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LAB MANUAL
FOR
Industrial Instrumentation
NAME: _________________________________________________________
INDEX
Sr. Page
Date Sign.
No. No.
Measurement and control of temperature
1
using RTD.
Measurement and control of temperature
2
using thermocouple.
To perform and measure the pressure by using
3
the pressure transducer.
To study the operation of synchro transmitter
4
and receiver.
To perform strain measurement using strain
5
gauge.
To study and perform the linear variable
6
differential transducer (LVDT)
To study and perform analog to digital
7
converter.
To study and perform digital to analog
8
converter.
To study angular displacement by using
9
electrical transducer.
INDUSTRIAL INSTRUMENTATION 1
LDRP‐ITR, GANDHINAGAR
Experiment No: 1
DATE:
Appartus:
a. Adtron’s trainer kit
b. Adtron’s heater unit
c. Digital multimeter
Theory:
Rt = R0 (1 + α0 Δt)
Generally Platinum (-190 to 660 0C) and Nickel (0 to 325 0C) are used
as metal resistance wire diameter varies from 0.002 to 0.06cm depending
upon the range. The wire is tested for purity and wound on a framework to
form a coil. Different framework are chosen for different kinds of
application .for instance ,a mica cross is used general purpose application
whereas for the surface temperature measurement a strain gauge type mesh
may be used. In case of measurement of temperature of flowing liquid layer
a self supporting helical form is more useful as shown in figure.
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The RTD’s are the most accurate of all the temperature transducers.
An accuracy of 0.000/ 0C can be achieved by these transducer and these are
very convenient for small temperature differences. However they have
inherent drawbacks of heat loss i.e. self heating error (=12 RT) thermo EMF
and requirement of separate power packs.
Procedure:
1. Connect the RTD probe to the RTD input jack provided on the panel.
2. Connect RTD in the bridge at points A&B respectively.
3. Also connect the heater unit to the main unit by the connecter
provided
4. Now connect the required supply and switch ON the unit.
5. Put switch S1 in the set temperature position.
6. Adjust with the Potentiometer P, the set temperature to the required
temperature say 35 0C.
7. Now keep the switch S1 in the actual temperature position and
observe the actual process temperature. We will observe that if the
actual temperature is say about 30 0C then the relay ON LED lows and
power delivered to the temperature increase and reaches temperature
approaches the set temperature the relay becomes ON & OFF to
maintain the error between the ser value and actual value to the
minimum.
8. Repeat the experiment with different set say 40 0C, 50 0C, 60 0C etc.
Conclusion:
INDUSTRIAL INSTRUMENTATION 3
LDRP‐ITR, GANDHINAGAR
Experiment No: 2
DATE:
Apparatus:
1. Adtron’s triner kit
2. Adtron’s heater unit
3. Digital multimeter.
Theory:
Thermocouples are most important temperature transducer in the
industry application. They work on the See back’s principle of thermo EMF
that “when two dissimilar metal are joined as shown in fig with metal are
joined as shown in fig with the junctions J1& J2 at temperature T1 & T2
respectively, then an EMF is generated causing a current to flow in the
circuit”. The reflection between output voltage (in mv) & junctions
temperature has been found empirically as
E = Σk 1/n * α* tn
n=1
The term ‘t’ is the hot junction temperature when the cold junction is
maintained at 0 0C. In practice K=3 is found to be sufficient .The constant α
depends on the materials of the thermo elements (metals)
Sr.
Type Combination Temperature Range
No.
Advantages of thermocouple:
1. Rugged construction
2. Inexpensive
3. Simpler to use than thermometer
4. Extremely wide temperature range 2700C to 28000C
5. Absence of need for bridge circuit
6. Good Accuracy
7. Electrical output adaptable to a variety of read out and control devices
8. High response speed compared to filled system thermometer
9. Calibration checking made easy
10. 0Good reproducibility
Disadvantages of thermocouple:
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Procedure:
Conclusion:
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Experiment No: 3
DATE:
Apparatus:
1. Adtron Kit
2. Pressure developing system
Theory:
(Rp – Ro) = Δ R = Ro β ΔP
INDUSTRIAL INSTRUMENTATION 7
LDRP‐ITR, GANDHINAGAR
WORKING:
Figure 1A shows a bridge circuit with four strain gauges Rsg1, Rsg2,
Rsg3 and Rsg4. Two strain gauges Rsg1 and Rsg4 are mounted so that
increasing pressure decreases their resistance. A change in temperature
affects all the four strain gauges in the same way resulting in no change in
the pressure direction.
Observation table:
Pressure Voltage
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Procedure:
Conclusion:
INDUSTRIAL INSTRUMENTATION 10
LDRP‐ITR, GANDHINAGAR
Experiment No: 4
DATE:
Apparatus:
1. Synchro transmitter
2. Synchro receiver (control transformer)
Theory:
The rotor is given single phase A.C. supply through two slip rings.
The resultant current produces a magnetic field and by transformer action
induced voltage in the stator coil depends upon the angular position of the
coil’s axis with respect to rotor axis.
Synchro can be subdivided into two basis groups, the torque units and
the signal transmitter units. Torque synchros do not amplify torque. This
type of transmitter is analog to mechanically driving a load through a
flexible shaft. Being open loop torque synchro transmitter suffers from
reduced accuracy and reduced sensitivity.
Procedure:
Conclusion:
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Experiment No: 5
DATE:
Apparatus:
Theory:
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Compensation Technique:
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adhesives and cement used should be non hygroscopic and should not
become brittle (breakable) in course in time.
Procedure:
1. Connect the trainer kit to the mains supply and switch ON.
2. Connect the strain gauge transducer to the input socket of the kit.
3. Connect the output of instrumentation amplifier to the digital
indicator.
4. Now adjust the zero adjustment potentiometer to get zero reading on
the indicator.
5. Now place the weight of 100 gm at the centre or near the border of the
pan fitted on the strain gauge cantilever arrangement.
6. Observe and note down reading.
7. Place and weight from 100 gm to 500 gm (1 kg maximum) in such a
way that maximum stress is applied at the cantilever arrangement. Put
the weight near the border of the pan. Note the reading of amplifier
output for each increment of 100 gm.
8. Draw the graph of weight v/s output in micro-volt.
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Observation table:
Conclusion:
INDUSTRIAL INSTRUMENTATION 18
LDRP‐ITR, GANDHINAGAR
Experiment No: 6
DATE:
Apparatus:
Theory:
The most commonly used inductive to translate the linear motion into
electrical signal is the linear variable differential transformer (LVDT) the
basic construction consists of a signal primary winding P1 and two
secondary winding S1 & S2 wound on a cylindrical former. The secondary
windings have equal number of turns and are identically placed on either
side of primary winding. The primary winding is connected to an alternating
current source. A movable soft iron core is placed inside the former. The
displacement to be measured is applied to an arm attached to the soft iron
core. In practice the core is made up of nickel iron alloy which is scatted
longitudinally to reduce eddy current source. When the core is in its normal
(null) position equal voltage arc induced in two secondary winding. The
frequency of the A.C. applied to primary may be between 50Hz to 20 Hz.
When the core is at its normal (null) position the flux linking with
both the secondary winding is equal and hence equal emf’s are induced in
them. Thus at null position Es1 – Es2. Since the output voltage of the
transformer is the difference of the two voltages the output E0 is zero at null
voltage. Now if the core is moved to the left of the null position more flux
links with winding S1 and less with winding S2 i.e. Es1 > Es2. The magnitude
of the output voltage is thus Es1 – Es2 and output voltage of the secondary
winding.
INDUSTRIAL INSTRUMENTATION 19
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Disadvantages of LVDT:
Use of LVDT:
Procedure:
Observation Table:
Displacement Output in
Sr. no.
in mm D.C. mill volts
Conclusion:
INDUSTRIAL INSTRUMENTATION 22
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Experiment No: 7
DATE:
Appartus:
A/D converter kit
Patch cords
Theory:
Resolution:
Accuracy:
Sampling Rate:
Over Sampling:
Circuit Description:
0. When this switch is moved to START position one shot will be triggered
and this will set the output of control flip flow to 1 level. Simultaneously the
START position of this switch will also make the counter start counting.
Two seven segment displays are provided to read the analog voltage
in decimal code directly. Another switch marked as ‘C’ and ‘P’ is provided
the clock pulse manually and automatically.States of the important point
displayed by LED to make clear understanding of A/D conversion.
Procedure:
1. Put the power ON-OFF switch to ON position JEWEL light will glow
on to indicate the instrument is ready to use.
2. Put the switch marked ‘C’ to ‘P’ position if you want to feed the clock
pulse internally. Put this switch to p position if you want to give
manual pulse from pulsar switch.
3. Set the analog input voltage to desired values with the help of
voltmeter provided on the panel. D.C. voltage can be varied from
0-15V by marked as ANALOG input.
4. Put the START-STOP switch to START.
5. Not the binary display on 4 lads provided at the output of counter or
the digital display on two seven segment display.
Observation Table:
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Conclusion:
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Experiment No: 8
DATE:
Appartus:
D/A converter kit
Patch cords
Theory:
DAC Types:
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LDRP‐ITR, GANDHINAGAR
determined by a digital input code. This technique is often used for electric
motor speed control and is now becoming common in high fidelity audio.
Over sampling DACs such as the delta signal DAC type. A stable current or
voltage is switched into a low pass analog resolution DAC internally.
Circuit Description:
5 volt in this case. A press switch marked as clock is provided to transfer the
data ‘D’ input of he flip flops to ‘Q’ input. Another press switch as CLEAR
is provided to CLEAR the register flip flops when this switch is pressed
momentarily all the D flip flop will be cleared off.
The four flip flops form the register necessary for storing the digital
information. The flip flops on the right represent the LSB and the flip flop
on the left represents the MSB. Each flip flop is 0 the simple D type and its
truth table is given below:
D Clock Q
0 1 0
1 1 1
Level amplifiers work in such a way that when the input from a flip
flop is high the output of the amplifier is at 5V when the input of resistive
ladder network analog output is 0 volts.
Output of level amplifiers are fed to the from inputs of resistive ladder
network analog output of D/A converter can be seen with the help of a
voltmeter provided at the left hand side of panel voltage at different points of
the ladder network can also be seen on the voltmeter.
Procedure:
1. Put the power ON-OFF switch ON position Jewel light will glow on
to indicate the instrument is ready to use.
2. Press the CLEAR switch to clear the output of all flip flop of storage
register.
3. Keep the input state switches at desired binary number.
4. Press the CLOCK switch to transfer desired input stated to the output
Q to each flip flop or at input amplifier.
5. Output of level amplifier will be at 5V for 1 level and 0 volt for 0
levels. LEDs are provided to indicate these stages at the input of
ladder network. LEDs will glow for 1 level and it won’t glow for 0
levels.
6. Connect the output V to positive and ground to negative terminal of
voltmeter to vad the corresponding analog output voltage.
INDUSTRIAL INSTRUMENTATION 29
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Observation Table:
Conclusion:
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Experiment No: 9
DATE:
Apparatus:
Adtron kit
Multimeter
Theory:
Application:
Angular displacement sensors or angle sensors can be used in
laboratory or industrial environment to measure or control angular
displacement the position of a moving body its rotary speed. The different
application for angular displacement sensors are online monitoring, safety,
tests macaronis etc.
INDUSTRIAL INSTRUMENTATION 31
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Procedure:
Observation Table:
Angular
Voltage(mV)
Displacement(θ)
Conclusion:
INDUSTRIAL INSTRUMENTATION 32
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Experiment No: 10
DATE :
THEORY :
A universal flow meter for all applications is not available and
probably never will be. There are, in fact, more ways of measuring flow than
of measuring pressure and temperature.
Flow can be measured by flow rate or flow volume:
Flow rate is the integrated velocity of the individual stream lines
making up the total velocity profile across the conduit.
Flow volume is the total volume of the fluid which has passed
through the conduit over a given period.
Flow measurement can be classified as under:
INDUSTRIAL INSTRUMENTATION 33
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ADVANTAGES :
1. Simple, no moving components.
2. A wide range of sizes and constructions are available.
3. Suitable for most liquids and gases.
4. Well proven and widely used.
5. Very good repeatability.
INDUSTRIAL INSTRUMENTATION 34
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PITOT TUBE :
The pitot tube is mainly an open-ended tube, positioned so that
the opening faces the flow stream of the fluid being measured.
This results in an impact pressure being produced in the tube,
which is derived from the loss of kinetic energy of the stream
striking it.
ADVANTAGES:
1. No moving components.
2. Unless made excessively large in relation to the size of the
pipeline, it produces very little pressure loss.
INDUSTRIAL INSTRUMENTATION 35
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ADVANTAGES :
1. Simple, can measure very low flows, low cost and easy
installation.
2. Flow rate can be read directly from a linear scale.
3. Substantially unaffected by approach pipe work.
4. No power supply is required for the glass tube meter.
5. The pressure loss due to the meter is low and constant.
DISADVANTAGES:
1. The glass tube meter is not suitable for high pressure, which
depends on the tube diameter.
2. Their capacity for maximum flow is limited.
3. The meters must be mounted in the vertical position.
4. Only clean fluids can be used with the glass tube type. Any
build-up of dirt on the glass surface makes the reading difficult.
INDUSTRIAL INSTRUMENTATION 37
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ADVANTAGES:
1. Good accuracy over a wide range and very good repeatability.
2. Suitable for high viscosity fluids and can accommodate large
viscosity changes.
3. Local or remote readout is available.
4. Wide flow range.
DISADVANTAGES:
1. The close tolerance required for the moving components makes
them susceptible to wear.
2. Frequent maintenance is required.
3. They are not suitable for dirty, non-lubricated or abrasive
liquids.
4. For the large sizes, they are bulky.
5. They develop a high unrecoverable head loss.
6. Installation is difficult and time consuming.
7. They are expensive, especially for the larger sizes.
TURBINE FLOW METER :
A turbine flow meter is basically a rotor fitted with a number of
blades: it is mounted in the centre of a pipeline with its axis parallel to the
flow. The blades rotate when the fluid impinges on them; the angular
velocity is proportional to the fluid velocity, which in turn is proportional to
the flow rate.
DISADVANTAGES:
1. Not suitable for high velocity fluids.
2. Individual calibration is required.
3. Damage can occur due to over-speeding or gassing. Moving
parts are subject to wear and damage.
4. Affected by upstream flow conditions. Filtration is needed.
5. Secondary readout is required.
INDUSTRIAL INSTRUMENTATION 39
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DISADVANTAGES:
1. Fluid must be electrically conductive (Not suitable for gases).
2. Subject to drift and therefore requires frequent checking.
3. Sensitive to asymmetric flow profile.
INDUSTRIAL INSTRUMENTATION 40
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As the vortex sheds on the one side of the bluff body, the
velocity on that side increases and causes a drop in the pressure. At the same
time, the opposite effect occurs on the other side, the velocity decreases and
the pressure increases. Therefore, the velocity and pressure distribution
around the bluff body changes at the frequency as the shedding frequency.
Either the pressure or the velocity changes can be measured by various
methods.
A potential difficulty is that most of the frequency sensors are
affected by vibration and some of them, particularly the capacitive type, can
be blocked and possibly damaged by dirt. Stream flow measurement with
INDUSTRIAL INSTRUMENTATION 41
LDRP‐ITR, GANDHINAGAR
this type of meter raises problems because of the fluid film that tends to
mask all sensors.
ADVANTAGES:
1. Contains neither moving part nor components affected by the
measured medium.
2. Complete no -obstruction of the pipe bore.
INDUSTRIAL INSTRUMENTATION 42
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DISADVANTAGES:
1. For the Doppler system the measured medium must contain
particles capable of reflecting sound waves.
2. The position of particles the flow profile the size of particle and
the relative velocities of particle and fluid all affect the Doppler
meter performance.
3. Maximum operating temperature is limited.
4. The claims for the accuracy and repeatability differ widely
from the proven values obtained from field mounted equipment.
The difference has been found to be greater for the Doppler
meter than the 'Time of Flight' meter.
RELEVANT IS:
1. IS 10189 (PT 2/SEC 1) : 1993 Industrial process control
valves : Part 2 Flow capacity, section 1 sizing equations for
incompressible fluid flow under installed condition.
2. IS 10189 (PT 2/SEC 2) : 1993 Industrial process control
valves : Part 2 Flow capacity, section 1 sizing equations for
compressible fluid flow under installed condition.
ASSIGNMENT:
1. Enlist the various solid and gas flow meters. Explain working
of each in brief with principle, diagram, advantages and
disadvantages.
Prepare a comprehensive note on Liquid Level Measurement and
answer the following:
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