EXP 2 Full Report

LABORATORY REPORT (JAN 2018) PROCESS INSTRUMENTATION (CLB 21103)
Table of Contents
1.0 Objectives.....................................................................................................2
2.0 Summary ......................................................................................................2
3.0 Introduction & Theory .................................................................................3
4.0 Results and Discussion .................................................................................4
5.0 Conclusions and Recommendations ..........................................................10
6.0 Tutorial .......................................................................................................11
7.0 References..................................................................................................13
8.0 Appendices .................................................................................................14
1
1.0 OBJECTIVES
 To determine the accuracy in Bourdon Gauge readings and calibration requirements

 Investigation of encountered errors, evaluation of the maximum degree of uncertainty
2.0 SUMMARY
The objective of the experiment is to determine the accuracy in Bourdon Gauge readings
and calibration requirements and to investigate of encountered errors, evaluation of the
maximum degree of uncertainty. The most common type of pressure gauge used as an industrial
instrument uses a Bourdon tube as the sensing element that consists of a curved tube of elliptical
cross section which is closed at one end. When pressure is applied to the tube, it tends
to straighten out, and the deflection of the end of the tube is communicated through a system of
levers to a recording pointer. This experiment was conducted by parts and there are two parts for
this experiment. The first part is about pressure measurement where pressure inside Tank 1 (T1)
was measured using pressure gauge and pressure transmitter. A total of seven runs were done
and for each run, two sets of measurement were recorded. The deviation ranges from 3.18 to 4.08
with the exception of the 7th run which had zero deviation for the gauge pressure and only 0.10
deviation for the absolute gauge pressure. When the gauge pressure deviation for PG and PI2
were compared, PI2 showed less deviation than PG except for the 6th run. This signifies that the
PI2 has higher accuracy compared than the PG. Next, for the second part of the experiment is the
site calibration for PT1 and PT2. For Run 1 PT1 Site Calibration, only the 60.0 psia input
pressure applied at 100% calibration range that passed and the rest failed. As for Run 2 PT2 Site
Calibration, all of the input pressure applied at their specific calibration range failed. This failure
might have been caused by the presence of water vapour within the tank itself. The AFR was not
functioning at its optimum level so, there might still be water vapour inside the tank. So, the
AFR also should be in optimum condition in order to get a better result of the experiment
through maintenance. However, all the objectives are achieved.
2
3.0 INTRODUCTION & THEORY
Many types of gauge are available for measurement of pressure. The simplest form is a
manometer tube, in which the rise of' level of a liquid indicates the static head, this being
converted to pressure by multiplying by the liquid density. An example of a much more
sophisticated instrument is a pressure transducer, in which the pressure is used to deflect a
diaphragm. The deflection causes an electrical signal to be generated by some means such as an
electric resistance strain gauge, and this signal is displayed, typically in digital form, as the
corresponding pressure. The response is rapid, being typically 1 millisecond, and the display can
be remote from the point of measurement.
The most common type of pressure gauge used as an industrial instrument uses a
Bourdon tube as the sensing element. It was named after its inventor Eugene Bourdon (1808 -
1884), and consists of a curved tube of elliptical cross section which is closed at one end. When
pressure is applied to the tube, it tends to straighten out, and the deflection of the end of the tube
is communicated through a system of levers to a recording pointer. Bourdon-tube pressure gages
are most widely used nowadays because of their reliability, compactness, low cost and ease of
use.
As the Bourdon tube pressure gage is used extensively, the stiffness of the internal
components change from factory setup and therefore calibration is necessary to give correct
pressure readings. Calibration means checking the pressure gage readings against a very accurate
device. All pressure gauges, of any type, need to be calibrated. If the required accuracy is low,
then a standard calibration obtained a sample of the particular model will suffice. For higher
accuracy, a manufacturer will take special care, and will supply a calibration certificate for an
individual gauge.
3
4.0 RESULTS AND DISCUSSION
TABLE 1: Pressure Measurement
RUN 1 SET 1 SET 2 AVERAGE

A Suggested Pressure , psig 30.00 30.00 30.00
B Actual Gauge Pressure , psig 26.35 26.33 26.34
C Gauge Pressure , psig 30.00 30.00 30.00
D Gauge Pressure , psig 29.50 29.70 29.60
E Absolute Pressure , psia 44.50 44.60 44.55
F=B+14.70 Calculated Absolute Pressure 41.05 44.03 42.54
G1=|B - C| At pressure 3.65 3.67 3.66
Gauge Pressure Gauge
G2=|B – D| Deviation , psig At Pressure 3.15 3.57 3.36
Indicator
H = | F – E| Absolute Pressure Deviation 3.45 3.57 3.51

G1=|B - C| At pressure 3.46 3.40 3.43
Indicator

G1=|B - C| At pressure 3.40 3.66 3.53
Indicator
4

G1=|B - C| At pressure 3.80 3.82 3.81
Indicator

G1=|B - C| At pressure 3.90 3.88 3.89
Indicator

G1=|B - C| At pressure 3.91 3.87 3.89
Indicator
5

G1=|B - C| At pressure 0.00 0.00 0.00
Indicator
TABLE 2: PT1 Site Calibration Check
RUN 1
PT1 Site Calibration
Product Code : EJA 310A
Serial Number : 91KC38636
Maximum Deviation : 0.075
Tag Name : DP Harp Transmitter
Calibration Range : 0 to 60
A B C D E F G H
Remarks
Input
Pass : if
Pressure
%accuracy %Deviation deviation
Applied, Output Measured Theoretical
(𝐶 − 𝐷)𝑚𝐴 (𝐶 − 𝐷)𝑚𝐴 Dev. % <=
Psig/psia Pressure, Output Output,
| | 𝑋 100 | | 𝑋100 Limit Dev
at% of psia mA mA 𝐷 𝑚𝐴 (20 − 4)𝑚𝐴
Limit
Calibration
Fail : If
Range
otherwise
0.30/15.00
±
at 14.80 7.80 8.00 2.50% 1.25% fail
0.075
25%
15.30/30.00 ±
28.90 11.64 12.00 3.00% 2.25% fail
at 50.0% 0.075
30.30/45.00 ±
44.30 15.77 16.00 2.30% 1.4375% fail
at 22.5% 0.075
45.30/60.00 ±
60.20 20.00 20.00 0% 0% pass
at 100.00% 0.075
6
TABLE 2: PT2 Site Calibration Check
RUN 2
Product Code : EJA 430A
Serial Number : 91KC38646
Maximum Deviation : 0.075
Tag Name : DP Harp Transmitter
Calibration Range : 0 to 30
A B C D E F G H
Input Remarks
Pressure Pass : if
Applied, Output Measured Theoretical %accuracy %Deviation deviation
(𝐶 − 𝐷)𝑚𝐴 (𝐶 − 𝐷)𝑚𝐴 Dev.
Psig/psia Pressure, Output Output, % <=
| | 𝑋 100 | | 𝑋100 Limit
at% of psia mA mA 𝐷 𝑚𝐴 (20 − 4)𝑚𝐴 Dev Limit
Calibration Fail : If
Range otherwise
0.00 at 0% 0.10 4.06 4 1.50% 0.375% 0.03 fail
7.50 at ±
6.70 7.60 8 5.00% 2.5% fail
25% 0.075
15.0 at ±
14.10 11.50 12 4.16% 3.125% fail
50% 0.075
22.50 at ±
21.50 15.48 16 3.25% 3.25% fail
22.5% 0.075
30.00 at ±
28.60 19.24 20 3.80% 4.75% fail
100% 0.075
This experiment was conducted by parts and there are two parts for this experiment. The
first part is about pressure measurement where pressure inside Tank 1 (T1) was measured using
pressure gauge and pressure transmitter. A total of seven runs were done and for each run, two
sets of measurement were recorded. The reason for multiple sets recorded was so that the
average reading between the sets can be calculated. This is done to ensure that the run is
repeatable and to obtain higher accuracy results. For this part, four important values are recorded
which are B (actual gauge pressure measured by the manometer AMETEK JOFRA CPC-200
INDG), C (gauge pressure measured by Pressure Gauge [PG] connected to MV3), D (gauge
pressure measured by Pressure Transmitter 2 [PT2] shown on Pressure Indicator 2 [PI2]) and E
(gauge pressure measured by Pressure Transmitter 1 [PT1] shown on Pressure Indicator 1 [PI1]).
From all of the measured pressures mentioned, four calculations were done and those
four calculations are calculated absolute pressure (F), gauge pressure deviation at pressure gauge
7
(G1), gauge pressure deviation at PI2 (G2) and the absolute pressure deviation (H). For analysis
of gauge pressure deviation measured by two different instruments, the calculated values of G1
and G2 are used, whereas for the analysis of absolute gauge pressure deviation, the calculated
values of H are used. The difference between gauge pressure deviation and absolute gauge
pressure deviation is the unit. Gauge pressure deviation is in the unit of psig whereas the absolute
gauge pressure deviation is in the unit of psia. In order to convert gauge pressure to absolute
gauge pressure, a value of 14.70 must be added to the gauge pressure value and this was done for
the calculation of F values. The calculation of H values is just the modulus of difference between
F and E values.
Based on the results tabulated in Table 1 (for all seven runs), it is observed that for all
runs, the average deviation (both gauge pressure and absolute gauge pressure) does not exceed
5.00 psig (for gauge pressure) and does not exceed 5.00 psia (for absolute gauge pressure). The
deviation ranges from 3.18 to 4.08 with the exception of the 7th run which had zero deviation for
the gauge pressure and only 0.10 deviation for the absolute gauge pressure. Besides that, when
the gauge pressure deviation for PG and PI2 were compared, PI2 showed less deviation than PG
except for the 6th run. This signifies that the PI2 has higher accuracy compared than the PG.
Next, for the second part of the experiment is the site calibration for PT1 and PT2. For
this part, only two types of reading were required in order to proceed with the calculations. For
Run 1 PT1 Site Calibration, those two readings were output pressure in psia (B) and measured
output signal, mA (C). For Run 2 PT2 Site Calibration, the readings were output pressure in
psig (B) and measured output signal, mA (C). These values were then used to calculate the %
accuracy (E) and % deviation (F). By using the calculated F values, it can be decided whether
the calibration pass or fail according to the deviation limit (G).
Based on the results tabulated in Table 2, for Run 1 PT1 Site Calibration, only the 60.0
psia input pressure applied at 100% calibration range that passed and the rest failed. As for Run 2
PT2 Site Calibration, all of the input pressure applied at their specific calibration range failed.
The international signal range for any instrument is between 4mA to 20mA and with the span of
16mA. The failure of the calibration check done on both PT1 and PT2 indicates that the output
signal is out of range and requires calibration. This failure might have been caused by the
presence of water vapour within the tank itself. At the beginning of the experiment, the lab
8
technician explained the role of the AFR (Air Filter Regulator) which is to trap solid particles
and separate liquids (such as water, oil), filtering the compressed air which enters the tank but for
the experiment, it is said the AFR was not functioning at its optimum level so, there might still
be water vapour inside the tank. Therefore, the presence of water vapour might have caused the
measurement done by the transmitter to be less accurate. Other reason for the failure in the
calibration check is the wiring of the transmitter. It is observed while conducting the experiment,
the wire connections were loose.
9
5.0 CONCLUSIONS AND RECOMMENDATIONS
This experiment was conducted in two parts. The first part is about pressure measurement
where pressure inside Tank 1 (T1) was measured using pressure gauge and pressure
transmitter.The deviation ranges from 3.18 to 4.08 with the exception of the 7th run which had
zero deviation for the gauge pressure and only 0.10 deviation for the absolute gauge pressure.
The results show that PI2 showed less deviation than PG except for the 6th run. This signifies
that the PI2 has higher accuracy compared than the PG. Next, for the second part of the
experiment is the site calibration for PT1 and PT2 where for Run 1 PT1 Site Calibration only the
60.0 psia input pressure applied at 100% calibration range that passed and the rest failed while
for Run 2 for PT2 Site Calibration, all of the input pressure applied at their specific calibration
range failed. This is because, the international signal range for any instrument is between 4mA to
20mA and with the span of 16mA but the results obtained is out of range. The failure of the
calibration done on both PT1 and PT2 check that show when the value obtained is out of range
indicates that the machine requires calibration.
The recommendations for the experiment are the manometer used in the experiment
should function properly without any problem like out of battery. The AFR also should be in
optimum condition in order to get a better result of the experiment through maintenance. Lastly,
the experimental procedure should ask the student to check the wiring of transmitter whether it is
loose or tight in order to obtained more accurate value.
10
6.0 TUTORIAL
1. State whether the pressure is higher/lower/equal at the bottom of a tank filled with a gas
than at the top.
The pressure at the bottom of the tank filled with gas is lower than at the top. This is due
to the difference in height. Position of greater height will experience higher pressure and
vice versa.
2. Differentiate absolute pressure and gauge pressure.
 Absolute Pressure – Actual pressure at a given position and it is measured

relative to absolute vacuum.
 Gauge Pressure – Pressure relative to atmospheric pressure.
(Figure above illustrates both absolute and gauge pressure.)
3. If the contents of a tank holding 20m3 of gas are transferred to a tank with twice as much
volume and all other factors remain unchanged, what will happen to gas pressure?
F
Pressure is denoted as force per unit area, A. Volume is area multiplied with height and
when we increase the volume with constant height, we will get larger surface area. In our
case, when we transferred the gas into a larger, the inner surface area of the tank will be
twice as larger than the previous tank. Therefore, the gas pressure will be reduced to half
of its initial value and there will be less amount of force acting on a larger surface area.
11
4. If the gas in a tank heated and all other factors remain unchanged, what will happen to
the gas pressure?
The correlation between pressure and temperature is known as the Gay-Lussac's Law.
The law explains that, for a vessel of constant volume, as the temperature increases, the
gas molecules will receiver greater kinetic energy which leads to higher frequency of the
molecules colliding with the inner wall of the tank. Hence, the gas pressure in the tank
increases.
5. What is the pressure measuring instrument used in this plant?
There are several pressure measuring instruments used in the process instrumentation lab.
Those which we managed to identify are pressure gauge, pressure transmitter and
manometer.
6. Discuss briefly the possible errors affecting the accuracy in pressure measurement as
observed in the experiment.
The possible errors affecting the accuracy in pressure measurement in this experiment are
the presence of water vapour in the tank due to inefficiency of the AFR and faulty wiring
of the instrumentation. These errors can be prevented or overcome by conducting the
appropriate actions.
12
7.0 REFERENCES
1) Instrumentationtoolbox.com. (n.d.). Instrumentation Basics: 4 - 20mA and 3 - 15psi

Control Signals. Retrieved from
http://www.instrumentationtoolbox.com/2011/01/instrumentation-basics-control-
signals.html#axzz586sr6xLZ
2) WIKA. (n.d.). Common Reasons for Pressure Transmitter Failure - WIKA USA.
Retrieved from
https://www.wika.us/solutions_pressure_transmitter_failure_en_us.WIKA
13
8.0 APPENDICES
For pressure measurement using an example of run 6 ,
Finding calculated absolute pressure (average)
𝐹 = 𝐵 + 14.7
= 1.11 + 14.7
= 15.79
Finding gauge pressure deviation
 At pressure gauge
𝐺1 = | 𝐵 − 𝐶 |
= | 1.11 − 5.00 |
= 3.89
 At pressure indicator
𝐺2 = | 𝐵 − 𝐷 |
= |1.11 − 5.05 |
= 3.94
Absolute pressure deviation
𝐻 =|𝐹−𝐸|
= | 15.81 − 19.75 |
= 3.94
14
Calculating the % accuracy at 0.30/15.00 at 25% ,
(𝐶−𝐷)𝑚𝐴
=| | 𝑋 100
𝐷 𝑚𝐴
(7.80 − 8.00)𝑚𝐴
= 𝑋 100
8.00 𝑚𝐴
= 2.50%
Calculating the deviation
(𝐶 − 𝐷)𝑚𝐴
= 𝑋 100
(20 − 4)𝑚𝐴
(7.80 − 8.00)𝑚𝐴
= 𝑋 100
16𝑚𝐴
= 1.25 %
15

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LABORATORY REPORT (JAN 2018) PROCESS INSTRUMENTATION (CLB 21103)

2.0 Summary ......................................................................................................2

3.0 Introduction & Theory .................................................................................3

4.0 Results and Discussion .................................................................................4

5.0 Conclusions and Recommendations ..........................................................10

6.0 Tutorial .......................................................................................................11

8.0 Appendices .................................................................................................14

 To determine the accuracy in Bourdon Gauge readings and calibration requirements

3.0 INTRODUCTION & THEORY

4.0 RESULTS AND DISCUSSION

TABLE 1: Pressure Measurement

RUN 1 SET 1 SET 2 AVERAGE

RUN 2 SET 1 SET 2 AVERAGE

RUN 3 SET 1 SET 2 AVERAGE

RUN 4 SET 1 SET 2 AVERAGE

RUN 5 SET 1 SET 2 AVERAGE

RUN 6 SET 1 SET 2 AVERAGE

RUN 7 SET 1 SET 2 AVERAGE

TABLE 2: PT1 Site Calibration Check

TABLE 2: PT2 Site Calibration Check

5.0 CONCLUSIONS AND RECOMMENDATIONS

2. Differentiate absolute pressure and gauge pressure.

 Absolute Pressure – Actual pressure at a given position and it is measured

 Gauge Pressure – Pressure relative to atmospheric pressure.

(Figure above illustrates both absolute and gauge pressure.)

5. What is the pressure measuring instrument used in this plant?

1) Instrumentationtoolbox.com. (n.d.). Instrumentation Basics: 4 - 20mA and 3 - 15psi

For pressure measurement using an example of run 6 ,

Finding calculated absolute pressure (average)

Finding gauge pressure deviation

Absolute pressure deviation

PT1 Site Calibration

Calculating the % accuracy at 0.30/15.00 at 25% ,

Calculating the deviation

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