| PURDY’S INSTRUMENT HANDBOOK By Ralph Dewey -_ aes fF ss en = sPURDY’S INSTRUMENT HANDBOOK By Ralph Dewey © Copyright 1996 by Ralph Dewey This book and many others are distributed by Maintenance Troubleshooting “The Biggest Name in Little Books” Additional copies are always In-Stock. Maintenance Troubleshooting Books 273 Polly Drummond Road Newark, DE 19711 (800) - 755-7672 Toll Free email: mtrouble@mtroubleshooting.com Web Site: http:/ /www.mtroubleshooting.com Ask for Pricing or our FREE Discount Catalog We take Purchase Orders, Visa, MasterCard and American Express and ship within 72 hours.OUR PURPOSE ‘This book represents years of instrumentation experience and know-how. It contains notes, examples, procedures, hook-up drawings and tables. Since most of the information is general in nature, there will be exceptions and cases where it will not applicable, Information in his book is not intended to overrule common sense or to violate any safety procedures or laws, This book was written with the assumption that the reader/user has some basic instrumentation knowledge and experience. It will be uscful to instrument crafispersons, operators and engineers as a quick reference, Our purpose was to make a field book, rather than a textbook, We have tried to make all of the information usefull, accurate and clear. However, neither the author nor Publisher shall be held responsible for any errors in content or the application of the information in this book or any damages or loses from its use. If you have any suggestions for improvements to this book, write and let us know about them. pe ISBN 1-880215-26-38 ABBREVIATIONS & ACRONYMS LAS FC FO FL FIP A/O AIC ATC ATO SP. LP VO SCFM SCFH GPM GPH UPS dBA pH DVOM P.S. ocs Instrument Air Supply Fail Closed Fail Open Fail Locked Fail in Place Air to Open Air to Close Air to Close Air to Open Set Point Current to Pacumatic Transducer Input/Output Standard Cubic Feet per Minute Standard Cubic Feet per Hour Gallons Per Minute Gallons Per Hour Uninterruptible Power Supply Decibels (or dB) Acid/Caustic term Digital Volt, Ohm, Meter Power Supply Distributed Contral System +MORE ABBREYV. & ACROD} ¥YbDC Volts Direct € VAC Volts Alt LRY Lower Range URY Upper Range MIR Minutes per Rey RIM Repeats por Minute Dir. Direct Rey, iu Inc./Ine, Tnc./Dec. ase/Inerense (direct : se/Deerense (reverse action) DEFINITIONS ALIGNMENT Adjusting the various parts of a contraller to make them work together properly, thus climinating offset. ANALOG SIGNAL A signal that has an infinite number of values and varies in strength, Two common types are 4 to 20 milliamps and 3 to 15 psig. AUTOMATIC CONTROLLER A device that compares process condition with the set point and generates the appropriate corrective action, CALIBRATION The adjustment of a measuring device, transmitter, gauge, transducer, cte, for the best accuracy of its range, signal or set value. CLOSED LOOP A control system where information and responses are continually felt throughout a closed loop. CASCADE CONTROL Automatic control involving the cascading of controllers such that the output of one controller varies the set point of another controller. CONTROLLER FEEDBACK The input signal to the controller representing the condition of the controlled yariable, either positive or ne; Ce DERIVATIVE ACTION A control mode that provides atemporary output boost based upon the RATE of the process change. The faster that the process changes, the greater the derivative action. DIGITAL SIGNAL A signal that has only two values, on and off. One type of digi nal uses a series of on/off pulses to communicate information. ELEVATION In level applications, compensation for an unwanted signal on the low pressure side of a differential level transmitte RANGE The lowest and highest values where a device or instrument operates, A range is always ¢ with two numbers, the lower range value (LRV) and the upper range value (URV). &RATIO CONTROLLER A controller that maintains a fixed ratio between two or more process variables. SET POINT The desired process value that a controller or control system is asked to achieve. SPAN The numeric difference between the lower and upper range . It is abyays expressed asa single numeric yaluc. SUPPRESSION In level applications, compensation for an unwanted alon the high pressure side of a differential level transmitter, TRANSDUCER An instrument device that translates one type or form of a signal into another type. An TP transducer converts a 4-20 ma input signal into a 3-15 psig output signal. VISCOSITY A term representing the res fluid to flow. ance of a MAINTENANCE TIP Ensure that 3-valve instrument manifolds are not installed backwards on flow loops. Do not use 3-valve manifolds on level loops that have seal legs. There is a risk of losing the seal fluid if the by-pass valve is opened. COMMON He—o—o— INSTRUMENT SYMBOLS PRESSURE TRANSMITTER CONTROL VALVE INSTRUMENT SUPPLY OR PROCESS CONNECTION PNEUMATIC SIGNAL LINE ELECTRICAL SIGNAL CAPILLARY TUBING HYDRAULIC LINE ELECTROMAGNETIC OR . SONIC SIGNAL (GUIDED) SOFTWARE OF DATA LINK liee) ©eS8e8eO LOCAL FIELO INSTRUMENT PANEL MOUNTED INSTR. DCS (or PLC} INSTRUMENT FIELD PANEL MOUNTED INSTRUMENT PLC OR COMPUTER INSTRUMENT TWO INSTRUMENTS IM THE SAME CASE, PANEL MTG. INSTRUMENT MOUNTED BEHIND PANEL INSTRUMENT MOUNTED BEHIND FIELD PANEL COMMON INSTRUS PREFIXES FOR LOOPS AT AIC CT DT EIT FIC FO FE FOR FFC HS IR IR LG LSH Analyzer Transmitter Analyzer Indic Controller Conductivity 1 hitter Density (or Sp Gravity) Transmitter Voltage (EMF) Indicating Transmitter Flow Indicating Controller Flow Orifice (Restriction Orifice) Flow Element (Measuring Orifice) Flow Integrator (Totalizer}) Recorder Flow Fraction (Ratio) Contraller Hand Switch Current Recorder Power Recorder Level Glass Level Switch High LAHH Level Alarm High High MT PIC Moisture (Humidity) Transmitter Pressure Indicating ControllerPY Pressure Relay or Compute SP. GRAVITY & VISCOSITY OF LIQUIDS Approximate values at standard conditions. f 5 qi (Could be an I/P Transducer) (temperature will vary values) $.G. centipoise PY Pressure Valve (Control Valve} Acctic acid 1.050 1.40 PCV Pressure Control Valve (Regulator) Acctone 792 380 PDT Pressure Differential Transmitter Benzene 879.655 PSL Pressure Switch Low ae eel a es PSLL Pressure Switch Low Low Guanine 751 ST Speed Transmitter Hexane 664 30 TT Temperature Transmitter Hydrochloric Acid 164 31 TE — Temperature Element Isobutane S361 175 TI Temperature Scan ak re ae 2.2 TV Temperature Valve (Control Valve) Piesphorie acid " oe a TCV Temperature Control Valve Propane 509 13 (Process-powered Temp. Regulator) Silicone (DC-200) 920 350 Temperature Well (Thermowell) Sodium hydroxide - 30% 133 13.0 Weight (or Force) Element Sulfuric acid 1.83 26.7 Position Light (Pilot) wialee 1000 1.12 Position Switch Clased Position Switch Open Standard Conditions are and 60 deg. F. (Some xr companies use other values.) 0 it@ Example: 25 PRESSURE CONVERSION FACTORS imes 6.895 equals 172.375 kPa (Kilopascals) PSI ATM. LBVFT2 IN.H2O FT.H20 MMHg. IN.Hg. kPa Kg/CM2 PSI 1 068 | 144.0 | 27.73 | 2.108 | 51.715 | 2.036 | 6.895 | .0703 AMM, | 14.69 | i | 2476 | 407,54 | 33.959 | 760.0 | 29.921 | 404.92 | 7.0932 “Leet? | tess | oooar | 1 93 | 018 | 3604 | 0142 | Gava9 | onda LIN,H2O | 0367 | 00245 | 5.19 1 08333 | 1.865 | 07342 | 24864 | 00253 [FT.H20 | 4327 | 02945 | 624 | 12 1 22.48 | 88108 | 29836 | 03042 MMHg. | .0193 | 00131 | 277 | Sae2 | 04468 | 1 | 03937 | 13332 | 00136 zy [Ha _[ 480 | 3942 | vo.ar [3.619 [4.1349 | 25.4 1 | 3.3064 | 03453 | kPa 1450 | 00987 | 20.80 | 4.0210 | 3382 | 7.5006 | 2959 | 4 | .04079 Kgicm? | 14.22 | 96784 | 2048.2 | 394.41 | 32.868 | 725.56 | 28.959 | 98.066 | 1 _ MM Hg. is mi IN. H,O is inches of water, FT. H,O is feet of water, ATM. is atmosphere Kg/CW? is Kilograms per Centimeter Squared, LB/FT? is pounds per square foot imeters of Mercury, IN. Hg. is inches of Mercury IN. H,0 and FT. H,0 are at 20 °C, MM H,O and IN. Hg. are at 0 °C IN. H,0 at 15.5 °G (60 °F) times .678 = Ounces oz.) of H,0 Ounces (02,) of HO times 1.730092 = IN. H,O at 15.5 °C (60 °F) PRESSURE | ea? esta ATMOSPHERIC POL 7 MM tty > *) 29.92 FES Hy ARSOLE | ort LVCHES WATER ALSSPECIAL PRESSURE CONVERSIONS. Some pressure terms start at absolute zero and go upward while others start at atmosphere and go down, The following formulas are for special pressures or for pressure terms that go in opposite directions 407.1 - (MM Hg}.534) = In. Water Vacuum Example: 407,1 minus (120 millimeters of mercury times 534) equals 343.02 Inches of Water Vacuum 407.) - (Inches HG abs.)(13.6) = In. Water Vacuum 29.92 - (In. Water abs.}(.0735) =In. Hg Vacuum 762.7 - (In, Water vac.}(1.87) = MM Hg Absolute 407.1 - (PSLA)(27.7) = Inches Water Vacuum 14.7 - PSIA = PSI Vacuum L4.7 - Negative PSIG = PSLA 14.7 - Gn. Water vac..0561) = PSIA 407.) - Inches Water abs. = Inches Water Vacuum 407.1 - Inches Water vac. = Inches Water Absolute * Normally MM Hg is understood to be Absolute. 1 gallon of wate density of water = 62.5 Ib./cubic foot 1 cubic foot of water = 7.481 gallons 1 gallon = .13368 cubic foot 1 gallon = 231 eubic inches 1 cubic foot = 1,728 cubic inches Centipoise = (Centistokes)(Sp. Gravity) it $.33 pounds CONVERSION FACTORS Mw = Molecular Weight PPH = Pounds Per Hour SCFH = Std. Cubic Feet Per Hour SCFM = Std. Cubic Feet Per Minute 8.G. = Specific Gravity GPM = Gallons Per Minute GAS FLOW PPH SCFH = ——— ( 379.2} Mw PPH SCFH = LE/FT’ @ BASE 13,1 SCFM = PPM 5.G. PPH (6.32) SCFM =—_____— Mw 5 rr aPPH = (SCFH)(S.G.)(.0764) FLOW [EUROPE to USA} em3/min = X_ .00026417 = GPM Mw)(SCFH cm3/min X= .002118 = SCFH PPH = (Mwy ) Ymin X .26417 = GPM 379.2 Vmin X 2.118 = SCFH . m3/min X 264.17 = GPM (Mw)(SCFM) m3/min -X 2118.88 = SCFH PH —— FLOW [USA to EUROPE] . GPM X = 3788 = em3/min GPM X 3.788 = min LIQUID FLOW GPM X .003788 = m3/min SCFH X $72.14 = em3/min H GPM = PP SCFH X 472 Vmin (8.3378)(*S.G.)(60) SCFH X = .000472, = m3/min PPH = (8.3378)(*S.G.)(GPM)(60)) DENSITY FORMULA * S,G. at flowing contitions PSIA = Pounds Per Sq. Inch Absolute Zf*- = Compressibility Factor GPM = (449)(CFS) Ib/fi3_ = Pounds Per Cubic Foot CFS = Cubic Feet Per Second (Mw)(PSIA) Ib/fi3 = (10.73)(460+ deg. FZE) - 6 7Metric Unit Prefixes Prelix Symbol Numerical Value mega M million kilo k thousand ane deci tenth canili hundredth Ol iil thousandth O01 at micro nil tior Ltt 000 001 pico trillionth 000 000 G60 001 SAFETY TIP Before removing a transmitter, check to see if it is part of a shutdown system, double check that you are on the correct instrument, and make sure the control loop is in manual, METRIC DECIMAL CONVERS <7 DECIMAL TG LEFT, » = TO THE RIG T. to af T T 1 | vega | Kile pe centi| Milli Fico | | | =e | ae feds be bese ss aes | Kilo | 2> a> 62> | 12 1 | Unit | | | : ! | | 1 Pa ged eee es 2 sil oa [ieee . -| 3S E: | 8 6: a) <9 sé] MAL POINT 4 PLACES RIGHT @ HOVE DECE SAFETY TIP When bleeding off a transmitter, have you checked the direction of the wind? Do you have an eseape path? Could the product drip on workers below? Should it be routed to a vent header?LOOP LOAD LIMITATIONS The typical “Two-Wire” transmitter loop uses a 24 VDC power supply voltage and has a total resistance of about 255 to 260 ohms. That would be the DCS. input resistor (250 ohms) plus a small amount of lead wire resistance. There is a limit to how many devices that can be added to a “Two-Wire” loop. Tf your supply is 24 VDC, the maximum load is 600 chms Use the formula below for other supply voltages. Max. Load Power Supply = +12 Voltage 50 If your total resistance 1s 800 ohms, you will need at least 28 VDC. Most DCS systems are designed with a fixed 24 VDC supply so if an increase 1s needed, a field power supply will be needed. NEC® IS A REGISTERED TRADEMARK OF THE NATIONAL FIRE PROTECTION ASSOCIATION, INC, , QUICNY, MA. ao UNDERSTANDING 4-20 MA SIGNALS A typical 4-20 ma controller has both an input and an output signal of 4 to 20 milliamps, However there is a difference between them. You should be able to measure close to 24 VDC across the controller’s input terminals and almost as much voltage across the input leads of the field transmitter. However, if you measure across the output terminals of the controller or across the input of the field transducer (I/P), you may only measure about 5 to 8 WDC. This ig entirely normal, A controller only puts out enough voltage that is required to support (or push) the 4-20 milliamp signal. MAINTENANCE TIP Loops that are powered from the field will be terminated on the DCS differently than loops that get their 24 VDC power from the DCS. Double check the wiring configuration,120 VAC POWER TTT THEUTRAL! 24 VDC POWER BLACK Mae -_— POSIT WHIT OSITIVE oh Patron APROLIN ee SROUND A SHEIC 4 SAFETY TIP Always use one hand to measure voltages, Keep the other hand in your pocket to prevent a path through your heart. FAILSAFE ALARM (HAS CONTINUITY) CLOSED LOOP, ALARMS UPON FIELD OfVvICE OPENING, 2 FIELD CONTACTS 4 “OR Logic *— “AND” LOGIC ot CONTACTS IN SERIES CONTACTS IN PARALLEL NON-F Al E ALARM (NO CONTINUITY) GPEN LOGF, ALARMS UPON FIELD DEVICE 2 FIELD CONTACTS “OR LOGIC —*- CONTACTS IN PARALLEL CONTACTS IN SERIES SAFETY TIP If you discover an electrical shock victim that is still touching wires, use a non-conductor to pull the vielim clear or to pull off the wires.OPEN-CO ALARM +; : - Sueee 1K OHMS 5 vealed aIODE : MIM IMEI Pes VIE ma Fy tlhe aw = KG Qo & g eee 2505 4£O.0u aa: WDC MAX zk FAILSAFE LEVEL SWITCH HIGH | | 100% (75 PSI ot - 75% (1 = = & = ce 5 eet o — 50 (9 PSIG) Oe - 25% ertiesSIMPLE FAILSAFE ALARM NON-FAILSAFE ALARM WITH ACKNOWLEDGE PLUS HOT WITH ACKNOWLEDGE NEUTRAL TEST LIGHT AND HORN. POWER SWI LSH ALARM CONTACTSTHERMOCOU PLE INFO RMATION a [fryer * WIRE = WIRE seh AEE = = - = a Iron Conetantan D to 1200 F White Red (magnetic) E Chromel Conetantan -300 to Purple Red 1600 F K | Chromel ALameL 800 to Yellow Red 2000 F (magnetic) T Copper Constantan -300 ta Blue Red 200 F THERMOCOUPLE ‘ARRANGEMENTS DIFF. AVERAGE 2 t +8 Ya z 7 2 | & |S s os o| 2 |e s Voie 8 e) & |S a lee] ¢ & | ta] Lolar|] & Net) tet L o a AYHO NOISHIANGS San lLvaad a1 eg . Kelvin dees net use the degree Note: symbel. > *F-32(5/9)=10 "C EXAMPLE: (°F-32) 5555 459.09 + °F "GE °R °F= 18 (C)+ 32 K °C+ 273.15100 OHM RTD CHART Resistance vs Temperature for a 100 ohm platinum RTD (Alpha = .00385) DIN 43760 and BS 1904 Degree F Degree C Ohms 1000 537,78 293.49 900 482.22 275,04 $00 426.67 256.23 700. 37LAL 237.07 600 315,56 217,55 S00) 260,00 197.69 400 204.44 177A? 300 148.89 156.90 200 93.33 135.97 150 65.56 125.37 100 37,78 114.68 50 16,00: 103.90 oO -17.78 93.03 -30 45,56 82.06 -100 -73,33 70.98 Bo LINEAR INTERPOLATION Find the ohmic value for 420 degrees F. When only given values above and below it. 450° = 187.620, 400° = 177.47 450 - 400 420 - 400 187.62 - 177,47 M-177.47 50) 20 11S X- 17747 50 (XK - 177.47) = 203 X= 181.53 Ohms [420°F = 181.530] MAINTENANCE TIP Make sure that all RTD and thermocouple sensors are fully “bottomed out” in their thermowells, All temperature sensors must make firm contact in order to sense the process temperature correctly. at120 Ohm Nickel RTD Temperature Coefficient of Resistance = 006720 ohms/ohm/degree C. | Degrees F Degrees C | 400 204.44 | 300 148.89 200 3.35 100 37.78 0 -17.78 10 Ohm Copper RTD Temperature Coefficient of Resistance = 004274 ohms/ohm/degree C. Ohms 208.68 247.82 194,62 148.07 107,66 Degrees F Degrees C Ohms 400 300 200 10g 0 204.44 148.89 93,33 37.78 17.78 16.95 14.78 12.64 10.49 $.53 7 Benny Resistor EEDED) TEMP, TRANS RES ANCE DECAGE BOX CALIBRATION FIG. 1 SHEATH A FOUR WIRE RTO % SAFETY TIP Don't try to remove pistons from piston actuators by applying air pressure. ‘The piston could shoot out like a cannon ball and injure someone. ccdMEASURING A T.C, SIGNAL Measuring a type "J" thermocouple 1. Measure the C/J temperature with a thermometer and using the appropriate T.C. tables, find the mv = a wo. aquivalent for it. If 80 degrees F was measured, Ho. 2 eat it would be 1.363 my Ez E oa Bag at OQ ul ae A. ; iO ce le? 2. Note the reading [.855 my] on the test my pot. In a oe i > our example the lead wires had to be crossed in order * > Lu = to get that reading. This means that the .856 mv = indicated on the test potentiometer is really a negative value, namely -.856 mv. Algebraically ADD the Cid my equivalent (1.363 mv) to the test my pot. reading (-.856 mv}. The answer is S07 my, 3. Lock up in the T.C. tables to find the true hat junction temperature for a mv equivalent af S07 This measured my velue translates ta a temperature R ® A of 50 degrees F. al a 38 : ‘ t FA oi @ = “In this case the test my pot. lead wires had te be Lal 5; ae so reversed and therefore the reading was negative. When rae dS eyes lead wires do not need to be reversed, the indicated my value would be positive. BEEEEEEEEDRIVING A T.C. SIGNAL Input range of 100 to 400 degrees F. (type 1, Using a thermometer, measure the cold junction temperature. From the thermocouple tables, find the C/J (cold junction) millivolt equivalent. In our example the temperature is 80 dag. F and it's millivolt equivalent is 1.363. 2, Select a temperature within the range of the temperature potentiometer. 100 degrees F was selected. Use the tables to find the cold junction millivolt equivalent which is 1.942. 3. Algebraically SUBTRACT the CiJ mv equivalent from the selected temperature mv equivalent, The answer is .579. *see nate below 4, Drive (using the test potentiometer) a 579 mv signal into the temperature potentiometer. It should indicate 100 degrees F. “Ifthe answer is 4 negative number, the leads must be reversed to drive the correct temperature signal. SEE EH EE Type Deeignntan 1 an ae NEMA and NEC Enclosure Types ational Electrical Macutacturers Anaesintion NEMA Standarée t10-1979. Intended Use and Description Enclosures ave intonting tor indoor use plimariy ta pronda a deges af protection against contact with the enclosed euin- mont Engloares are intended for indoor use orimarity io provide 8 Gagne of protection aqnins| immed amounts af falling water andor Encinauifea are intended fer auigeot use arimanly tc provide 2. dogroc of prolection against wrdolown duit, rain, leet, ancl ecxlernal ice formation Enclosures are iniendnd tor curktoor une primaity ko provide a degree of proiectian ayainks taling rain, slog! and extomal ice sora indoor or outdoor use prmarily be iret wineioiown clust andi rain, Ensiosures ate intended for indoor o cunidoer usa peimntly 16 Powice 0 dagres a! protectin agensl comosion, dust and fain, splashing wates, and hoso.dincind wna Subenouble, walerigh, dushoht and see!ioa) resistant— inoper snd quldooe. ype Gerciodunmas pubis lerindooe and ‘outdoor applicatce whom the ocapmert may be subject 00 O6- Tasionel sumersion, as i qubenes, mings nnd manholos. The Socign of the enclosuie wll depend upon the spacihed eond+ ons ol pressure and tine ‘Sines | [Groups 4, 8, C a7 Dp indoce Hazardous Locations Ar Break Equioment Sutabla 19 insoons, these encores are ecsigned 1 mest the agglicaton requivomecen of the Naticeunl Floctical ode tor Glass | hazardous locations which may me i etlect roen Eva to time In thie type of equiamant, the creuit in. ‘TeATUpoan OsoUrE we Class 11 (Groups E, F, or G) bndoge Hazandeus Locallans—Alr Fraak Ecuipmeet Suitable tor meoors, thabe enclosaras are designed 1a mocl Ihe aaicalisn requenments al te Navonal Electrical Code for Clase 1. Groups E, F and G locaton. Enclosures ara infended tit doer uso pomarty 10 provide a cagrn a! protection against cust talling det, and depeing ream eorvasive Squid Enclowunes ste iendes tor indoo! ust primarily to provide a degees of prolecicn agairal dust, spraying of water, oll, and nonooTneiNe GOOLE, The geucading cenenipacns aca nat mended lo be comepinte mprasnmatare cf Natonsi lecine Manulacheers Assoaation standards fx ancktaras,OR COLOR CODE OHM’'S LAW/ POWER FORMULAS TOLERANCE SOLO aLUE GOLD SILVER, RESISTOR “EF” CODE Precision resistors often use a code that ends with the letter “F"_ The number just before the “F” denotes how many zeros should be added to the first three numbers, 274F = 2740 ohms, 2500F = 250 ohms, L003F = LOOK ohms SERIES RESISTANCE Ris RI-fZeels. MILLianeS x ONS COMMON DCS FUSE SIZES (hallpark vatues only) VOLTS Analog Inputs 24VDC 8 amp MILLIAMFS = ——— Analog Outputs 2VDC U4 amp Roe Digital Outputs 120VAC Variable up to 2 amps SARALLE! VOLTS Digital Outputs 24VDC Variable up to 2 amps 2:RESISTORS AM: PARALLEL = Digital Inputs 120VAC 1/4 amp a: ee == aaron Digital Inputs 24VDC 4 amp aPHONE OUT A WIRE To identify wires in a cable, use two old phone handsets and a9 volt battery, The entire system should be connected in series. Clip off the surge resistor found across the earpiece to help increase the system amplification, Connect onc lead from each handset to ground or the drain wire of the cable to be tested. It will take two people, one should pick a wire and the other person should systematically touch each wire until communication is made between the two people on the handsets. CUP OFF CUP OFF. RESISTOR “— DRAIN te WIRE "19 VOLT BATTERY = OF ACCURACY = AVIN READINGS SLio0 (ERROR) FULL SCALE SPAN TRUE PROCESS PRESSURE = 115 PSIG TRANSMITTER RANGE = 0-200 PSIG READING OF TRANSMITTER = 118 PSIG ae 178-115 ACCURACY = SX 100 (ERROR) 200 GF ACCURACY (ERROR) = 1.5% PEAK AVERAGE PEAK TO PEAK AC VOLTAGE FORMULAS @SWITCH LIQUID LEvi SSURE & VACUUM SWITCHES PRE J ; i uo ze |* f zz pu “ Eo ro Bi oO 2 3 | tz a= Ek ae a > Oo i "slg) = +8 oO > oe as WS F ae zy uvl2 AL S§ a Ea < fo - i @ = a ee as o =? Foye > alz A um SPDT SPST-N.C SPST-N.O, aasol3 ATTA ON sttoa pe xOILS av3H 370% ic rH ano Gai | 71880) KOOHHENAT ous s1Enod iNgwig STONIS LOvANOD OBNIv LN] LOWLNOD Ay LNSHOW SNOLLNG HSOdROTAMETER he 4 GAUGE _- SUPPLY “S QUTLET PRESSURE REDUCING REGULATOR PRESSURE REDUCING REGULATORS . The bast method to sel pressure reducing regulators is 49 the field under actual operating conditions. If you need 25 psig, simply adjust the knob on the top until yau get that output pressure, The test hook-up shawn above simulates the field flow conditions with a rotamete: js good only if you know the flow rate required. here could be an ervor if you set the regulatar without using the operating flow rat This is because as flow tmrough the regulator increases. the regulated output will tend to “Droop” or decrease. tL OUTLET REDUCING FEGULATOR| SWALL BLEEO BACK PRESSURE REGULATOR BACK PRESSURE REGULATOR A back pressure regulator operates Tike an adjustable relief valve. That is, it will begin to spen only when stream.pressure exceeds the set value. Suppose we wanted te set @ Gack pressure regulator te 35 psig. Hook back pressure regulator as shown in the drawing. ut test pressure to the decired pressure, 25 s case, Increase the back pressure regulator inti] pressure [any amount) starts showing on the rge Lest gauge. Decreese the inpul test pressure slightly (maybe down 32 psig) so that the discharge pressure bleeds off, it by SLOWLY increasing the input test pressure agzin to 35 psig and see if pressure again shows on the diicharge gauge. Acjuct and repeat as necessary to get Lhe back pressure regulater to just start discharging pressure when you apply 35 psig to the inlet. ‘ cIINSTRUMENT LOOP CALIBRATION TWO-WIRE PRESSURE ‘ TRANS! IF 250 OHMS NEEDED RESISTOR ATMOSPHERL BEEES DIFFERENTIAL PRESSURE T (Ho alavation or suppression! Theew-paint calibration chwck NSMITTER CALIBRATION To calibrate a u "A201, you will seed 3 wa transmitter for a range of 9 to 29 inches of water ply, adigital valk ohm mater (DYOM) amps tra) a suitals of pressun feduring regulator and an accurate ater of other pressure rresuring device), Te 28 suriaa] & Not ogeded with mognra astruments buts only shawn Peay 5 cast gauge (mat sisiar {he for cages wie! ein. Ioan STEP 1 Cannect a! of the wires end wuting a8 shown in the drawing. The low pressure sida al the wansmater shauld ke vented te abmeaohure, STEP 2 Test all five calibrations paints by aaproacning Inem bath upscale and downscale, Use ihe presiure requiater to apaly 0, 80, 100, 60, and O ale it wauld bos O, 15, and O fies OF water, Record the qutpur value “as found” at each calibrator ard calculate the percent af owecentof ine rans. in our ex in en appay Co inenes af water 10 saute aide of th raramitter. Wf the OVOM dees nor read exactly 4 ma a! current, adjust zoro serew ta aotinn i ply 30 inches af wator to che high pros! ‘ng Ine reguistar and twst gaume. Hy adjust Ine span scraw until it does. STEP 4 Anges 6 3 and 4 until a ie AO MFP, STEPS | Cnagk tha caligration in the mitidly (50% of ine range at 18" HEC, It there 1d an efor gag the qranamister has a Sneurity ata wands do not) make an agua lirent to rarmove the oF 3-8 4 singe any argjustment can altect the calibration s arverrer Sut you do aot have a linearity adjestmant, earermine if tho errar s tea larga and wherefore unacceptable. If ot is, repair ar replace the rane STEP 6 The final calaration check should be for all calibration poi to 307 H20 and then back dawn to zere apainas you diet calibration is naw complsted. Aemave te calibranan nq) sida of the transi IM dors nor reas 20 ma 38 fom zero step 1 The arent,NOTES: * Sings rogulatars may leak slightly, it is best 19 vert the high presure cide of the Tranmeritter to atmospners rather than to use the reguimtor for the zero value. * Usually the “as found" and the final calibration ovtout xalues are documented an tha calbration sheet. To find the percent of evar, divide the differance between the “ag found!” ouTput valve ana thm correct cuIaur valve oy the OUIoUL span 11 in this cose! Than nuliply by 100. As an example, suppose the “ac found” value war 12.2 ma when the comest value ig 12 ma. Therefore 2 divided by 16, times 100 is an enor at 1.28 parcont. * When calibrating with analog devieas such as pressure regulators and tamparature baths. each eaibration point must ba aparoached slowly without overshooting it, Because of ihe effects of hysteresis, i; is necessary to slowly approach each ratipn prasiure pent rom belgw i and trom abave it. Uso the foltawing farmulas to determine the ansiog Qulput (4-20 ead signal or the inghes of wayne input value far any calibration point. * Otten the aeceatable percent of arror laccurseyl tolerances for process insarumanis % #/- 1.0% of san. Critical anolications or custady transfer loads may have mora ‘SUict 1olarances of possibly © / 0.1% of span, Usually the test equigment will hawe at Iwast fou times Ina socuraey of tha inatrurment Gang calibrated RECEIVER IRSTRUMENT — —POma SIGNAL) 120 VAC 7 QUTPUT SIGNAL INCHES OF WATER [4-20 mal = x (16) + 4 MAX. INCHES OF WATER RANGE ENT ma SIGNAL = 4 HUF Ba FIELD-POWER! GENERIC INCHES OF WATER = % (MAX, INCHES OF WATER RANGE} E 14 “AS FOUND" = “CORRECT OUTPUT VALUE - OUTPUT VALUE PERCENT OF ERROR = 100 ‘OUTPUT SPAN CALIBRATION EQUIPMENT FOUR-—WIRE INSTRUMENT CALIBRATION GENERIC aVACUUM TRANSMITTER CALIBRATION Hook up the vacuum transmitter as shown. The vacuum is regulated by adjusting the bleed valve. Make sure that there are no tubing leaks. The example shown has a range of 0-150 inches of water absolute, Since the manometer must be connected in reverse, convert the terms to inches of water yacuum by using the proper formula. Some manometers use mercury yet are marked in inches of water column. Valucs D 200 WATT LAMPS US AS LOAD THREE AMMETER Oo 4 = ° os ' 4 LOAD oe la E = = va Zz a fe r > near absolute zero are impossible to obtain with ms = avacuum pump. You may want to pick a value 49 = . x a3 near it: as your zero point for calibration purposes. Ene wSte aia = gees a G BLEED — e oo Pus wae elbe8 aati “a o}20 aro ae See Bee 4/55 Qt] 2/228 Z\5e4 a E\3=2@@9 i a VACUUM PUMP | = - ta = « & ao Fy & oe ABSOLUTE Re ey 5 5 ld BRESSURE | P a a 3 = TRANS, = 5 * a 0 120 vac POWER WT ie m4 mu mn at = mn gi ma mILEVEL CALCULATION EXAMPLES STATIC HEAD TYPE LEVEL CALCULATIONS Two main things have te be considered with static head level measurements; the range of the transmitter and the elevation or suppression forces. Clevation is compensation for unwanted forces on the low pressure connection of the level transmitter. Suppression if compensation for unwanted forces on the high pressure connection. Notice the typical example following. SPECIFIC 1, Determine the span in inches of water (also called Chavirt inches of water column [inches of W.C.} or " H2Q) by eas multiplying the distance between the measurement taps and the specific gravity of the process fluid. 45 inches times .98 equals 44.1 inches of water. Since the span is 44.1 " H2O that means the range is equal to 0 to 44.1 " H20. 2. Next determine the effects of any elevation or suppression, Since the transmitter is mounted even with the lower tap (the OX point), there is no suppression te consider. However, in this case a seal Fluid of 1.2 specific gravity is used, therefore elevation must be considered, To determine the plavation multiply the height of the seal leq times the seal fluid specific gravity. 45 inches times dak equals $4 inches of water. See z ORY LEG 5 | + The calibration becomes: Range = D to 44.1 ° Heo Elevation = 54 " H2d SPECIFIC GRAVITY *NOTE* When you have both elevation and suppression ae forces, they may cancel or partially camcel out each other. Tf they are not equal, subtract the lesser from the greater [usually elevation is the greater) and calirate the transmitter using the difference of the greater force. on— : * fae 1 . 52~~ | 40° x 5 515° HzO SPaH 6S x ey BUBP. % 5S = 12.5 Hz0 | RANGE = ELEY, = 75° Xt = 75° Heo 1 BS * B= 5 —- 12.5 = 62.5 H20 ELEY. RANGE = 0 TO 15” HzO WITH B25 Hza ELEY. 100% —= 8O SUPPRES H20 OF TERMS H20 10 SPECI ic GRAVITY faay O68 ee see ALTERNATE TERMS; -62.5 H20 TO -47,5" H20 a — ta = a-+ 4a” W320 SPAN bw 44" HZ a DATUM LINE JO SWAP THE HIGH & LOW PRESSURE TAPS | | Ie DBE EEEEEE- ( \ > a 2 wu = ae 6a i y 20 Span = HEIGHT X 5.6, me a ELEV 110 «a = a8 Hao SPECIFIC + " faugE = oTO BB M20 OE Beary ALTERNATE MQ ELEY. GF SUPP. = a 55, aa” H20 Faxs 1 re" a2zGc 1 = = 7 z DATUU LINE = 4 POINT OF 2 SPECIrC | HEASUREMENT FOR LEVEL == oie S Mon OS PS GRAVIT CALCULATION > - . nee oy ba 20 Lr une + ze cog Aee io ' ‘ o Sy i = * NOTE:zum CONTROLLER ACTION Mast control loops use ne cess able (PV fthe PV drifts tive feedback to keep move back in the apposite direction. to determine the proper controller action with a PV incr See the contral loop ex: below, If the PV (flow in this case) inereus reverse acting controller would send a de Lito the control valve. Less air to the A/O to open) valve will tend to close it. When the control valve closes, it will reduce the flow, With less flow, the PV reduces back to the set point. The controller has the correct action, SET POINT‘payeaqr [wa eq oy peeu TTA abneb @ ‘aonebh ayy o4 uoTyeauuer 243 bupd Sug sackod AT [Njeavg "4NG UTPap uua [TG buy [was 9yq yo suou IRR as patedn abeb ayy jo uaiqoauuda ayy daay "egouy Xet] ayy Grower on sjeyaod Ip due 4QnouatA Ting pinbep do pus pynoys ebneb su Seuya XPS Oy dno gnoge peqredet oq prnos Sanpesead ef yy ApLewaon ‘apoaaosea ayy WP Buriqgng au ATpenqaqa st saeyy Tqqun obneb |u3 1 y2eq Upeap oy [PS Su) BuTAGi LY pue annoen fuydtdde jo wsoqE aupuaoid aa qwedex nied uty aug UO Wan} BYE Bates pasta Den aya ADOIG Upeby "yna um Gaby} BUT] PUL qUOTI Oo seTqIqGNG ate [[# AOTI® oO} davssaueu UoTjosagp Ajeas UT Sbneb ayy jueyao pue uanL ‘uayshs oyg Ud uMoeA oy uel 0} eA TBA peeTq wNnoen oui uedo pur dund ayy gjo wang "pauyeyqo useq Bey uNNoUA 4sou buy 4e3y¥ "a}onaveel aa UL Burraqna AtsnorebyA [yo ayy aoTIaw Ll Ts hoy cdund andes ayy wo UaNg PUL BATeA paaTa wnnes BY APSLS ‘iagea StW3 UE Ty) PIN] [ees Guy PRE OL “BUTAeap aya UT uReKe se sofaep 43 dn yooH 'sBur33ty eaten pue BuTqny Aqessasou oul pue aso STqTXeTy Teqou ‘aBnub @ ype dund unngea @ *atonaeser [Jo uy peel TITA Tox vineb sansseid yeas wheaydepp & ouaie BuTReap payarqge 444 SoTIOH “ENNoeA esn oy SB] ebnub ae Guewnaysut ue oquT PENT? Tess & Buismposquy oj spouse seq ay Fo SUD SGNIHMELSNT GY SBONVS ONTIVES GAUGE Perea SFOPEN LOOP PN ALIGNMENT CHE CONNECT THE CONTROLLER TO BE ALIGNED AS SHOWN. After placing the set point and process together anywhere on the scale: 1. The output should be 9 psig. ?. The gain can be changed without an output change. 3. The action of the controller can be changed without an output change. {This is not true for all models. >} of EEE CLOSED LOOP PNEUMATIC -CONTROLLER ALIGNMENT CHECKS = REVERSE = MAXIMUM = MAZIMUM = MINIMUM g CONNECT THE CONTROLLER TO BE ALIGNED AS SHOWN. The set point and process will track (since the tied together} 3 to 15 psig. With the set point a on the scale; 1. The gain can be changed without an output change. 2. Tne action can be changed without an output change. (This is not true for all models)SPECIAL CONTROLLER ALIGNMENT Controllers that use process forces such as pressure or temperature instead of a 3-15 psig input signal can be checked for proper alignment by usiny an open loop method. Use the example of the pressure controller shown in the drawing. The input range is O to 150 psig, Set the gain to 1 and the reset to @ fast setting such as 005 M/R (minutes per repeat). Place the set point to mid-scale (75 psig) and apply half of the process pressure (75 psig). Adjust the nozzle for a 9 psig (50%) output signal. Reduce the set point to 10% of scale and apply 10% (15 psig) of the process. The output should again have a 9 psig signal. Increase the set point to 90% of scale and apply 90% of the process (135 psig). Verify that the output signal again shows 9 psig. If the output signal was not fairly close to 9 psig, the nozzle assembly may need to be adjusted for better alignment. fy) 20 PSIG vast | SUPPLY, HIGH PRESS. PROCESS REGULATOR . —— SET POINT ——~ NOZZLE ASSEMBLY atHelpful Pipe Flange Information Series 150 Flange Raised F. ts aoe |ange | "hw 20m! z6 Dis [Sind | Ring [ath No. | Bet ie a- 4 | aid | RA 4 Rad 4 Raa 3 Roe 1 PF, 6 1 4 6 18 1-13/16] 16 [1-4] 6 Lied | 2L-5-8 b-Lee 20 Lagi) eo ficial eta fagaea | ea-eea feraee | 7 | Ree 24 2 20 [L-Lea} ? abled | eet rad | Rib | Series 300 Flange , Flange Ralsed Fa Rares | Pipa | Wrench | Bofta aise NOPE i = eicige'| neon Size Size - Gasket Oa Ee ec | Quan. z Stud | Ring } aes | Ltpth | No. 4 R16 : Rea e Red a Ra? Ra kaa Roo 16 | 3 le 16-59 Ro? 20 5 Il 19-14 REL 20 S 15-14 | ab-Lea RES ea eRe ReaSeries 600 Flange CONTROLLER TUNING INFORMATION | Ring Na PLG Red kK: Bp RY Reis Rag RSF 5P REL Rea hed aes eT 10% Proportional Band (P,B.) = fst = narrow band 13) 200% Proportional Band (P.B.) = slow = wide band 12 igs | Suz z| ue? len 10 fast action Ea ies BEEG |wrad| aga [us| .] Gain = slow action —_ T _ | 2s \3 S S lure Change in output 10 j= | S2Sh|Naee [O| E Gain= Gai = | prop [2 eee ES Change in input “PB. id | Seer [A ete [feat | \..|% reer |e ecus [fs 234 + how Change in input joist. | BS Baas |S B= — “4 P.B.=——_______ X 100 3 |S] case auss (2h Gain Change in output = “\se vex |zEge|S2 5 |S | | Go) Stee |bats| Shoes [ao Minutes/Repeat (MR) Repeats/Mimite (RIM) Te) esee 2 St) zese 22) Roms RIM =s en) a) OPO [Pte leat ey 10. MIR = slow 10 RM es ath| baae [as #2 go Za ; = = e 5 vree [PLUS RARE |e Derivative (Pre-Act. Rate) i] es of Le; Tr c= Vide i . 5 2.3, Mee 238 22 | 0 Minutes of Lead! Time NO der alive action s2 | SES" [8ba Ame lee 20 Minutes of Lead Time = lots of derivative action aa ae (SME 4 an = BOG [Sade | eecucuds [eee | a cry £2 | tam |e9rg) Zee jel i { i i oFINITIAL CONTROLLER SETTINGS GAIN RESET (M/R) DERIVATIVE Flow at Ll - Pressure 1.4 ab - Temp. (slow) 15 5.0 1.0 minute Temp. (fast) 0.5 a = Level (slow) 24 40) - Level (fast) 1.0 20 mt Analyzer (slow) a 30.0 = These inilal controller sellings are only 2 good starting place. Adjustments will be needed Lo obluin the best setlings. The 1/4 decay waveform shawn below is the best response thal most loops can achieve. * Too much loop gain causes confnuous eycling of the process variable. Too little loop gain causes the process variable (lo wander. Too much reset action (.1 M/R or 10 RM) will cause conlinmous cycling. Too little reset action will cause an OFFSET between the set point snd the process variable, Very few loops ever benefit fram derivative action, use il sparingly 6f BEEEEEERESE a * When tuning cascade loops, tne the slave first by itself, Have the master loop in qmanual, Tune the slave 50 that rapid set point changes do not cause it lo go into oscillation. With that done. place the loop back into cascade control. Now tune only the master loop keeping in mind that the strength of the reset action of both the master and slave loops tend to be multiplied. In other words, a little reset action in the master loop will go 4 long way. The Bump and Watch Method For a proportional and reset controller using gain and reset in minutes per repeat (MR). 1. Line out controller in manual mode. If it will not reasonably line out in manual it will be difficult to tune. 2. Change’ sctlings to make it a proportional only controller. (No reset or rate) Try a robust gain initial setting of about 4 or more. If the process starts cycling continuously. decrease the gain enough to make it stop. . 4. In Automatic mode and process not cycling, Increase the gain by about 50% of it’s reading. (A 25 gain would increase to 375 gain) a 69SAFETY TIP Never take someone’s word that an instrument has been de-pressured. Carefully test it yourself. 4. Make a 10% change (bump) in the set part and varteh the process variable (PM) to see il il (Give it ample time to react} [Start with a 10% set point bunip upward Nest time bump it 10% downwind, “That would brim at back to the original setting, Alternate the bump actions to keep the set pomnt in the general area | 6. [necessary. keep increasing the gai reading, by St’ and bumping the set point {by Hl) antl the process viriuble cycles cominuously, 7. Once vou have eveling, set the gain at halfoat the list rending just before it started eyeling 8. With the gain set. add 4 M/R of reset, Buinp the set poi and watch for continuaus cycling. 9. If no PY eveling. cut reset time i ball (2 MAR) then burp and w; rin. Repeat this witil vou do hive continuous cxcling Set the resel al twice the last soning where the PV did not cvele. ha Aes WANDERING—-LOW GAIN VAVAVAVAVA CYCLING-HIGH GAIN wits egcling DIAPHRAGM ~ DIAPHRAGM PLATE ACTUATOR SPRING — ACTUATOR STEM SPRING ADJUSTOR (STARTING AIR) -- TRAVEL SCALE AIR TO CLOSE VALVE = PACKING BOX -— VALVE STEM -VALVE PLUG - SEAT RING Fi] cONTROL vetve PARTS wvBENGH SETTING A CONTROL VALVE After a valve has bean overhauled or disassembled, the banch set should be properly adjusted. TO BENCH SET AN AIR TO OPEN VALVE [for 3-15 psig) 4. With the plug slem disconnected fram the actuator, adjust the starting air so that the actuator stem begins to move at 3.25 psig, Check the actuator to ensure that it will travel 100% with 3 to 15 psig applied. The travel indicator should agree at 0, 25, 76 and 100% of travel. Apply an increasing then decreasing signal in order to lest for hysteresis, which should not oxcoed 1/4 psig. 2, With the valve plug in the closed position and 3 psig applied to the actuator, connect the valve and actuator stems togather. 3, Stroke the valve by applying 2-15 psig to the actuator. It should smacthly travel over ils entire range. The valve should be lightly closed at 3 psig, Check the total valve hysteresis to make sure that it docs nol excead 1/4 psig. BENCH SET FOR AIR TO CLOSE VALVE (3-15 psig) 4. With the plug stem disconnected fram the actuator, adjust the starting air ¢o that the actuator stem bagins to move at 3.psig. Check the actuator to ensure that it will travel 100% With 3 lo 15 psig applied. The travel indicator should agroe at 0, 25, 75 and 100% of travel. Apply ant increasing thon decreasing signal in order to test for hysteresis, which should not excaad 1/4 psig. 2. With the valve plug in the closed position and with 44.75 psig appliod ta the actuator, connect the vaive and actuator stams together. 3. Stroke the valve by applying 3-15 psig to the actuator. It should smoothly travel over its antire range. The valve should be tightly closed at 15 psig- Check the total valve hysteresis lo make sure that it dos nol exceed 1/4 psig. aSPLIT RANGE BENCH SET (3-9 PSIG AIR TO OPEN) Split range and sequencing bench sets are done in similar fashion like the two cxamples above. Ua valve positioner is to be used, bench set the valve first, then add the positioner. VALVE LEAKAGE TEST One method to determine the approximate amount of leakaga in a control valve is to cover the outlet connection with a wot paper towal. The water will allow the paper to adhere and form a seal. With the actuator in the closed position, apply about 20 psig of air to the inlet port. With zero leakage, the wel paper towel will maintain it's seal. Small amounts of leakage will bubble up and break the seal occasionally. When you have excessive leakage, you will not be able to keep the seal formed very long. SPLIT RANGE OPTIONS When a typical 3-9 psig and 9-15 psig split range system is needad, there are several ways to accomplish it. 4, Use two valves with spring ranges of 3-9 psig an 9-15 psig. 2. Use two valves wilh normal 3-15 psig spring ranges. Equip one with a positioner so that an input of 3-9 psig will give an output air signal of 3-15 psig. Equip the other one with a posilioner so thal an input of 9-15 psig will give an output signal of 3-15 psig. 3. Use two valves with normal 3-15 psig spring ranges but use pneumatic devices (signal conditioners) that will take 3-9 psig and 9-15 psig as input signals and give 3-15 psig as an output. 4, Use two normal 3-15 psig valves with individual output gignals from the DGS. Configure the DCS systom do the aplit range. STANDARD BENCH SET Most control valves have a standard bench set of 3-15 psig. You can also find 6-30 psig used as a standard loo, but not as often. When process differential pressures act upon a valve plug, they either tend to help the valve open or tend to help it close. When a small actuator is chosen, (usually for economic reasons) its bench set will have to be non-standard in order to compensate for the pressures. BENCH SET FOR AIR TO OPEN (5-15 PSIG) When process conditions force you to purchase valves with 4 non-standard bench set, such as 5-16 psig, the valve will have a specific range spring. Thatis why the spanis 10 psig instead of the usual 3-15 psig. Differential pressure across the valve trim is compensated by the non-slandard bench set. When such a valve is placed in the actual process, it will stroke approximately 3-15 psig. Wadjusted correctly, the valve will be closed at 5 psig, half open at 10 psig and fully open with 15 psig applied. Non-standard bench settings such as this are used to overcome process pressures that tend lo open the valve if you desire to have a 3-15 psig bench set, you must purchase a larger actualor which can exert more force. SAFETY TIP Never add stem packing to a control valve while it is in service and under pressure. It could eas blow out product and cause an injury. reCONTROL VALVE MAX. LEAKAGE RATINGS VALVE SIZING FORMULAS Class1 sno test required Class 1.5% of valve capacity, air at 50 psid Class TIL .1% of valve capacity, air at 50 psid Class IV .01% of yalve capacity, air at 50 psid Class V .0005 ml per minute of water per inch of port diameter per psi differential. (water at service differential pressure) Class VI Air tested at service diff. or 50 psid PORT DIAM. BUBBLES/MIN. CRITICAL FLOW 1S WHEN THE PRESSURE DROP FOQUALS OR EXCEEDS ONE-HALF OF THE ABSOLUTE INLET PRESSURE. SUBCRITICA LOW IS WHEN THE PRESSURE OROP IS LESS THAN ONE-HALF OF THE ABSOLUTE INLET PRESSURE. CRITICAL AND SUBCRITICAL ARE TERMS THAT RELATE 1 inch 1 ONLY TO GAS OR STEAM SIZING FORMULAS. 1-1/2 inch 2 =a ———e __ inch 3 BuID FLOW SIZING EQUATIONS | 2-1/2 inch 4 — ee — Jinch 6 Cv = 4 inch u 6 inch 217 8 inch 45 v = AP = r Cy = VALVE FLOW COFFFICIENT _ TEST AP = PRESS. DROP @ MAX FLOW, PSI — PRESSURE G = SPECIFIC GRAVITY @ FLOW TEMP. Wo= GPM @ FLOWING TEMPERATURE. 77[cas SUBCRITICAL CRITICAL FLOW FLOW oO < Hondo wn FLOW SIZING EQUATIONS — | a c ate [Glo i 563 \Ap(Pi+P2) Oo = 963 cvfB PIP11P2) GTa ZS _afp2 ( Q4STa 2 ap = Pin Vp (Saker g = 835_0v PI ‘eta _ @ Gta Cv = 335 FI VALVE FLOW COEFFICIENT PRESS, DROP @ MAX FLOW, PSI SPECIFIC GRAVITY @ FLOW TEMP. SCFH FLOW @ 14.7PSIA & 60°F INLET PRESS. @ MAX FLOW, PSIA OUTLET PRESS. @ MAX FLOW, PSIA ABSOLUTE TEMP. (460+ °F) BEEEEERESE- [STEAM FLOW > EQUATIONS | Cy Ww og7 38) 2 2.12 YA P(P1+P2) = iy a, le cv YA P(PT+P2) 52 “7 + 0,0007 § oy —=.. op = Pt 2 yy = LB Cw PA os (+0.0007 § —O , ~ I w(1+0.0007 5) a Ba PI Cv = VALVE FLOW COEFFICIENT AP = PRESS. DROP @ MAX FLOW, Ps w = LB./HOUR S = DEGREES OF SUPERHEAT P INLET PRESS. @ MAX FLOW, PSIA Pp b apres 2 = OUTLET PRESS. @ MAX FLOW, PSIA5.0 Volts 1 { t i Ww wy La ' aca. 5 lw > ! om wy | 2b z 2 ale t wy "i * gt re See ; (2x sei ‘i I Li 1 =! “2 18 & Bios | = ais ad Ses me Fieases = 2iasdud = a S gis i L A = iw Got Se 5s ws B/SEES Fireman = Ate r AAS ov, O04 WALSAS TOYLNOD Sdid-anos 3LON34 SILWANAINd . nowyss Tad LIS Tran /OL aie o-aNO =| ia ywULKODSQUARE ROOT {3-15 PSIG SIGNALS | FLOW FORMULAS (Fuow Rate \? OUTPUT SIGNAL re an KV2 + 333-15 PSIG) MAK _) FLOW FLOW Ratt — OUTPUT SIGNAL (4-20 MA} - MAX FLOW FLOW RATE — OUTPUT SIGNAL e = "(1-8 voc} MAX _ FLOW \ Tay — * Flow RATE BEEEEEEEE DIFF. PRE FLOW RATE MAX. FLOW! INCHES OF WATER AT THAT FLOW RATE IN, H20 AT FLOW RATE Max FLOW Max. INCHES H20 * FLOW RATE 5-15 PSIG $Q. ROOT FLOW EXAMPLE: FLOW RANGE = 0-40 GPM WOULD 7 GUTPUT BE IF THE IS 20 GPM ER = 6 PSIG { 20 GPM ‘40 GPM GUTPUT SIGNAL Jou + 3515 6 PsiG BALL PARK ORIFICE RANGE FORMULA * ONL’ WHEN USENG QPERATING COND! NEW j TRANS. =| T RANGE 1 R * TYPICALLY KEEP "M20 BETWEEN 20 & 250 THE SAME ORIF Se AND ALL IS ARE THE $4 Vif NEW FLow | fp) SOLD Flow / NEW . | OLO | EW TRANS. Range Flow FLOW fF \!" OLD TRANS. RANGE aAP LOCATIONS FoR IMPULSE VERTICAL ORIFICE FLOWMETERS STEAM “Hig oaog aang = oney wag sl [srr a sony aay amaags “UMOp Muay a3}quME]p adi Z/T Pun 234) suey ureaayed i eeo.ay asyaungp adyd pisdey cupryy nyd Fo Ueda asuap 3p umapen side adyep mp tod) We AAaeUALeR WYaXISNMOG F WVaU.Lsan wk ez e to a 2 FS E Ee = 7 a o vib ~ Oe =. z St 22 a , Zz 3 oa ft] oe wz Fu Ze ey Ee 20 ao LS vy ous wo 6 8 iret ous oer =a< feo ear hia te at Wieies =i fou oS seg athemp adey sro = — idee unaqies oma sid aogg E WEaapsdn pIENS Jy LpIMPULSE TAP LOCATIONS FOR HORIZONTAL ORIFICE FLOWMETERS LIQUIDS FILLING TEE 7 Can FALL TRANSMITTER FLUID 5 * SIDE IMPUL TAPS ARE GEST IMPULSE TAP LOCATIONS FOR HORIZONTAL ORIFICE FLOWMETERS STEAM < CONDENSATE ‘Wor N SCALE CAN o* PLUG HERE CONDENSATE OR a ANTIFREEZE FILLED a6 ANIONS FOR ul E FLOWMETERS 2 VAPORS WO WET GAS OR VAPOR SLIGHTLY WET GAS. OR VAPOR ¥ 4 * MOTE ALL TRA HAVE 3-VALVE INS MANIFOLDS, SUMENTSCALE FACTORS (linear) Usually rotameters in manufacturer's catalogs arc based upon either water flow or air flow at standard conditions. Their scales wall be either in percent of flow or actual enginecring units (SCFIT, GPM, ctc.). If you use a different fluid, such as hexene, you must first calculate the full range flow of hexene, then a meter factor. It is best to use the formula provided in the catalog to find the full range flow. EXAMPLE: The selected rotametcr has a 0- 100% scale and the catalog shows 0-100 GPH of water. The catalog’s formula tells us that if we use hexene, the full scale flow will be 117 GPH. To determine the flow factor, divide the maximum hexene flow by the maximum scale value. The an is 1.17. SCALE 117 GPH FLOW FACTOR = ——————""— 100% Therefore. the flow factor 1s 1,17 times the reacling. If the Moat indicated 41%, the hexene flow would be about 48%, ag SCALE FACTORS (for orifice Mowmeters & square root scale) Man. Flaw (GPM, SCFM, ete.) Flow Factor = Max. Sy. Roat Scale Value EXAMPLE an, flow is 7 GPM and the is 0-30, The e multiply the seale readi 2334 (flow factor) to obtain the actual flow r ASI reading of 18.3 is a flow of 4.27122 GPM, (for orifice flowmeters using * This is not a youl idea a linear Seale) scale reading Flow Rate = xX max. flow rate max. scale EXAMPLE: Mun, flow is 20 SCFH, The scale re Son av-15 Take the square root of 6.8 over 6733. Multi { O733, ply .6733 [flow factor] by 20 SCPE to obtain a flaw rate of 13.466 SCFH.LINEAR TRANSMITTER FORMULAS SIG SIGNALS. LEVEL (7% LEVEL , OUTPUT SIGNAL \ 100 -) X12 4 3 = 5315 Psic) OUTPUT SIGNAL - 3 niet ay ie REGS) PyLEMEL _ OUTPUT SIGNAL | X16 + 4 = (4-30 MA) OUTPUT SIGNAL - 4 joq = 2% 16 LEVEL LEVEL EXAMPLE: What is the 4-2(ma output signal of the transmit- ter when the level glass indicates 48 percent level? Divide 100 inte 48, then multiply it by 16 and add +. The answer is 11.68 ma, which represents a 48% level output signal, [fusing a pneumatic transmitter, the answer would be 8.76 psig. 90 BEEEEEEEE UNIVERSAL LINEAR FORMULA TRANSMITTER INPUT TRANSMITTER OUTPUT (INPUT } TART OF ) (CUTEUT {START OF WALUE/ \ RANGE /_ \ ‘VALUE RANGE INPUT SPAN 7 BUTPUT SPAN TEMPERATURE EXAMPLE: RTD TRANS. RANGE = 206 TO TRANS. SIGNAL = 4-20 MA ey IS THE INPUT TEMP. FOR & TRANS. OUTPUT OF 14 AP 100 DEG. F ANS DEG. F Reet CB so = 16 X= 20 = 514 THEREFORE ¥ = 71.4 DEG, F MAINTENANCE TIP When a control yalve is used tof a split-range lonp or if the action of a valve is reversed by using the valve positioner, do not by-pass it. w43N9]K2 ALIANIINGD | i navid - 4 aja +—* —_ LNOAWT F18ISSOd 0 0 4 kK | 1 4 saadbad INIOd ONIZATH4 “Zo +o a =20 Box ao% 30% PERCENT CONCENTRATION sox GLYCOL IN WATER BY VOLUME MAINTENANCE TIP A common mistake is to install pressure reducing regulators and control valves backwards.] | LOOP CHECKER when large process units ara under construction, it is expensive to give everyone on the check out crev a OVOH and a Loop = “a sinulatar. Since the area ia nat classified as hazardous during # 3 the eangtruction phase, an ines a davice could ge used, Tha d 5 gp eis o Leag Checker (or Oewey Sax) shown in the drawing is fer function ee 23 Soe = OE and loop cheek eut, sot for highly accurate calibration. Tt can ay abe SPepees & Simulate « field transmitter, drive a ¢-20 ra algaal inge an t/? a eZ gHenms & fran: © for stroking a control valve, chuck relay cantacts for 2c > Ee voce 2 conkinal2y ay pesduce s 1-5 VOC input wignal for reesrdox. os =e? Za ois SERat = s a 3 Ls gS 2 SIMULATOR The red and Diack test jacks ara neesally heaked to 4 | = 532 Ze 2,327 522 Ticld transeitter. The DPOT switch has threo positions; INzernally | cl BE =u Sk ESsH2E% povered, OFF and Eternally pavered, If the transmitter is loop 26s a BE aesEf®EStg Bovered fran tha comtreller ar 203, the switch should be in EXT. | a 25% = = £S4os cba Tf thu transmitter ia field powered, the switch snoulc pe in THT. a aa 2 ee Fee sc8 Binuistion in done by adjusting the 10% ohz potentiometer for any a Sac 2 Seco aa value frog 4 te 20 na on the meter. It is a good idea before you = poe 2 GS e8ang¢gesa® make any connaetiong to have the LOK ohm pot positioned to about | = San rm Pie a B= mid point. = EST Ugete ee pe aoe eee VALVE BTRORER ou 5 Sepx Pe ses Wich, the awiteh “in thal/TWTs: postion: andthe! red cand lack = 2 gee geese ct tect jacks heekad ta an I/P, you can stroke a contral valve. at Ea 7 oe oS a. 2 Adjust the 10K one pot far your desired 4-20 ma output value, 5 ee map eeegyee & 32 wSDP Sas ve VOLTAGE GENERATOR S aug ~225 With the switcn in the INT. position and tha red and black oe SHEE SeFEuad = tose’ jacks shorted togacher, you L ta § VBE outpue = as a4 Seelea tee nai. The voltage vill ‘appear accons the 280 one preciaton ag Ea ,EBSESBELEL ES. resistor Adjust the 10K ohn pot for your desired voltage. E a8 F®iseuntitwns Renesber that tha water vill be snowing a 4-20 ra signal so you 5 FE Ew wee sore ias L have ts translate the value or use a DVOM to view the voltaqe me Soe 2 SEne8274 225 direct ly- x tI S ws be Spee gs e a pas EB -Basi®eb Res CONTINUITY cHRERER Ea oo Be Sele 2ee8= With the awiteh in any position you can test for continuity by = co Ace Sy oe Ore rd connecting acroaa tha twa continuity tes! The 8 VDC Licht ao 9 2s Ber gas will te on if you have a compl. @ireuie. ra =e aS Beetowssegt : 2 ESS 3 Goes aaa Fay = Seg as Bape, ea O £82023 Cee e Sa ee 2 85 22 8 EeuEFeEtees < Ea Ele oes bee a2 a Be 3 EF oZ BSEBESeS¢Ey LS 4 2RGSS ShHEZSRRSGREBE Btes GEEGESsS3 Go 633 4 wea BBt2B8 a c + 94 ©is Tips 2 : -E Ow o IAL CHECKS: Louk for ubvious problems: hralen 2 » moisture, corrosion, plugged measurement t a charred circuit board, wires erussed or parts installed wrung, uw a SUBSTITUTION: Sime problems can easily be fiund hy cing or substituting p reph ty circuit boards or components. Don't overlook the passibility af taking parts From a god the problem, This is a method ta elimi the true problem will be reveated. ures so that 2 : unit temporarily. Trade out only one part at atime so chat = pr wou Will know for sure which item was at fault, oe 7 3 : eo o SIMULATION: Ifyou can accurately simulate fichl al ote conditions on the bench, instrument and control problems 24S =s = i Be om may he solved, But be sure that type of input signal or Lz? Se firocess conditions are the same as im the fiell. en ew a> See : | io = DIVIDE & CONQUER; When vow li = su t 5 i a ‘ nw fata nal, find a mid-point (divide the signal path) and test for oO > oO ae it, Depe we upon whether vou find the signal ue net, either = a ee divide it upstream ur duwnstreaim and test, < Wee re em Ul ; tn : 7 = OS el ELIMINATION; Some instrument problems could be trans a i a 2 a = the process, the inst jon, the clectromies, sume type of a o me EE + interference or equipment failure, Try couse methods, such oo. a 26 Zs as simulation or substitution, that en y ch pabrt is not un aCONSULTATION; Many diffi preblems cane fixed if you ask the right person for advice, Often you can find old timers, operators, engincers ar maintenance peaple who have encountered the same problem before, Use thi experience to give youu direction to investigate. ily be INSTALL HELPS: Tr if vou install gauges, m recorders or other dev process is doing. hleshooting can be made a fot casier ¥, rehiys with indicating neon bulbs, sthat tell you what the instrament or FRESH START: After fighting a difficult problem far a lon: time, step back and look atit with new eves. Think of all of the things that could w those symptoms. Check all a us if it were a new problem. Don't assume a ne your test equipment hing ix correct, OTHER TIPS: Intermittent electronic proldems that a related may be found by using a het air gon to warm the board. Use care not to ow ait the components. Problems with duplicate addresses may be resolved by deleting each dev until commu nowith the computer is reste red, SHOTGUN METHOD: Once of the fastest yet cost find a problem ix to replace every cireuit device in the entire instrument, Tt may working quickly, but you seldom was the offending component, witys to or plug-in et the equipment eacluc as toowhich part w SAFETY TIP Da you have all of the proper safety Has the equipment bese ned off and its before st pchied aut mie venvoltage tor AMPS 3 a 2 n eb a24 z “on ue coe eet SE aoe 4 3 c DB = ~0 = _ * 4 oe oS = 3 ; ES’sss = a =} a YL a = a 3 ee A a oo : Sp a on ab S22] sq— a|8 2/58 2 F 5 -p8 8|s 5 | 6 - a Oe eed |e Ele as = @ 8 oe a ‘S = Saexs S 2 Feeee S > 5 Steam ° Socket ll U A 2 See eS fa5 ae = as = os — a S a4 hos T Ne 3 2 S26» wn we 2 = oa sD ay ae GOS Be im ce a oe) = S soe). 3 a2 Beog uy aay to 5.2 2S ao ase. = (ey en. 4 = 225234 oe = fee aS ‘MIO8 OL Ll Aldd¥ BARN “NOLLYDIONI 142 FHL OL #O (10d OFHMas3ad JHL) WHOIS ids 3H1 OL 44H1a Ode 34 °N¥9 SNINGIIONDS L008 “OS + 30L © TWNOIS WAOE—F 40 & WOU O3aNd1zNOD MOLVIIOM MOTI 1OOe "DS TYNSIS avd dS at c 4 VANOZ—-? MOM = X¥A x oF — 90 : WO “os SmoHs ! = woLoyd ae - -i---------- a----- osu “NE FB SMOH! lL WILIN ¥AOOL-O a ee ind1no - DOL-o BYVSRIT 35Nvd WHOS YG OTH STs al Wd Of Si 31H MOU4 “JONWH MOT4 Ado 09-0 | = s ozH.sz", OZH ‘NI TNOIS ONSd 9, ool ‘. WNOIS INdLNO iva nd zh Ht tt Ht ff 4) a9ONvY MO1Z = XW XE — 90H = HOLDYE JIvaS [nas of] TWNOIS fuieaveeMAKe wd = 9 x 508 QISd Sl-€ aera seaceadl ® = wOLavi TOS fA % gia 07-0 awinsaa yeaNr MOU 205 HO awss SL00N ¢ SMOHS 3ONwo 43003338 tooa “OS ai=0| CHECK OUT FUNDAMENTALS When mew instrumentation i installed, several checks should be made. Among them arc, wire checks, function checks, failsaliz actions and logic checks, 1) Wire Cheeks: The wiring should be checked for secure and correct connections, proper wire size, proper labeling, continuity, shorting to pround and excessive resistance (Typically. short wire rans will have less than 40, long nme will have less than 12%), These checks should be done without the luop fuses installed. High Voltage cables are tested for faults by using a DC Hypot (Thumper) lester 2) Function Checks: (For Anilog Inputs) Afier the transmitters have heen bench calibrated and tagwed, install them in the field, Install loop: fuses. Use actual process changes (first choice) or loop simulators (ike the Altek} and test to see if ignal at MG, 50% and 100% (in both directions, incre: decreasing), For analog outputs to control valves, stroke the contol valve from the DCS und see if it sesporids at 0%, 30% and 100% (in both directions, increasing and decreasing). 3) Failsafe Cheeks: In addition to the function test that manipulates (or is simulated) the process to an alarm condition, a check should be mule ifa wire breaks * (For control valves) In tum, remove the 4-20.ma sip the air supply and ihe 3-15 psig a inal to the to cheek for proper-valve failure, * Simple process-powered pressure (or level, temperature, flow, etc.) switches should have a contact wire lifted to determine how it fails, * Speed and temperature switches with electronics have tro failsale action possibilities, the failure of (he power and the failure or the opening of the contacts or wiring. First test for power Juilsafe action, by removing the power and see the results, Restore the power. Neal, test the contacts by lifting a wire of the contacts and see the result: 4) Logie Checks: For Large interlock systems, test und simulate the logic and schematics beforehand by using another DCS system, For smaller less compli fy their Proper action, Ww the transducer, control valve or pos ner Wied interlocks. force points or jumper them to ve eZ Possible Solutions to Level Problems 1 Usea vanes loca ta prevent liquids fiom condensing in the Low press. leg, Use a compatible fluid as a scal leg, which is cq] to or heavier than the 4. Add steam tracing to boil out any Liquids tn the lenw pressure lep 5 Add adinp leg reservoir It will need la be drained perindic: 6 ise an i Srainine liquid trap. | 4 7. Wthe seal uid tends to evaparale, use to keep liquids out of the low pres 9. Use a renvote diaphrapen seal transmitter. {not shown 10, Use a [7] nonehubbling submersible type level transmitter (not shown) 11. Use a hquid of vapor purge to Mush solids fram Ihe level tape ioeINDEX OF MAJOR ITEMS Definitions/Symbals Conversions/Physical Data Loop Information Contacts/Alarms Temperature Data‘lnfo Ohm's Law & Ete. Calibration/Regulators Calibration/Haok-ups Calibration/Misc. Level Calculations Scaling A Gaupe Controller Alignment Pipe Flange Data Controller Tuning Control Walve Info/Sizing Flow Formulas Flowmeter Installations Misc, Formulas Loop Checker Box Leak Bubbler Tester Troubleshooting Info lod |z > Ic Im ors te simi 3 = Mo bo ro at wenn 86 fe. GU-63 64-06 OF TL-7Y 81-84 HAa-87 S891 Yay 95-96 TUS