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pressure to one side greater than the c lie existing on the other, the diaphragm deflects
away from the higher pressure sid @ , -iie maximum deflection occurring at the centre.
It is possible to link the diaphragm centre to a pointer a pen a slider on a scale or
through beverages to make an indicator recorder or a transmitter.
The deflection depends upon the following factors.
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The space between the seal and the gauge tube is generally filled with liquid. Any
movement in the seal caused by a change in process pressure is transmitted via the tube
liquid. In some installations compressed air is used. The liquids used in the tube of the
gauge is chosen to meet the operating temperature. The liquid should not vapourize at
the operating temperature.
The material chosen for the seal must resist corrosive action.
2.6.2 LIQUID SEALS FOR STEAM AND VAPOUR
Many bourdon gauges are not meant to be used at high temperatures. In order to keep
live steam out of the pressure measuring instrument shown in Fig. 2.17(A) or a U tube
Secondary measuring circuits are connected to measure this voltage as a measure of the
pressure. Different forms of secondary system are in use.
2.1.2.3COMPARISON OF DIFFERENT TRANSMITTERS
The force balance transmitter is one of the early designs of two wire transmitters and is
still used widely. It has inherently rugged construction and is of simple design.
However, it has a very large number of mechanical linkages and moving parts. This
inherently reduces its accuracy and makes it prone to errors due to hysterises &
deadband etc. It also makes it very bulky and heavy. The zero and span adjustments
are also mechanical and as such achieving good calibration accuracy is not very easy.
The capacitance type and strain gauge type are definitely of superior design. They have
virtually no moving parts and hence are very accurate and have a good repeatability.
LEVEL
3 INTRODUCI'ION
In power station applications level can be defined as 'the height of liquid or solid media
above or below a reference line', usually the base. Levels, below the reference line may
also be required in dynamic condition, such as for boiler dnnn etc.
If the diirnensions of a vessel are known then the volume or mass of its contents can be
determined by measuring the level. Hence the vessel contents can be directly displayed
in units of level (meters), volume (liters) or mass (kilograms).
There are three main reasons viz safety, economy & monitoring for making level me
asurements of solid particles or liquid level. The safety of personnel and plant is the
most important.
3.1 SAFETY
The boiler drum level monitoring and control system is probably the most important
level measurement made in a power station.
Factories Act places a statutory duty on the boiler operators to monitor drum level and
inspector of factories is legally entitled to enter a power station at any time to confirm
that the boiler operators are complying with the Act.
Irrespective of statutory requirements the boiler drum level must be controlled within
pre-defined limits.
Obviously if water level is too low then there is a danger that riser tubes will overheat
and burst, if too high, water droplets may be carried over to the super heaters or H.P.
turbine with equally disasterous results.
3.2 ECONOMY
Some plant units operate more effectively when levels are maintained within clearly
defined values. An example of this is in a coal fired station the fuel level in the
pulverising mills; the effectiveness of the pulverising process and the overall efficiency
of the Unit will be influenced by incorrect fuel levels.
3.3 MONITORING
The monitoring of levels in bulk storage and process vessels is necessary in order that:
For accuracy the base of the stick is usually coated in metal and the stick is inserted in
the vessel perfectly vertically.
For level measurement in a dosed tank the stick must be withdrawn and level
determined by the wet/dry line junction on the scale.
If required, the stick scale can be calibrated in terms of volume if the shape of the
vessel is taken into consideration.
3.5.1.2HOOK GAUGE (Fig. 3.2)
When the level of liquid in an open tank is read off a dipstick it is sometimes difficult to
read accurately because it is difficult to focus one's eyes on the same level as the liq7
uid due to parallax. In this case a hook gauge type can be used. It consists simply of a
wire cord'of corrosion resisting alloy, such as gun metal or stainless steel, about 4"
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diameter, bent into a 'U' shape with one arm longer than the other. The shorter arm is
pointed with a 600 taper, while the longerone is attached to a slider, havinga vernier.
FIG. 3.6 RIGD ARM FLOAT LEVEL GAUGE WITH MAGNETIC COUPLING
A rigid arm float has the advantage of being completely self-contained and may be
fitted to open or closed tanks in virtually any position, though itsrange is much smaller
than that of the cable-and-pulley type. Remote indication may be built in as in the other
type.
The float movement is limited to about 1200 as a maximum, the motion being
transmitted to the pointer by a worm drive or similar arrangement. If the gauge is
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the gauge reads correctly only when the displacer is immersed in a liquid for which it
was designed.
This system can be 1 used for enclosed vessels with a working temperature of up to
SOOOC and a static,pressure up to 340 bars.
3.5.3.3.2 FLOAT SYSTEMS - POSSIBLE FAULTS
1. Float and counterweightty-pes
a) Change to length of cord or tape causing zero error.
b) Dirty or worn pulley bearing.
∴ P = mg
A
but m = Vp
∴ P = Vpg
A
But V = Ah
PAGE68
P = Ahpg
A
P = hpg
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nature, adversely effect the manometer fluid or transmitter diaphragm material then
liquid seals should be used.
The sealing liquid must not mix with the vessel liquid, be attacked by it, or absorb
corrosive elements from it. Of course it also must have no adverse effects on the
manometer i or iap ragm materia.
4.5.4.6ZERO SUPPRESSIONIELEVATION SPAN AND RANGE CONSIDERATIONS
When using a differential pressure transmitter for level measurement the location and
type of system (i.e. open or closed tank, dry or wet leg) must be considered when
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3.5.4.8.1BELLOWS TYPE (Fig. 3.18)
In the above type the diaphragm box is replaced by a box containing a bellows of
synthetic material. Changes of pressure within the bellows due to changing levels are
communicated to the measuring bellows by copper tubing having a fine bore. The
bellows are filled with air at a pressure slightly above atmospheric pressure. As the
level increases the measuring bellows is compressed - this increases the pressure in the
system and the detecting bellows detects the change in pressure and indicates it on a
gauge, calibrated directly in units of level. In common with other instruments, its
FIG.3.18 BELLOWSTYPETANKCAUGE
3.5.4.8.2 DIAPHRAGM STACK SYSTEM
As the level increases the diaphragm stack is compressed, this compresses the air in
the system which creates an increase in pressure. This increase is detected by a
suitable indicator which is calibrated in terms of liquid level, volume or weight.
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ELECTRICAL/ELECTRONIC METHODS OF
LEVEL MEASUREMENT AND CONTROL
Electrical methods for level measurement are very useful as generally there is minimum
limitation on transmission distances between transducer and display or control devices.
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steam. A small amount of hysteresis is built in so that in the reverse direction the
change back to water occurs at about +3.5V DC, to avoid excessive operation due to
insignificant level fluctuations.
At the time that the use of a direct electrical measurement was first considered for the
determination of drum level, little was known of the resistivities of water and steam at
elevated temperatures as exhibited in a dynamic system with continuous condensate
flow through a side-arm vessel from the boiler drum. A series of measurement were
made, therefore, using the vessels designed for the field trial equipments, on boilers in
the 1 1 0 and 183 bar pressure groups. These measurements are presented and show
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When a voltage is applied across the plates an electrical charge is stored proportional to
the applied voltage.
Q = CV where
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provided that power supply is maintained, until the solid level falls sufficiently to allow
the paddle to rotate again.
3.5.5.2.3 VIBRATING TUNING FORK LEVEL SWITCHES (Fig. 3.23)
This system has proved very reliable for solid particle level alarm measurement and
could be used in Power Stations to detect pulverised fuel & ash levels in the precipitator
hoppers etc. Rotating paddle switches and capacitance controllers have been found to
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readily usable form of energy. Above a certain frequency (20 kHz) it is known as
ultrasound or ultrasonic sound. For level switching a range between about 36 and 40
kHZ is used. Ambient noises or their harnionics are ineffectual in this range.
3.5.6.1THE ULTRASONIC LEVEL SWITCH (Fig. 3.24a and 3.24b)
This system detects ultrasonic sound at a diaphragm of the receiver and converts it into
electrical energy; this, in turn, is fed into the input of a high gain amplifier which feeds
it to the, transmitting sensor. Here the electrical energy is converted into ultrasonic
FIG.3.27 LINESOURCESYSTEMLEVELMEASUREMENT-NUCLEONICMEMOD
3.5.7.3 GAMMA SOURCES
giving
v2 = 1/(1-m2) 1/2 (2g [(P1 -P2 ) + 2gp (Z1 -Z2 )] / p)1/2 ..............(7)
But since Q = A2V2 (7) can be written
Q = A2 / (1-m2) 1/2 (2g [(P1 -P2 ) + 2gp (Z1 -Z2 )] / p)1/2 `............ (8)
A further step yields
Q =t.A2 (2g [(P1 -P2 ) + 2gp (Z1 -Z2 )] / p)1/2 `............ (9)
4.2.2.8TURBULENT FLOW
In practice in all cases of flow in pipes for industrial purposes the flow is turbulent, that
is, the particles of the fluid do not follow paths parallel to the direction of flow. Some,
if not all, of the particles have a transverse motion as well as longitudinal one and form
little eddies or swirls giving rise to turbulence. Stream line or laminar flow formulae
will not apply here without modification and a new set of equations must be derived.
4.2.2.9DISCHARGE COEFFICIENT
Due to friction and velocity distribution, the practical flow figures do not agree to the
the oritical ones. Observe that the stream area contracts after leaving the orifice to the
The differential required for the Venturi case is less than half that required for the orifice.
if the differential remains the same and the throat and orifice diameters are equal and
if Q1and Q2 are the prospective flows:
Q1/0.99 = Q2/0.60 ...........(21)
p 2g p
Rewriting:
v12 = 2g (P2 - P1)
p
1/2
V1 = 2g (P2 - P1)
p ..................(27)
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FIG. 4.11 THE EFFECT OF IMPOSING A BLUNT FIG. 4.12 SEPARATE STATIC
AND IMPACT PRESSURE TUBES
OBJECT IN THE FLOW STREAM
We now replace the blunt object with a tube having a small opening facing the direction
of fluid flow. Next consider that the tube is joined to one connection of a pressure
measuring instrument of the diaphragm type suitable for measuring relatively sn-tall
differential pressures. There is no flow through the tube and the point of impact or zero
velocity can be considered to be at the impact hole. This produces p 2 in Equation (27)
and if a static pressure tapping is taken upstream, a little way from the tube, this gives
us Pl. Both pressures are applied to the differential pressure instrument, and a means of
measuring the velocity of the fluid is obtained since both g and p will be known. We
have, then. the Pitot tube in its simplest form (Fig. 4.12).
FIG. 4.13 STANDARD PATTERN PILOT TUBES FIG. 4.14 AN IDEAL TRAVERSE OF A PIPE
tube may be placed at the pipe centre and the instrument calibrated in terms of average
velocity.
Another theoretically possible means of determining the average velocity is to select a
position where the velocity corresponds to the average value. This has some practical
FIG. 4.15 A
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Differentiating (46) with respect to p,, and equating the result to zero, produces the
condition that for complete density change immunity, P2 must be infinite. Practically,
of course, this cannot be achieved, but the density of the float may be made very large,
i.e. many times that of the fluid. This results in reducing the density errors to
reasonable proportions.
Differentiating (47) with respect to p, and equating result to zero, produces the
following condition:
FIG. 4.23 PLUSE SCHEME FOR ELIMINATING THE EFFECT OF C THE VELOCITY OF
SOUND. THE DIRECTION OF FLOW IS FROM LEFT TO RIGHT.
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A similar pulse is tr1ansmitted from T toT and calling the repetition frequency
here f2.
f1 = C-V / d ........... (68)
f1 - f2 = Δf = 2 V/d .............(69)
Equation (69) is independent of C.
5. A further technique u ed has been a differential arrangement across the pipe. It can be
shown that a beam of sound can be deflected in the downstream direction in traversing a
pipe from one side to the other. The.deflection x is approximately given by
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addition to mercury for thermometric work are given below:
PAGE 155
CO-efficient of expansion. The wall of the chamber is made of the steel material. The
space between the core and the wall is filled with the system liquid. If the size of the
chamber and volume of the Invar material are carefully proportioned, then on any
change in ambient temperature, the volume of the angular space, due to the expansion
of the outer wall is sufficient to accommodate any variation in volume of the liquid in
the capillary and so prevent it exerting an effect on the bourdon tube.
5.3.2.2DOUBLE CAPILLARY
The second method used a second capillary of the same diameter as the first one fined
with the same liquid under the same condition. This second capillary and is sealed off
without the bulb and run along the first capillary and connected to a second bourdon.
This bourdon is made to act on the instrument points in an opposite sense to that of the
main bourdon.
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Three types of resistance thermometers are available having the above properties.
They are Nickel, Copper and Platinum.
5.5.1.1 NICKEL RESISTANCE THERMOMETERS
Its characteristics are not linear throughout the range but is frequently used due to its
specific resistance and less cost. The specific resistance is 6.38 n-ticro ohm-cm,
temperature coefficient .0066 ohm/ohm (OC).
5.5.1.2 COPPER.RESISTANCE THERMOMETERS
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6. PNEUMATIC INSTRUMENTS
6.1 INTRODUCIRION
For many years pneumatic instrument systems were the main method of monitoring
controlling and industrial plant. Electrical instrument systems, with fast response times
and ease of installation, have already overtaken pneumatic systems and are now used
PAGE 175
Whilst in principle the single flapper/nozzle is an effective transducer it does have
sortie serious drawbacks, for instance any change in supply pressure would affect the
output pressure and also since the amount of flapper movement is so small even the
slightest amount of wear on pivots o@ linkages would render the system useless. The
difficulties may be overcome by the use of negative feed-back bellows. The feed-back
can be used to oppose the measuring element force (force balance) or it can be used to
change the position of the flapper relative to the nozzle (position balance).
6.3 POSITION BALANCE - PRINCIPLE (Fig. 6.3)
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6.6.1 THE FIELDEN E/P CONVERTER (Fig. 6.9)
This Fielden E/P converter is a force balance device without feed-back. Because of the
lack of feed-back the setting up of the nozzle is critical. The device is supplied with air
chamber into two parts, the upper sections receiving the pneumatic signals from the
controller via the air input. The input signals deflect the diaphragm which is fixed to
the thrust plate, the spindle attached to the thrust plate, extends downwards into the
body of the valve. The deflection is opposed by the range spring whose, rating
determines the extent of travel of the spindle for a given pressure range and effective
diaphragm area. Since the spindle is connected to the valve plugs we have the means of
A control valve must be capable of responding smoothly and rapidly to small changes
in the controller output signal. The quality of control will be impaired if any force, for
example, that due to friction of working parts, opposes the movement of the spindle
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Will outstroke (+); and if air is applied to P2 ( with P1 open to exhaust) the piston will
in-stroke (-).Ref. Fig.6.17.
The circuit symbols for cushioned cylinders are as shown in Fig. 6.21.
6.11 SEQUENEC CONTROL VALVES
An ordinary on off valve has one inlet and one outlet. However, for sequence control
PAGE 189