Abu Dhabi National Oil Co.

ADNOC Technical Institute

INSTRUMENTATION
INSTRUMENTATION 1

UNIT 3

THE PRESSURE TRANSMITTER

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UNITS IN THIS COURSE

UNIT 1 INTRODUCTION TO INSTRUMENTATION

UNIT 2 PRESSURE MEASUREMENT

UNIT 3 THE PRESSURE TRANSMITTER

UNIT 4 FLOW MEASUREMENT

UNIT 5 MEASUREMENT OF LEVEL

UNIT 6 PRACTICAL TASKS

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TABLE OF CONTENTS
Para Page

3.0 COURSE OBJECTIVES 7

3.1 INTRODUCTION 8
3.2 THE FLAPPER-NOZZLE 9
3.3 THE PNEUMATIC RELAY 10
3.4 THE PNEUMATIC TRANSMITTER 11
3.5 THE PNEUMATIC SIGNAL LOOP 14
3.6 THE AIR PRESSURE REGULATOR 14
3.7 THE ELECTRICAL PRESSURE TRANSMITTER 16

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3.0 COURSE OBJECTIVES

The student will be able to:

 Explain the operation of a simple flapper nozzle.

 Explain the function of a pneumatic relay.

 Using a diagram, name the parts of a typical pneumatic transmitter.

 Explain the need for the feedback (positioning) bellows.

 State the standard signals produced by a pneumatic transmitter.

 Draw the layout of a typical electrical transmission loop.

 State the standard signals produced by an electrical transmitter

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3.1 INTRODUCTION

The previous unit (Unit 2) explained the basic devices used to measure
and indicate pressure. This unit will describe the methods used to
convert the pressure measurement to an instrument signal for the
controller.

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3.2 THE FLAPPER-NOZZLE

The flapper-nozzle is the primary device for all pneumatic instruments

which convert a measurement to a pneumatic signal. Figure 3-1 shows
the layout of the device.
PIVOT

RESTRICTOR APPLIED
MEASURED VALUE

FLAPPER
AIR SUPPLY V x
INPUT

NOZZLE

AIR SIGNAL
OUTPUT

Figure 3-1 The Flapper-Nozzle

Operation:

The air supply input (20 psi (1.4 bar)) passes through a restrictor (small
hole). It then goes out of the nozzle or down the air signal output line. If
the flapper is placed against the nozzle, no air can escape through it. So,
the air signal output shows full pressure. If the flapper is pulled away
from the nozzle, most of the air flows out of the nozzle, so the air signal
output pressure is very small. The back pressure output signal depends
on how near the flapper is to the nozzle. A simple graph of the output
pressure (P) against flapper distance (X) is shown below.

P
MAXIMUM A

OUTPUT
PRESSUR
E
B

X FLAPPER
DISTANCE
0 MAXIMUM
The graph is linear (straight) over the distance A B. This reflects only a
few millimetres of travel of the flapper. This part of the curve is used to
convert a change in a measured value connected to the flapper into an
output signal. The restrictor increases the speed of operation. The small
volume (V) can change pressure quickly before the air supply can pass
through the small hole in the restrictor.

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The change in output pressure due to flapper movement is very small. It

must be enlarged (amplified) using a device called a PNEUMATIC
RELAY.

3.3 THE PNEUMATIC RELAY

Different manufacturers make pneumatic relays in different ways.

However, they all work on the same principle. A simplified explanation of
this device is given in Figure 3-2.

FLAPPER NOZZLE
OUTPUT PRESSURE

DIAPHRAGM

VENT
AMPLIFIED
OUTPUT SIGNAL

BALL VALVE AIR SUPPLY

CONTROLLING
SPRING

Figure 3-2 The Pneumatic Relay

Operation:

The output pressure from the flapper-nozzle goes to the top of the
diaphragm. The diaphragm moves down against the controlling spring
and opens the ball valve. The air supply now enters the area under the
diaphragm and goes into the output.

At some point, the pressure from the air supply under the diaphragm will
equal the pressure above. The diaphragm moves up and the ball valve
closes and they hold momentarily at that pressure. If the flapper-nozzle
pressure increases, the ball valve will open and hold momentarily at the
new higher output pressure. If the pressure on the diaphragm decreases,
the ball valve stays closed and the output signal falls as air escapes
through the vent. When the output pressure has fallen enough the ball
valve opens again to maintain the output at the new lower pressure. This
kind of relay is called a continuous bleed device because it controls the
output signal pressure by slowly venting the air supply all the time.

The standard amplified signal from the relay is:

(a) 3 -15 psi imperial (b) 0.2 -1 bar ISO.

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Remember that these standards are not the same. The control system
can work on (a) or (b). It must never work on a mixture of the two
standards.

3.4 THE PNEUMATIC TRANSMITTER

There are many different types of pneumatic pressure transmitters.

However, they are not used much nowadays.

One of the few types still in use is the Foxboro type 11. This is shown
below as an example of the pneumatic transmitter.

RESTRICTION AIR SUPPLY

RELAY

NOZZLE
FLAPPER
FLEXURE CONNECTOR
OUTPUT SIGNAL

RANGE WHEEL
(SPAN ADJUSTMENT)

FORCE BAR

RANGE ROD

FEEDBACK BELLOWS

ZERO SETTING
DIAPHRAGM SEAL

PRESSURE
DIAPHRAGM CAPSULE

Figure 3-3 The Pneumatic Pressure Transmitter

Figure 3-3 shows the basic design of a Foxboro pressure transmitter.

Operation:

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 The process pressure to be measured and transmitted as a standard

signal is applied to a diaphragm capsule.

 The pressure moves the capsule. This movement is applied to one

end of a force bar pivoted about the diaphragm seal.

 The force bar moves the flexible connector. The connector pulls the
flapper to and from the nozzle.

 The back pressure from the nozzle is amplified by the relay. This
gives the standard output signal.

The system is not stable. The flapper will go either full on or full off. So a
feedback bellows is added. The output signal goes to the bellows. The
bellows applies a force to the range rod in opposition to the force bar.
The system balances to give an output signal which depends on the
position of the range wheel.

FLAPPER

APPLIED FEEDBACK
PRESSURE MOVEMENT
MOVEMENT

B C
RANGE ROD
FORCE BAR

DIAPHRAGM RANGE WHEEL

SEAL

A D
FEEDBACK
BELLOWS
PRESSURE
APPLIED

Figure 3-4 Balancing action

Figure 3-4 shows the balancing action of the transmitter. The movement
of the flapper is the pressure applied times B over A (B:A). The feedback
movement is the output pressure times the ratio D:C.

The ratio B:A is fixed but D:C can be changed by the range wheel. If the
D:C ratio is large the feedback is small. This makes the range larger.

Calibration Adjustments

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 When there is no pressure (zero gauge), the zero spring, which sets
the force on the range rod, is adjusted for a 3 psi or 0.2 bar output
signal.

 With the maximum pressure (range) applied, the range wheel is

adjusted to give 15 psi or 1 bar output signal.

Note : Figure 3-3 shows a gauge pressure transmitter. This

transmitter can easily be adapted to measure differential
pressure. This is done by adding an extra input to the
diaphragm capsule as shown below. The force bar now
moves according to the differential pressure applied.
Remember the device must be connected correctly to the high
and low pressure connections. It will not read correctly if it is
connected the wrong way round.

HIGH PRESSURE LOW

PRESSURE

DIFFERENTIAL PRESSURE APPLIED TO THE

CAPSULE

DIAPHRAGM CAPSULE
ABSOLUTE PRESSURE
REFERENCE PRESSURE TO
BE MEASURED.

ABSOLUTE PRESSURE APPLIED TO THE CAPSULE

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3.5 THE PNEUMATIC SIGNAL LOOP

20 psi AIR PRESSURE

REGULATOR MAIN AIR SUPPLY 100 psi

SIGNAL LINE
ISOLATION VALVE 3-15 psi
PROCESS LINE RECEIVER CONTROLLER
PRESSURE
TRANSMITTER
CONNECTIO
N
DRAIN VALVE

Figure 3-5 The Pneumatic Signal Loop

Figure 3-5 shows a block diagram of the pneumatic signal loop :-

 The process line to the pressure transmitter (usually 3/8” or 1/4”

stainless steel tubing) has an isolation valve and a drain valve so it
can be disconnected.

 The pressure transmitter has an air supply set at 20 psi. This comes
through the air pressure regulator from the main air supply (usually
about 100 psi).

 There is a signal line (usually 1/4” stainless steel tubing) which

transmits the signal (3-15 psi) to the receiver in the controller.

3.6 THE AIR PRESSURE REGULATOR

The air pressure regulator is a simple device. It is used to lower the main
instrument air supply of a plant to a pressure suitable for an air-operated
instrument; eg, a transmitter, control valve, etc.

Normally, each air operated instrument has its own regulator. So an air
regulator is one of the most common devices in the plant. There are
various manufacturers of air regulators, eg, Masoneilan and Fisher.
However, they all work in much the same way. The example given is
manufactured by Fisher (see Figure 3-6).

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ADJUSTING SCREW

RANGE SPRING
DIAPHRAGM
VENT
AIR PASSAGE
IN OUT

VALVE ASSEMBLY

FILTER

INLET CHAMBER

DRAIN

Figure 3-6 The Air Pressure Regulator

Operation:

 The main air supply is connected to the IN port. Air passes into the
inlet chamber at the bottom of the regulator.

 Air passes through the filter which removes dirt particles in the
incoming air which may block nozzles etc. It then goes into the valve
assembly.

 The valve assembly is moved by the range spring pressing on the

diaphragm.

 The range spring will hold the valve assembly down until the output
pressure is high enough to lift the diaphragm (via the air passage
shown). At this point the small spring in the valve assembly closes the
valve.

 Air is allowed to pass through a hole at the centre of the diaphragm

and out of the vent. This maintains balanced pressure across the
diaphragm.

 If the outlet pressure is above the pressure set by the range spring,
the air will go out through the vent above the diaphragm. When the
outlet pressure is correct, the valve assembly opens to set the correct
pressure.

 If the outlet pressure is below the pressure set by the range spring the
valve assembly will stay open until the set pressure is reached.

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Note :-

 The drain valve should be opened regularly to drain any moisture

in the inlet chamber.

 Range springs come in various sizes. The most common is from

5-35 psi (0.34-2.4 Bar). This is set to give an output of 20 psi for
transmitters, etc.

3.7 THE ELECTRICAL PRESSURE TRANSMITTER

Electrical transmitters have replaced pneumatic transmitters in most

petrochemical plants. This is because they are cheaper to install and
maintain. The transmission of the signal is also cheaper and easier to
install. This is because an electrical transmitter has one pair of wires
instead of expensive stainless steel signal tubing and air supply lines.

There are three main types of transmitters. They use three kinds of
capsules: capacitive (Rosemount), strain gauge (Honeywell) or vibrating
wire (Foxboro). The output from the capsule is electronically converted to
a STANDARD 4-20 mA SIGNAL for transmission to the control room.

An electrical transmitter is calibrated with an instrument screwdriver or

push buttons. There are two adjustments, zero and span (range).

The calibration and servicing depends on the manufacturer. It must be

carried out using the manual. Modern transmitters have become throw
away items. If they cannot be calibrated they are not serviced. They are
thrown away and replaced with a new transmitter.

Figure 3-7 below shows, as an example, a Rosemount electrical

transmitter.

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ZERO AND SPAN

ADJUSTMENTS UNDER
COVER

ELECTRICAL TWO WIRE

CONNECTIONS

LOCAL PRESSURE READING

IN % OF SPAN

PROCESS PRESSURE
CONNECTION

Figure 3-7 The Rosemount Electrical Transmitter.

Any electrical transmitter uses an electrical series loop and it acts as a

variable resistor. The basic diagram of the loop is shown in figure 3-8.

PLANT CONTROL ROOM

SAFETY
+ POWER
SUPPLY
4-20 mA BARRIER

RB 4-20 mA
TRANSMITTER TX
RT

4-20 mA SAFETY

RC
BARRIER 4-20 mA CONTROLLER

RB

Figure 3-8 The Electrical Series Loop

The power supply provides the EMF, around 24V d.c., to drive the series
loop. This loop consists of:

 Two safety barriers(RB) which protect the plant from dangerous

voltages in the case of a fault.

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 The transmitter, whose resistance (RT) changes with the measured

pressure changes.

 The controller with a resistance RC. The voltage across the

resistance provides the signal for the controller electronics.

The current around the circuit () will be

V SUPPLY
I
RT  2RB  RC

RB and RC are constant. So, the current changes as the resistance in the
transmitter (RT) changes.

The system is set so that with zero pressure, the current is 4 mA and 20
mA at the maximum value of the measured pressure.

Note : Both pneumatic and electrical transmitter signals have a live

zero. This means that a broken circuit can easily be detected.

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