature measures in different four scales named Fahrenheit, Centigrade, Kelvin, Rankine
and Reaumur.
In industries most commonly temperature measures in Fahrenheit and Centigrade.

13. 1) RESISTANCETEMPERATURE DETECTOR:
Resistance thermometers, also called resistance temperature detectors (RTDs), are sensors
used to measure temperature by correlating the resistance of the RTD element with
temperature. Most RTD elements consist of a length of fine coiled wire wrapped around a
ceramic or glass core. The element is usually quite fragile, so it is often placed inside a sheathed
probe to protect it. The RTD element is made from a pure material whose resistance at various
temperatures has been documented. The material has a predictable change in resistance as the
temperature changes; it is this predictable change that is used to determine temperature.
A RTD Sensing element consists of a wire coil or deposited film of pure metal. The element’s
resistance increases with temperature in a known and repeatable manner. RTD’s exhibit
excellent accuracy over a wide temperature range.
 Temperature range: -200 to 700ºC
 Sensitivity: the voltage drop across an RTD provides a much larger output than a
thermocouple.
 Linearity: Platinum and copper RTD’s produce a more linear response than thermocouples or
thermistors. RTD non-linearities can be corrected through proper design of resistive bridge
networks.
The most commonly used element material is platinum with a resistance of 100 ohms @ 0ºC
and a temperature coefficient (Alpha) of 0.00385 ohms/ohm/ºC.
Other element materials also used are copper, nickel and nickel-iron. Platinum elements
predominate because of their wider range, and because platinum is the most repeatable and
stable of all metals.
Tolerance of PT100 Ω (Alpha = 0.003850 @ 0ºC)

14. Connection / Wiring details:
Different connection Types. Standard Color code; A is white, B is red.
Basic connection where the lead is short. No lead wire
2 wire
compensation, introducing an error into the reading.
Most common connection 3 wire, the instrument
measures the lead wire resistance in the B legs and
allows for this in its reading.
3 wire
4 wire connection is the most accurate measurement.
4 wire The instrument measures the lead resistance of all four
lead wires removing these values for its reading

15. Duplex Duplex 3 wire RTD connection as per single RTD but
RTD two individual element windings.
Classes OfRTD :
TOLERANCE CLASS A B
TOLERANCE 0.06% 0.12%
RANGE -200°C to 650°C -200°C to 850°C
RTD Element Types:
There are three main categories of RTD sensors.
Thin Film
Wire-Wound
Coiled Elements
Thin Film Elements have a sensing element that is formed by depositing a very thin layer
of resistive material, normal platinum, on a ceramic substrate. This layer is usually just
10 to 100 angstroms (1 to 10 nanometers) thick. This film is then coated with an epoxy
or glass that helps protect the deposited film and also acts as a strain relief for the
external lead-wires. Disadvantages of this type are that they are not as stable as their
wire wound or coiled counterparts. They also can only be used over a limited
temperature range due to the different expansion rates of the substrate and resistive
deposited giving a "strain gauge" effect that can be seen in the resistive temperature
coefficient. These elements work with temperatures to 300 °C.

16. Wire-wound Elements can have greater accuracy, especially for wide temperature ranges. The
coil diameter provides a compromise between mechanical stability and allowing expansion of
the wire to minimize strain and consequential drift. The sensing
wire is wrapped around an insulating mandrel or core. The winding core can be round or
flat, but must be an electrical insulator. The coefficient of thermal expansion of the
winding core material is matched to the sensing wire to minimize any mechanical strain.
This strain on the element wire will result in a thermal measurement error. The sensing
wire is connected to a larger wire, usually referred to as the element lead or wire. This
wire is selected to be compatible with the sensing wire so that the combination does
not generate an emf that would distort the thermal measurement. These elements work
with temperatures to 660 °C.

17. Coiled elements have largely replaced wire-wound elements in industry. This design has
a wire coil which can expand freely over temperature, held in place by some mechanical
support which lets the coil keep its shape. This “strain free” design allows the sensing
wire to expand and contract free of influence from other materials; in this respect it is
similar to the SPRT, the primary standard upon which ITS-90 is based, while providing
the durability necessary for industrial use. The basis of the sensing element is a small
coil of platinum sensing wire. This coil resembles a filament in an incandescent light
bulb. The housing or mandrel is a hard fired ceramic oxide tube with equally spaced
bores that run transverse to the axes. The coil is inserted in the bores of the mandrel
and then packed with a very finely ground ceramic powder. This permits the sensing
wire to move while still remaining in good thermal contact with the process. These
Elements works with temperatures to 850 °C.

18. The current international standard which specifies tolerance, and the temperature-to-electrical
resistance relationship for platinum resistance thermometers is IEC 60751:2008, ASTM E1137 is
also used in the United States. By far the most common devices used in industry have a nominal
resistance of 100 ohms at 0 °C, and are called Pt100 sensors ('Pt' is the symbol for platinum).
The sensitivity of a standard 100 ohm sensor is a nominal 0.00385 ohm/°C. RTDs with a
sensitivity of 0.00375 and 0.00392 ohm/°C as well as a variety of others are also available.
Advantages Of RTD:
High accuracy
Low drift
Wide operating range
Suitability for precision applications
Limitations Of RTD:
RTDs in industrial applications are rarely used above 660 °C. At temperatures above 660 °C it
becomes increasingly difficult to prevent the platinum from becoming contaminated by
impurities from the metal sheath of the thermometer. This is why laboratory standard
thermometers replace the metal sheath with a glass construction. At very low temperatures,
say below -270 °C (or 3 K), because there are very few photons, the resistance of an RTD is
mainly determined by impurities and boundary scattering and thus basically independent of
temperature. As a result, the sensitivity of the RTD is essentially zero and therefore not useful.
Compared to thermistors, platinum RTDs are less sensitive to small temperature changes and
have a slower response time. However, thermistors have a smaller temperature range and
stability.

19. 2) THERMOCOUPLE:
One of the most common industrial thermometer is the thermocouple. A thermocouple is a
device consisting of two different conductors (usually metal alloys) that produce a voltage,
proportional to a temperature difference, between either ends of the two conductors.
Thermocouples are a widely used type of temperature sensor for measurement and control
and can also be used to convert a temperature gradient into electricity. They are inexpensive,
interchangeable, are supplied with standard connectors, and can measure a wide range of
temperatures. In contrast to most other methods of temperature measurement,
thermocouples are self powered and require no external form of excitation. The main limitation
with thermocouples is accuracy and system errors of less than one degree Celsius(C) can be
difficult to achieve.
Any junction of dissimilar metals will produce an electric potential related to temperature.
Thermocouples for practical measurement of temperature are junctions of specific alloys which
have a predictable and repeatable relationship between temperature and voltage. Different
alloys are used for different temperature ranges. Properties such as resistance to corrosion may
also be important when choosing a type of thermocouple. Where the measurement point is far
from the measuring instrument, the intermediate connection can be made by extension wires
which are less costly than the materials used to make the sensor. Thermocouples are usually
standardized against a reference temperature of 0 degrees Celsius; practical instruments use
electronic methods of cold-junction compensation to adjust for varying temperature at the
instrument terminals. Electronic instruments can also compensate for the varying
characteristics of the thermocouple, and so improve the precision and accuracy of
measurements.
Thermocouples are widely used in science and industry; applications include temperature
measurement forkilns, gas turbine exhaust, diesel engines, and other industrial processes.

20. A thermocouple measuring circuit with a heat source, cold junction and a measuring
instrument.
Principle of operation:
In 1821, the German–Estonian physicist Thomas JohannSeebeck discovered that when any
conductor is subjected to a thermal gradient, it will generate a voltage. This is now known as
the Thermoelectric effect or Seebeck effect. Any attempt to measure this voltage necessarily
involves connecting another conductor to the "hot" end. This additional conductor will then
also experience the temperature gradient, and develop a voltage of its own which will oppose
the original. Fortunately, the magnitude of the effect depends on the metal in use. Using a
dissimilar metal to complete the circuit creates a circuit in which the two legs generate
different voltages, leaving a small difference in voltage available for measurement. That
difference increases with temperature, and is between 1 and 70 microvolts per degree Celsius
(µV/°C) for standard metal combinations.
The voltage is not generated at the junction of the two metals of the thermocouple but rather
along that portion of the length of the two dissimilar metals that is subjected to a temperature
gradient. Because both lengths of dissimilar metals experience the same temperature gradient,
the end result is a measurement of the difference in temperature between the thermocouple
junction and the reference junction.

21. Types Of Thermocouple:
Certain combinations of alloys have become popular as industry standards. Selection of the
combination is driven by cost, availability, convenience, melting point, chemical properties,
stability, and output. Different types are best suited for different applications. They are usually
selected based on the temperature range and sensitivity needed. Thermocouples with low
sensitivities (B, R, and S types) have correspondingly lower resolutions. Other selection criteria
include the inertness of the thermocouple material, and whether it is magnetic or not. Standard
thermocouple types are listed below with the positive electrode first, followed by the negative
electrode.
K Type:
Type K (chromel {90 percent nickel and 10 percent chromium} – alumel {95% nickel, 2%
manganese, 2% aluminium and 1% silicon}) is the most common general purpose thermocouple
with a sensitivity of approximately 41 µV/°C, chromel positive relative to alumel. It is
inexpensive, and a wide variety of probes are available in its −200 °C to +1350 °C / -328 °F to
+2462 °F range. Type K was specified at a time when metallurgy was less advanced than it is
today, and consequently characteristics may vary considerably between samples. One of the
constituent metals, nickel, is magnetic; a characteristic of thermocouples made with magnetic
material is that they undergo a deviation in output when the material reaches its Curie point;
this occurs for type K thermocouples at around 350 °C .
E Type:
Type E (chromel–constantan) has a high output (68 µV/°C) which makes it well suited to
cryogenic use. Additionally, it is non-magnetic.
J Type:
Type J (iron–constantan) has a more restricted range than type K (−40 to +750 °C), but higher
sensitivity of about 55 µV/°C. The Curie point of the iron (770 °C) causes an abrupt change in
the characteristic, which determines the upper temperature limit.
N Type:
Type N (Nicrosil–Nisil) (nickel-chromium-silicon/nickel-silicon) thermocouples are suitable for
use between −270 °C and 1300 °C owing to its stability and oxidation resistance. Sensitivity is
about 39 µV/°C at 900 °C, slightly lower compared to type K.

22. Platinum Type Thermocouple:
Types B, R, and S thermocouples use platinum or a platinum–rhodium alloy for each conductor.
These are among the most stable thermocouples, but have lower sensitivity than other types,
approximately 10 µV/°C. Type B, R, and S thermocouples are usually used only for high
temperature measurements due to their high cost and low sensitivity.
B Type:
Type B thermocouples use a platinum–rhodium alloy for each conductor. One conductor
contains 30% rhodium while the other conductor contains 6% rhodium. These thermocouples
are suited for use at up to 1800 °C. Type B thermocouples produce the same output at 0 °C and
42 °C, limiting their use below about 50 °C.
R Type:
Type R thermocouples use a platinum–rhodium alloy containing 13% rhodium for one
conductor and pure platinum for the other conductor. Type R thermocouples are used up to
1600 °C.
S Type:
Type S thermocouples are constructed using one wire of 90% Platinum and 10% Rhodium (the
positive or "+" wire) and a second wire of 100% platinum (the negative or "-" wire). Like type R,
type S thermocouples are used up to 1600 °C. In particular, type S is used as the standard of
calibration for the melting point of gold (1064.43 °C).
TType:
Type T (copper–constantan) thermocouples are suited for measurements in the −200 to 350 °C
range. Often used as a differential measurement since only copper wire touches the probes.
Since both conductors are non-magnetic, there is no Curie point and thus no abrupt change in
characteristics. Type T thermocouples have a sensitivity of about 43 µV/°C.
CType:
Type C (tungsten 5% rhenium – tungsten 26% rhenium) thermocouples are suited for
measurements in the 0 °C to 2320 °C range. This thermocouple is well-suited for vacuum
furnaces at extremely high temperatures. It must never be used in the presence of oxygen at
temperatures above 260 °C.

23. MType:
Type M thermocouples use a nickel alloy for each wire. The positive wire (20 Alloy) contains
18% molybdenum while the negative wire (19 Alloy) contains 0.8% cobalt. These
thermocouples are used in vacuum furnaces for the same reasons as with type C. Upper
temperature is limited to 1400 °C. It is less commonly used than other types.
Advantages with thermocouples:
Capable of being used to directly measure temperatures up to 2600 oC.
The thermocouple junction may be grounded and brought into direct contact with the
material being measured.

24. Disadvantages with thermocouples:
Temperature measurement with a thermocouple requires two temperatures be
measured, the junction at the work end (the hot junction) and the junction where wires
meet the instrumentation copper wires (cold junction). To avoid error the cold junction
temperature is in general compensated in the electronic instruments by measuring the
temperature at the terminal block using with a semiconductor, thermistor, or RTD.
Thermocouples operation are relatively complex with potential sources of error. The
materials of which thermocouple wires are made are not inert and the thermoelectric
voltage developed along the length of the thermocouple wire may be influenced by
corrosion etc.
The relationship between the process temperature and the thermocouple signal (mill
volt) is not linear.
The calibration of the thermocouple should be carried out while it is in use by
comparing it to a nearby comparison thermocouple. If the thermocouple is removed
and placed in a calibration bath, the output integrated over the length is not
reproduced exactly.
RTDs vs Thermocouples:
Basic differences between RTDs and Thermocouples are given below:
RTD THERMOCUPLE
Temperature Requirement -200 to 500 °C -180 to 2,320 °C
Time Response Slow Fast
Size (Sheath Diameter) 3.175 to 6.35 mm 1.6 mm
Accuracy And Stability High Low

25. 3) DIGITAL TEMPERATURE INDICATOR:
Under the category of temperature measuring instruments, we offer technically advanced
digital temperature indicators and controllers. These are available with us in models DTIP and
DTCP in which indicators or controllers are housed in flameproof casing. These modals are duly
certified by CMRI as per gas group II A and II B of IS 2148. Some technical specifications of these
measurement instruments are following:
Digital Temperature Indicator:
Temperature Range : -20OC to 600OC (J Type) Fe/Constant, -50OC to 1200OC (K Type)
Cr/Alumel, -50OC to 199.9OC RTD (Pt 100), -50OC to 300OC RTD (Pt 100)
Display : 3 ', Oigil 12.5 mm hi Red LED
Resolution : 1° C tor T/C and RTD - 50° C lo 199 9" C, 0.1°C(PI-100)RTD
Accuracy : 0.5% of FSD /- 1count
Power Supply : 230VAC ±10% 50 Hz
Compensation : Automatic Cold junction compensation using solid state circuitry (built
in) over a range of 0°C to 5O°C for T/C type 3 wire system for RTD
Open Sensor : Display shows "1" at MSD
Overall Dimension : 96 X 96 X110 (D) mm
Panel Cutout : 92 X 92 mm

26. CHAPTER-3
LEVEL MEASUREMENT
The height of the water column, liquid and powder etc., at the desired measurement of
height between minimum level point to maximum level point is called level.
Level is measure with the help level gauges (sight glasses), other level meters etc.
1) ULTRASONIC LEVELTRANSMITTER:
Measures by Reflected Ultrasound
The Ultrasonic Level Transmitter allows simple and reliable non-contact level measurement of
fluids in a tank, sump or other container. The microprocessor-controlled circuit generates a
pulse that is transmitted from the transducer face. This pulse is reflected back from the surface
of the liquid. The "round trip" transit time is then converted into the current output, which is
directly proportional to the fluid level.
The current output (4-20mA) can power a load of up to 750 ohms.

27. Specifications
Electrical specification:
Power 100 to 230 VAC ,50/60 HZ ,18 to 30 V DC
Fuse Slow-Blow ,0.25 A , 250 VAC
Repeatability 0.25 % of full range
Reasolution 3 mm
Output Relay 2 form c (SPDT)
Contacts , Rated
5 A at 250 VAC ,
Non inductive
Environment specification:
Location Indoor / Outdoor
Temperature range -40 to 60 C
Relative Humidity Type 6 , NEMA 6 , IP 67 Enclousure
Process Pressure 0.5 Bar
Mechanical specification:
Switching range Liquids : 0.25 to 5 m
Solids : 0.25 to 3 m
Enclosure Terminal block ,
Material : plastic

28. 2) RADAR LEVEL TRANSMITTER:

29. The distance to the surface is measured by shortradar pulses, which are transmitted from the
antenna at the tank top. When a radar pulse reaches a media with a differentdielectric
constant, part of the energy is reflected back to the transmitter. The time difference between
the transmitted and the reflected pulse is proportionalto the distance, from which the level,
volume and level rate, are calculated.
Environmental Influence
Temperature Pressure Vapour Mist Product Density Turbulences
No influence Slightly No influence No influence Little influence
dependent
RADAR vs ULTRASONIC LEVEL TRANSMITTER:
RADAR ULTRASONIC
RANGE 1.5 to 780 inch. 1 ft to 20 ft
MEASURE Liquid(also in highly Liquid
inflammable), solid
ACCURACY +/- 0.12 inch. Closer to 5mm
PROCESS MOUNT ¾ inch. NPT 2 inch. NPT
CERTIFICATION Standard: NEMA 6 Intrinsically safe, Zone 0
Optional:Explosion proof,
Zone 1

30. CHAPTER-4
FLOW MEASUREMENT
Measurement of quantity which is flowing through close surface is known as flow.
Basically flow measurement is classified in three categories:
Instantaneous flow measurement
Total flow measurement
Mass flow measurement
1) MAGNETIC FLOW METER:
BASIC PRINCIPLE: Faraday's law of electromagnetic induction.
Magnetic flow metersuse a magnetic field applied to the metering tube, which results in a
potential difference proportional to the flow velocity perpendicular to the flux lines. The
potential difference is sensed by electrodes aligned perpendicular to the flow and the applied
magnetic field.

31. The magnetic flow meter requires a conducting fluid and a non conducting pipe liner. The
electrodes must not corrode in contact with the process fluid; some magnetic flow meters have
auxiliary transducers installed to clean the electrodes in place. The applied magnetic field is
pulsed, which allows the flow meter to cancel out the effect of stray voltage in the piping
system.
A magnetic flowmeter is a device that can measure a water-based or conductive volumetric
flow with no moving parts.

32. 2) VORTEX FLOW METER:
Another method of flow measurement involves placing a bluff body (called a shedder bar) in
the path of the fluid. As the fluid passes this bar, disturbances in the flow called vortices are
created. The vortices trail behind the cylinder, alternatively from each side of the bluff body.
The frequency at which these vortices alternate sides is essentially proportional to the flow rate
of the fluid. Inside, atop, or downstream of the shedder bar is a sensor for measuring the
frequency of the vortex shedding. This sensor is often a piezoelectric crystal, which produces a
small, but measurable, voltage pulse every time a vortex is created. Since the frequency of such
a voltage pulse is also proportional to the fluid velocity, a volumetric flow rate is calculated
using the cross sectional area of the flow meter.
The frequency is measured and the flow rate is calculated by the flowmeter electronics using
the equation where is the frequency of the vortices, the characteristic
length of the bluff body, is the velocity of the flow over the bluff body, and is the Strouhal
number, which is essentially a constant for a given body shape within its operating limits.
Benefits:
Maintenance-free due to fully welded sensor construction providing excellent stability and
reliability
Contains three measuring points in one device with no extra equipment, installation or cabling
costs
Saves downtime because of isolation valve, which makes an exchange of pressure sensor
possible without interrupting the process

33. Easy installation because of Plug & Play
Redundant system as a dual transmitter version is available

34. CHAPTER-5
PRESSURE MEASUREMENT
It is defined as amount of force applied to a surface & it is measured as force per unit
area. The essentials of pressure measurement are encompassed in the above definitions &
following observations.
1. Pressure is independent of direction.
2. Pressure is unaffected by the shape of confining boundaries.
Types of pressure
Gauge pressure: (Kg/cm2)
It is the difference between absolute and atmospheric pressure.
Absolute pressure: (Kg/cm2)
It is actual total pressure acting on a surface.
Vacuum pressure:
It is the pressure having value below zero.
Static pressure:
It is pressure at a particular point when the fluid is in equilibrium.
Different scales of pressure:
Pound per sq. in. (PSI)
Pascal (Pa)
Atmospheric pressure (atm)
Pieze
Torr
mmHg
kg/cm2

35. 1) PRESSURE GUAGE:
Most standard dial type pressure gauges use a bourdon tube-sensing element
generally made of a copper alloy (brass) or stainless steel for measuring
pressures 15 PSI and above. Bourdon tube gauges are widely used in all branches
of industry to measure pressure and vacuum. The construction is simple yet
rugged and operation does not require any additional power source.The C-
shaped or spirally wound bourdon tube flexes when pressure is applied
producing a rotational movement, which in turn causes the pointer to indicate
the measured pressure. These gauges are generally suitable for all clean and
non-clogging liquids and gaseous media. Low pressure gauges typically use an
extremely sensitive and highly accurate capsule design for measuring gaseous
media from as low as 15 INWC to 240 INWC (10 PSI). Digital gauges use an
electronic pressure sensor to measure the pressure and then transmit it to a
digital display readout.
TYPES OF PRESSURE GUAGE:
1) Industrial gauges
2) Commercial gauges
3) Digital guages
4) Process gauges
5) Precision & Test gauges
6) Low pressure gauges
7) Specialty gauges
CALIBRATION:
Pressure gauges are either direct- or indirect-reading. Hydrostatic and elastic gauges measure
pressure are directly influenced by force exerted on the surface by incident particle flux, and
are called direct reading gauges. Thermal and ionization gauges read pressure indirectly by
measuring a gas property that changes in a predictable manner with gas density. Indirect
measurements are susceptible to more errors than direct measurements.

36.  Dead-weight tester
 McLeod
 mass spec + ionization

37. 2) DEAD WEIGHT PRESSURE TESTER:
A dead weight tester apparatus uses known traceable weights to apply
pressure to a fluid for checking the accuracy of readings from a pressure
gauge. A dead weight tester (DWT) is a calibration standard method that
uses a piston cylinder on which a load is placed to make an equilibrium with
an applied pressure underneath the piston. Deadweight testers are so
called primary standards which means that the pressure measured by a
deadweight tester is defined through other quantities: length, mass and
time. Typically deadweight testers are used in calibration laboratories to
calibrate pressure transfer standards like electronic pressure measuring
devices.

38. CHAPTER-6
OTHER FIELD INSTRUMENTS
1) ORIFICE PLATES & FLANGES:
An orifice plate is a device used for measuring the volumetric flow rate. It uses
the same principle as a Venturi nozzle, namely Bernoulli's principle which states
that there is a relationship between the pressure of the fluid and the velocity of
the fluid. When the velocity increases, the pressure decreases and vice versa.
An orifice plate is a thin plate with a hole in the middle. It is usually placed in a
pipe in which fluid flows. When the fluid reaches the orifice plate, the fluid is
forced to converge to go through the small hole; the point of maximum
convergence actually occurs shortly downstream of the physical orifice, at the
so-called vena contracta point. As it does so, the velocity and the pressure
changes. Beyond the vena contracta, the fluid expands and the velocity and
pressure change once again. By measuring the difference in fluid pressure
between the normal pipe section and at the vena contracta, the volumetric and
mass flow rates can be obtained from Bernoulli's equation.
There are three types of orifice plates:
1) Concentric
2) Eccentric
3) Segmental

39. FLANGE:A protruding rim, edge, rib, or collar, as on a wheel or a pipe shaft,
used to strengthen an object, hold it in place, or attach it to another object.

40. 2) I to P CONVERTER:
"current to pressure" converter (I/P) which converts an analog signal (4-20 mA) to a
proportional linear pneumatic output (3-15 psig). I To P Converter's purpose is to
translate the analog output from a control system into a precise, repeatable
pressure value to control pneumatic actuators/operators, pneumatic valves,
dampers, vanes, etc.
CALIBRATION:
Zero adjustment of the unit is made by turning a screw that regulates the
distance between the flapper valve and the air nozzle. Span adjustment is
made by varying a potentiometer, which shunts input current past the coil.
An integral volume flow booster provides adequate flow capacity, resulting in
fast response time and accurate control.

41. 3) R to I Converter:
These DIN rail mounted electronic modules have been designed to convert
the position of a lever, tiller, steering wheel or azimuth control head into
industry standard 4-20mA current signals.
FEATURES:
• Adjustable R/I-conversion circuit with span- and offset level calibration.
• 10 Volts reference voltage to power the potentiometer.
• The output signal is isolated from the power supply.
• Large power supply range (24VDC±30%)
• ‘Power-on’ indication (green LED).
• Mounted on a DIN-rail according to EN50022.

42. BENEFITS:
Easy maintenance
Longer service life
Use friendly

43. 4) STRAINERS & TRAPS:
STRAINER:
One Spirax Strainer upstream of every trap, control valve, and flowmeter can
save you a bundle in annual maintenance and wear & tear costs. Available in Y or
T type designs, our Strainers remove suspended grit from steam and condensate
that would otherwise damage your downstream equipments with no additional
pressure drop.
TRAP:
The duty of a steam trap is to discharge condensate while not permitting the
escape of live steam.
No steam system is complete without that crucial component 'the steam trap'
(or trap). This is the most important link in the condensate loop because it
connects steam usage with condensate return.

44. A steam trap quite literally 'purges' condensate, (as well as air and other
incondensable gases), out of the system, allowing steam to reach its destination
in as dry a state/condition as possible to perform its task efficiently and
economically.
The pressures at which steam traps can operate may be anywhere from vacuum
to well over a hundred bar. To suit these varied conditions there are many
different types, each having their own advantages and disadvantages.
Experience shows that steam traps work most efficiently when their
characteristics are matched to that of the application.
It is imperative that the correct trap is selected to carry out a given function
under given conditions. At first sight it may not seem obvious what these
conditions are.
They may involve variations in operating pressure, heat load or condensate
pressure. Steam traps may be subjected to extremes of temperature or even
waterhammer.
They may need to be resistant to corrosion or dirt. Whatever the conditions,
correct steam trap selection is important to system efficiency.

45. SELECTION OF STEAM TRAP:
Maximum steam and condensate pressures.
Operating steam and condensate pressures.
Temperatures and flow rates.
Whether the process is temperature controlled.

46. 5) SIGHT GLASSES:
A sight glass or water gauge is a transparent tube through which the operator
of a tank or boiler can observe the level of liquid contained within.
Industrial observational instruments have changed with industry itself. More
structurally sophisticated than the water gauge, the contemporary sight glass —
also called the sight window or sight port — can be found on the media vessel at
chemical plants and in other industrial settings, including pharmaceutical, food,
beverage and bio gas plants. Sight glasses enable operators to visually observe
processes inside tanks, pipes, reactors and vessels. The modern industrial sight
glass is a glass disk held between two metal frames, which are secured by bolts
and gaskets, or the glass disc is fused to the metal frame during manufacture.
Borosilicate glass is superior to other formulations in terms of chemical corrosion
resistance and temperature tolerance, as well as transparency. Fused sight
glasses are also called mechanically pre-stressed glass, because the glass is
strengthened by compression of the metal ring.

47. 6) SWITCHES:
PRESSURE SWITCH:
A pressure switch is a form of switch that makes electrical contact when a
certain set pressure has been reached on its input. This is used to provide on/off
switching from a pneumatic or hydraulic source. The switch may be designed to
make contact either on pressure rise or on pressure fall.
FLOW SWITCH:
A flow switch is a mechanical device that is switched on or off in response to the
flow (or lack of flow) of a liquid or a gas. Flow switches are widely used in
domestic air conditioning, heating and hot-water systems.
TEMPERATURE SWITCH:
A temperature switch is a switch that is responsive to temperature changes.
Temperature switches generally are provided with a temperature responsive
element which will open or close a switch when a predetermined minimum
pressure or temperature is sensed by the responsive element.

48. CHAPTER-7
CoNTROL VALVES
What Is A Control Valve?
A control valve is the final control element, which directly changes the flow rate of the
manipulated variable.
Characteristics of control valves:
Quick Opening
Linear
Equal Percentage

49. BASIC PARTS OF CONTROL VALVE:
Body
Bonnet
Actuator
TYPES OF ACTUATOR:
Direct Acting
Reverse Acting

51. REVERSE-ACTING
ACTUATOR
TYPES OF CONTROL VALVE:
Ball valve
Globe valve
Sliding gate valve
Butterfly valve
Diaphragm valve
Venturi valve
Pinch valve

53. CONCLUSION :
During preparation of this project, we had great experience with this company. Thecompany
provided us with a great platform to prove ourselves & our knowledge. Thecompany was kind
to us & they provided great help in terms of instruments, projectfeasibility.
We understood the Measurement of TEMPERATURE , LEVEL , FLOW , PRESSURE . We
understood the working of different types of field instruments . We were also do the calibration
of different types of indicators , Gauges &converters…