Process Measurement

Measurement
Measurement is an important subsystem of a
mechatronics system. Its main function is to collect the
information on system status and to feed it to the micro-
processor(s) for controlling the whole system. Measurement
system comprises of sensors, transducers and signal
processing devices.
Measurement
Measurement is an important subsystem of a
mechatronics system. Its main function is to collect the
information on system status and to feed it to the micro-
processor(s) for controlling the whole system. Measurement
system comprises of sensors, transducers and signal
processing devices.
Methods of Measurement

Direct Method
➢ the process variable is directly measured in units that
represent the basic nature of that variable.

Inferential Method
➢ is the measurement of a process variable indirectly by
using another variable.
 Direct Method

The measurement for level in this tank

is measured directly in units of height
since the level of the tank is seen
directly through a sight glass (scaled)
representing the current level of the
tank.
Inferential Method

The level of liquid is measured based

on the hydrostatic pressure below the
tank. Since pressure is directly
proportional to the height of the
liquid, any change in level will also
have the same proportionate change
in the readout pressure.
Types of Measurement

Single Point Type

➢ the measurement depends on a fixed value of the
process variable.
➢ the reading is indicated either as high or low

Continuous Type
➢ the measurement indicates the actual value of the
process variable.
Single Point Type Measurement

Sensor A and Sensor B will only

trigger when the level reaches
the set height high and low
respectively.
Continuous Type Measurement

The magnetic float indicates the

current measurement of the level
through a sight glass according to
its range regardless of the current
height of the liquid in the tank.
The actual level, in real time, is
monitored.
Instrument Range - refers to the capability of the
instrument to measure a variable.

Calibration Range - refers to the set of values within the

instrument measuring range where the scaled output;
4-20 mA, 3-15 psi or 1-5 V is set during calibration.
Instrument Span
It is the distance (or difference) between the upper range
value (URV) and lower range value (LRV).

Upper Range Value (URV) is the highest value of the measured

process variable that the output of a transmitter is currently
configured to measure.
Lower Range Value (LRV) is the lowest value of the measured process
variable that the analog output of a transmitter is currently
configured to measure.
Discrete Process Measurement
 In engineering, a “discrete” variable or measurement refers to
a true-or-false condition. Thus, a discrete sensor is one that is only
able to indicate whether the measured variable is above or below a
specified setpoint.
Discrete sensors typically take the form of “switches”, built to
trip when the measured quantity either exceeds or falls below a
specified value. These devices are less sophisticated than so-called
continuous sensors capable of reporting an analog value, but they
are quite useful in industry.
“Normal” Status of a Switch

The “normal” status for a switch is the status its electrical

contacts are in under a condition of minimum physical stimulus. For
a momentary-contact pushbutton switch, this would be the status of
the switch when it is not being pressed.
Electrical switch contacts are typically classified as either
normally-open or normally closed, referring to the open or closed
status of the contacts under “normal” conditions.
Normally-Open Status
The lamp will energize only if someone presses the switch, holding its
normally-open contacts in the closed position. Normally-open switch are
sometimes referred to in the electrical industry as form-A contacts
Normally-Closed Status
The lamp would energize only if the switch was left alone, but it would
turn off if anyone pressed the switch. Normally-close switch are sometimes
referred to in the electrical industry as form-B contacts.
Hand Switches
A hand switch is an electrical switch actuated by a person’s hand
motion. This may take a form of toggle, pushbutton or rotary.
Limit Switches
A limit switch detects the physical motion of an object by direct contact
with that object. A limit switch will be in its “normal” status when it is not in
contact with anything.
Proximity Switches
A proximity switch detects the proximity (closeness) of an object. By
definition, these switches are non-contact sensors, using magnetic, electric
or optical means to sense the proximity of objects.
Pressure Switches
A pressure switch detects the presence of fluid pressure. Pressure
switches often use diaphragms or bellows as the pressure sensing elements,
the motion of which actuates one or more switch contacts.
Level Switches
A level switch detects the level of liquid or solid (granules or powder) in
a vessel. Level switches often use floats as the level-sensing element, the
motion of which actuates one or more switch contacts.
Temperature Switches
A temperature switch detects the temperature of an object.
Temperature switches often use bimetallic strips as the temperature-sensing
element.
Flow Switches
A flow switch detects the flow of some fluid through pipe. Flow
switches often use “paddles” as the flow-sensing element, the motion of
which actuates one or more switch contacts.
Discrete Control Elements
On/Off Valves
An on/off valve is the fluid
equivalent of an electrical
switch: a device that either
allows unimpeded flow or acts
to prevent flow altogether.
Valve styles commonly
used for on/off service include
ball, plug, butterfly, gate and
globe.
Continuous Process
Measurement
Analog Electronic Instrumentation
An “analog” electronic signal is a voltage or current whose magnitude
represents some physical measurement or control quantity. An instrument
is often classified as being “ analog” simply by virtue of using an analog
standard to communicate information.
4 to 20 mA Analog Current Signals
The most popular form of signal transmission used in modern
industrial instrumentation systems is the 4 to 20 mA DC standard. This is
an analog signal standard, meaning that the electric current is used to
proportionately represent measurements or command signals.
Relating 4 to 20 mA signals to instrument variables
To calculate the equivalent milliamp value for any given
percentage of signal range, the equation takes the form of the
standard slope-intercept line equation y=mx + b.
y = equivalent current in milliamps
x = the desired percentage of signal
m = the span of the 4-20 mA (16mA)
b = the offset value, or the “live zero” of 4mA
Example 1:
A flow transmitter is ranged 0 to 350 gallons per minute,
4-20mA output, direct responding. Calculate the current
signal value at a flow rate of 204 GPM.
Example 2:
An electronic loop controller outputs a signal of 8.55 mA
to a direct-responding control valve (where 4mA is shut and
20MA is wide open. How far open should the control valve be
at this MV signal level?
Example 3:
A pneumatic temperature transmitter I ranged 50 to 140
degrees Fahrenheit and has a 3-15 PSI output signal.
Calculate the pneumatic output pressure if the temperature is
79 degrees Fahrenheit.
Example 4:
A pH transmitter has a calibrated range of 4pH to 10pH,
with a 4-20mA output signal. Calculate the pH sensed by the
transmitter if its output is 11.3mA.
Example 5:
A current-to-pressure transducer is used to convert a 4-
20mA electronic signal into a 3-15 PSI pneumatic signal. This
particular transducer is configured for reverse action instead
of direct, meaning that its pressure output at 4mA should be
15 PSI and its pressure output at 20mA should be 3 PS I.
Calculate the necessary current signal value to produce an
output pressure of 12.7 PSI
“You don’t want to look back and know you could’ve
done better.”
-Anonymous

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