SELECTION OF VARIABLES FOR PROCESS MEASUREMENT

Objectives:

1. To be able to define and discuss each process variable

2. To be able to discuss the equipments that measure process variables

Discussion:

Equipments and instruments are used to monitor and control a process by keeping it
within a correct limit. The parameters or quantities that we wish to control at the correct limit
are called Process Variables. It is a condition of the process fluid (a liquid or gas) that can
change the manufacturing process in some way, with this; instrumentation systems measure
the variable then control the variable to keep the variable within the given limits. Main
process variables are: Temperature, Pressure and Flow.

Temperature Measurement
A measurement of the hotness or coldness of a body or a fluid is commonplace in the
industries. Temperature is the most important one because it provides a critical condition for
combustion, chemical reaction, fermentation, drying, calcinations, distillation, concentration,
extrusion, crystallization, and air conditioning. Poor temperature control can cause major
safety, quality, and productivity problems. Although highly desirable, it is often difficult to
control the temperature. Temperature-measuring devices utilize systems with properties that
vary with temperature in a simple, reproducible manner and thus can be calibrated against
known references. The three dominant measurement used in automatic control are
thermocouples, resistance thermometers and pyrometers.
 Thermocouple
Temperature measurements using thermocouples are based on the discovery of
Seebeck in 1821 that an electric current flows in a continuous circuit of two different
metallic wires if the two junctions are at different temperatures. It measures
unknown temperature of the body with reference to the known temperature of the
other body.

1
  Resistance Thermometers
The resistance thermometer depends upon the inherent characteristics of
materials to change in electrical resistance when they undergo a change in
temperature. It is an instrument for measuring electrical resistance that is calibrated
in units of temperature. It usually made up of platinum, copper, or nickel, and more
recently semiconducting materials which have an accurate resistance/temperature
relationship which is used to provide an indication of temperature.
 Pyrometer
A pyrometer is a very accurate kind of thermometer that is used when dealing
with too high temperatures. It measures temperature with the measure of the
wavelength of radiation even from a distance. In theory, if the heat behaves exactly
according to the laws of physics, the radiation it produces is related to its temperature
in a very predictable way.

Pressure Measurement
Pressure is a critical operating parameter in process control, in fact, it is the second
most common parameter measured after temperature. Pressure measurement applications
range from simple set point monitoring to ensure sufficiently high or low pressure levels, to
continuous monitoring as part of a complex automation system. Poor pressure control can
cause major safety, quality, and productivity problems. Overly high pressure inside a sealed
vessel can cause an explosion. Therefore, it is highly desirable to keep pressure in good
control and maintained within its safety limits. Process pressure measuring devices may be
divided into two groups: those based on the measurement of the height of a liquid column and
those based on the measurement of the distortion of an elastic pressure chamber.
 Liquid-Column Methods
Manometer is the most common form of liquid-column pressure-measuring
devices. The pressure being measured is balanced against the pressure exerted by a
column of liquid. If the density of the liquid is known, the height of the liquid
column is a measure of the pressure. The height of the liquid column may be
measured in length units or calibrated in pressure units. Because the density of the
liquid used varies with temperature, the temperature must take into account for
accurate pressure measurement.
 Elastic Element Methods
Elastic element pressure-measuring devices are those in which the measured
pressure deforms some elastic materials, usually metallic, within its elastic limit, the
magnitude of the deformation being approximately proportional to the applied
pressure. This are used very extensively to measure pressure in technical applications
because they are both robust and easy to handle. One of the mechanical pressure
gauges is produced with bourdon tube.
 Bourdon tubes are circular-shaped tubes with an oval cross-section. The pressure of
the media acts on the inside of this tube, as the tension builds up, the end piece will be
compress causing the pointer to move, thus measuring the pressure inside the circular
tube.

Flow Measurement
A flow meter is a device to measure the amount of liquid flowing through a pipe and
the quantity of the liquid streaming. It is of utmost importance in any industry as it not only
quantifies the liquid but also detects leakages by which the wastage can be avoided. Flow,
defined as volume per unit of time at specified temperature and pressure conditions, is
generally measured by positive displacement or rate meters. Positive Displacement (PD)
Flow Meters applies to a device in which the flow is divided into isolated measured volumes
when the number of fillings of these volumes is counted in some manner. Rate Meter applies
to all types of flowmeters through which the material passes without being divided into
isolated quantities. The principal classes of flow-measuring instruments used in the process
industries are: variable-head, variable-area, positive-displacement and turbine instruments.
 Variable Head Meter
The basic principle of such device is that due to obstruction, the velocity of the
fluid increases and the pressure decreases. Then the volume flow rate is proportional
to the square root of pressure difference across the obstruction. The most widely used
flowmeter is an orifice plate which involves placing a fixed-area flow restriction in
the pipe carrying the fluid.
 Variable Area Meter
Variable area flow meters are simple and versatile devices that operates at a
relatively constant pressure drop and measure the flow of liquids, gases, and steam.
The position of their float, piston or vane is changed as the increasing flow rate opens
a larger flow area to pass the flowing fluid.
The rotameter is the most widely used variable area flowmeter because of its
low cost, simplicity, low pressure drop, relatively wide rangeability, and linear output.
It consists of a plastic, metal or glass tube and float. The float response to flowrate
changes is linear, and a 10-to-1 flow range or turndown is standard.
 Turbine Instrument

Turbine flowmeter is velocity type flowmeter which shows a linear

relationship with the flow of fluid in the stream. As it shows a linear relationship,
there is no need of using square root extractor.

The turbine flowmeter uses a free spinning turbine wheel, which rotates as the
fluid flow through the pipeline. The angular velocity of the turbine is directly
proportional to the flow velocity of the fluid.
REFERENCES:
Fundamentals of control. (2006). Retrieved July 23, 2018, from
https://www.pacontrol.com/download/Process Control Fundamentals.pdf

Green, D. W. (2008). Perrys chemical engineers handbook (8TH ed.). New York: McGraw-
Hill.

Head type flowmeters – Based on Differential Pressure Measurement. (n.d.). Retrieved July
25, 2018, from http://instrumentationandcontrollers.blogspot.com/2011/01/head-type-
flowmeters-based-on.html

OMEGA Engineering. (n.d.). Retrieved July 25, 2018, from

https://www.omega.co.uk/literature/transactions/volume4/variable-area-flow.html

S. (2017, December 29). Flow measurement using Turbine flowmeter. Retrieved July 27,
2018, from https://automationforum.in/t/flow-measurement-using-turbine-
flowmeter/2886
 University of Mindanao
Matina, Davao City

Process Measurement:
Selection of Variables for Control

Submitted by:

Ariane Jan E. Tongco

BSChE - 4

Submitted to:

Engr. Ramiro Emerson C. Amon

Professor