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Basics of pressure measurement

— Pressure is a critical factor in manufacturing and This document provides a primer on pressure
Doug Greaves
U.S. Product Manager, process industries. It provides the force that pushes or transmitters, including the most-common types/
Pressure pulls fluids and gasses through a facility, and is a key technologies, a review of some key components,
ABB Measurement metric used to control processes and ensure safety. In and an overview of common applications.
& Analytics order to control pressure, it’s essential to be able to
measure it. That is the role performed by pressure
transmitters, mechanical devices that measure the
expansive force of liquids and gasses.

Pressure measurements are expressed as the amount

of force per unit of surface area required to stop a
liquid, gas, or vapor from expanding, as in pounds/
square inch and pascal (one newton per square meter).
 Pressure transmitter features
and types
Some people use the term transducer and transmitter
interchangeably. There are similarities in that they
both rely on an internal sensor that converts the
applied force into an electrical signal used to derive
the pressure measurement. But there are significant
differences that make one or the other a clearly better
choice for a particular application.
Signal Level: Transmitters typically produce higher
signal levels, enabling them to communicate over
longer distances, and are able to relay information via
fieldbus protocols such as FOUNDATION Fieldbus,
Profibus, or HART.
Durability: Transmitters are generally more suitable
for harsh and/or industrial environments. Transducers
are more often used in labs or niche applications.
Size: Transducers are more compact, but may be
too small to be easily be fitted to standard industrial
piping.
Environment: Transducers must be protected from
contaminants like water or dust. Transmitters are
better able to tolerate harsh environments and often
carry hazardous-area approvals not available on
transducers.
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01
Pressure transmitters
installed at chemical plant.
Process variation: Transmitters are more tolerant of
wide swings in process conditions and better able to
withstand overpressure occurances.
Adjustability: Transmitters provide higher levels of
adjustability to accommodate process or
measurement requirements across a wider span. This
calibration performance range is usually referred to by
such terms as “scale down”, “span reset” or “turn
down”. For instance, a transmitter with a measuring
range of 0 to 400 psi and a range reset 1/10 can be
calibrate to a measuring range of 0 - 40 psi while still
giving a full output signal (4 - 20 mA, for example).
Transducers are often fixed-range devices where only
a fraction of the output signal is relevant to the
desired measurement span.
Accuracy: Transmitters provide higher levels
of accuracy.
In addition, the secondary electronics package
incorporated in many transmitters are highly
sophisticated and perform many functions that
transducers cannot. For example, variations in
process or ambient conditions measured by the
primary sensor can be compensated.
 Transmitter types
There are basically three types, but multivariable is a
fourth, less common type that will also be discussed.
Gauge pressure transmitters
These transmitters compare the gas or liquid pressure
relative to atmospheric measure (total pressure -
atmospheric pressure = indicated pressure). these are
the most-commonly used pressure-measurement
devices. gauge pressure transmitters expose one side
of a diaphragm to ambient pressure and the other
side to the liquid or gas being measured. the flexing
or distortion of the diaphragm is converted into an
electrical signal.
when the gauge pressure is higher than atmospheric
pressure, that is referred to as positive pressure. when
gauge pressure is lower than atmospheric pressure, it
is negative pressure or vacuum.
Absolute transmitters
Absolute pressure transmitters compare a liquid or
gas pressure relative to absolute pressure (a perfect
vacuum or zero pressure, 0 psia). Absolute pressure is,
therefore, always a positive value. These transmitters
are designed for applications that require readings
not influenced by changes in altitude or weather.
They are frequently used in applications using high-
performance vacuum pumps, turbines, or where ideal
gas properties are critical.
— —
02
Differential pressure transmitter
with integral and remote seals.
Differential transmitters
These devices indicate the difference or differential
between two pressure points. They typically consist of
a dual-sided diaphragm, sensing pressure on both
sides simultaneously and then calculating the
difference between them. These transmitters are
commonly used to measure level of liquids and
liquefied gases in pressurized tanks, and to measure
flow in combination with a differential pressure flow
element like an orifice plate or venturi. They can
detect differential pressures of only a few millibars.
Multivariable transmitter
A multivariable transmitter captures multiple
parameters in a single device. They simultaneously
measure differential pressure, static pressure and
external temperature all in one device. They are
commonly used when flow measurement must be
adjusted for temperature and/or pressure. The main
advantage of these transmitters is that one
instrument does what would otherwise require
several transmitters.
03
Multivariable transmitter with
temperature sensor attached.
 Transmitter technologies
A variety of sensing technologies are at work in
pressure transmitters. In many applications, and one
of several different technologies will provide
satisfactory results. Some technologies, though, are
especial well- or unsuited to certain applications.
Piezoelectric crystal
The force (pressure) on the face of a piezoelectric
crystal sensor creates an electric charge that is
proportional to the pressure. They have excellent
dynamic sensitivity, able to detect and measure even
changes in pressure over a range of pressure levels.
Inductive
This technology relies on electromagnetic induction,
the creation of an electric current by the movement of
a conductor (wire coil) in the diaphragm relative to a
magnet/magnetic field. While there are various
designs, these devices typically consist of a coil, a
movable magnetic core and the pressure-sensing
element attached to the core. As pressure varies, the
element moves the core inside the coil. There is an AC
voltage applied to the coil so that, as the core moves,
the inductance changes. Inductive transmitters are
particularly well-suited to harsh environments, and
are able to withstand shocks and vibration.
—
04
Wired and wireless
pressure transmitters
enable flexible
application options.
Bridge (Wheatstone bridge or strain gage)
In these sensors, the electrical signal is created by the
deformation of strain gages (resistors) that are
bonded to the diaphragm. “Wheatstone bridge” refers
to the design or configuration of the electrical circuit
that generates the signal. This technology is usually
used for high-pressure applications.
Pneumatic
These transmitters incorporate a bellows capsule that
is part of a force-balance measurement system. As
the bellows compresses under pressure, an attached
bar moves, changing the gap or clearance between a
flapper and a nozzle. The changes the output pressure
from the pneumatic relay to a feedback bellows. The
output pressure continues to adjust until the force on
the feedback bellows matches the bellows capsule.
This output pressure is proportional to the force
applied to the bellows capsule, providing the
measured pressure value.
Field termination
Transmitters are available that provide a range
of field terminations. Device choice depends
on a number of application requirements,
including whether the process or operation
being measured requires simple pressure
measurement indication or digital process
data for incorporation in an automation or
SCADA scheme.
Typical termination choices include:
-- 4-20mA + HART
-- 1-5V + HART – Low power consumption for
remote battery or solar power
-- WirelessHART– Enables adding devices to
existing systems without new wiring
-- Modbus
-- FOUNDATION Fieldbus
-- Profibus PA
Remote seals
Some pressure-measurement applications require devices beyond
standard transmitters. This could include processes with fluid or
gasses that are:
-- Highly corrosive
-- Dirty, viscous or laden with solids that can block or foul the
impulse lines
-- Likely to solidify in the impulse lines or the transmitter body
-- Subject to extremes of temperature
In this situations, remote seals provide an alternative solution,
isolating the transmitters from conditions that will either shorten
their operational life or dramatically affect their performance. They
consist of a transmitter body, a capillary and a seal element
incorporating a liquid-filled diaphragm.
The right transmitter to
meet your needs
The variety of potential applications and installation
locations for pressure measurement means it is
difficult to set any hard and fast rules. This guide
advises on some basic guidelines that will help to
shape and narrow down the eventual choice of
pressure measurement device for your application.
This white paper was drawn from a webinar on this
topic. To view the webinar, visit Click here for a pre-
recorded webinar on this topic.

Special seal coatings or metals offer further protection from process

hazards. Only the parts actually in contact with the process need to
be made from such materials, greatly reducing device costs.

Remote seal transmitters also provide an ideal solution for hygienic

processes, such as in the pharmaceutical and food and beverage
industries, where standardized process connections and food safe
materials are in direct contact with the product. —
05
ABB offers a full-range of pressure transmitters
and seals backed by a knowledgeable service team.
Applications
The range of applications for pressure transmitters in virtual limitless, but
each industry has a short list of the most-common uses.
Oil & Gas
-- Safety systems for high pressure and
pressure loss monitoring
-- Production pipeline basic tubing
and casing
-- Plunger-lift applications for production
optimization
-- Injection systems (water, chemical or gas)
-- Valve control applications for flow rate
control with pressure overrides
-- Separator applications to maintain and
monitor pressures
-- Closed- and open-tank level
Chemical
-- Safety Instrumented Systems
-- Over-pressure control
-- Control-loop-input monitoring
-- Automation processes
-- Cooling towers
-- Steam and natural gas storage and control
-- Condensation evaporation pressures
-- Ethane production
-- Ammonia production processes
-- Reactor-balancing batch control
— —
ABB Inc.
ABB Measurement & Analytics
125 East County Line Road
Warminster, PA 18974
1-800-HELP-365
www.abb.com/pressure
Power industry Water & wastewater
-- Flue/burner gas measurement -- Pumping and boosting station
-- Condenser pressure and level -- Filtration
-- Combustion-chamber-flow measurement -- Aeration
-- Pulverized coal processing -- Sedimentation
-- Boiler-water feed -- Sludge digestion
-- Boiler steam -- Gas storage
-- Drum-water levels -- Leak detection
-- Induced and forced draft -- NSF registration mark for potable
-- In-Out turbine flow water distribution
Pulp & Paper
-- Decomposition waste paper / pulp level
-- Pulp vats / white water tank level
-- Auxiliary products / starch / kaolin /
dye level
-- Pressurized screen / disk filter
monitoring
-- Storage tanks / auxiliary product tanks
-- Drying cylinders
-- Rinsing water / splash water
-- Power plant / steam system
superheated steam
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